Relay Block Cavity Alignment for Vehicle Power Distribution Height Reduction

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Solution Overview

Problem

Traditional power distribution device relay blocks have a high average height due to the 'component aligned design', which increases packaging and shipping challenges and costs, particularly in vehicles with stringent dimensional constraints.

Innovation Solution

The relay block assembly features a 'block aligned design' with cavities starting from a common upper plane, reducing the overall height by approximately 30% through a molded plastic construction with varying depths and the use of clearance ribs on the upper cover to prevent component backout and ensure proper installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a component aligned design is used where top surfaces of electrical components are aligned in a common plane, then ease of manufacture of the cover is improved, but the average height of the relay block increases

Engineering Contradiction:

Improveease of manufacture of coverVSAvoidaverage height of relay block

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

Instead of aligning the top surfaces of electrical components in a common plane (component aligned design), the patent inverts the approach by aligning the bottom surfaces of cavities in a common plane (cavity aligned design). This allows components of different heights to be accommodated while maintaining a uniform top surface for the cover, thereby reducing the average height while preserving manufacturing ease.

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If cavities are made deeper to accommodate taller electrical components like fuses, then adaptability to different component sizes is improved, but the overall height of the relay block increases

Engineering Contradiction:

Improveadaptability to different component sizesVSAvoidoverall height of relay block

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The patent applies local quality by creating cavities with different depths within the same relay block structure. Each cavity is locally optimized to match the height requirements of specific electrical components (relays, fuses, etc.), while all cavities share a common bottom plane. This allows the relay block to accommodate various component sizes without increasing the overall height, as each component sits in a cavity tailored to its specific dimensions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10355465B2Reduced height relay block for vehicle power distribution device

Publication Date: 2019.07.16 SUMITOMO WIRING SYSTEMS LTD

AI summary

A reduced height relay block for use within a power distribution device for a vehicle electrical system. In one embodiment, there is provided a power distribution device that routes or distributes power throughout a vehicle electrical system and includes a lower housing, a relay block assembly, a module with a printed circuit board (PCB), an array of serviceable electrical components, and an upper cover. The relay block assembly includes a relay block with an upper side that is generally planar and includes a number of cavities for receiving the serviceable electrical components. An underside of the upper cover includes clearance ribs specifically designed to oppose certain serviceable electrical components and prevent them from backing out of their respective cavities.