Sealed Modular Power Distribution Housing for Custom Vehicle Circuits
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Solution Overview
Problem
Existing power distribution assemblies for vehicles are expensive to manufacture and assemble, and lack scalable customization to meet the needs of smaller applications.
Innovation Solution
A sealed modular power distribution apparatus with interchangeable modules that are sealed to a housing assembly, allowing for customizable electrical connections and direct terminal connections to components within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multi-part housing assembly with multiple components is used, then power distribution functionality is achieved, but manufacturing and assembly costs increase
Solution Approach 1:
The power distribution assembly is divided into separate modular components: a housing assembly and interchangeable modules. Each module contains specific electrical components (fuses, relays, circuit breakers) mounted on a circuit board with terminals. This segmentation allows manufacturers to produce standardized housing assemblies and various module types separately, then assemble them through a simple snap-fit connection, reducing overall manufacturing and assembly costs while maintaining full power distribution functionality.
Solution Approach 2:
The housing assembly is designed as a universal base structure that can accommodate multiple different module types through standardized openings and sealing mechanisms. The same housing can work with various modules containing different combinations of electrical components, allowing a single housing design to serve multiple power distribution configurations, thereby reducing the need for custom housing designs for each application.
2Adaptability or versatility
If custom power distribution assemblies are designed for specific applications, then application-specific needs are met, but manufacturing volume requirements increase
Solution Approach 1:
By segmenting the power distribution system into a universal housing and interchangeable modules, the invention enables small-volume production of customized solutions. Instead of manufacturing entire custom assemblies in large volumes, manufacturers can produce standardized housings in high volume and then create smaller batches of specialized modules to meet specific application needs, significantly reducing the manufacturing volume threshold for customization.
Solution Approach 2:
The modular architecture introduces dynamic reconfigurability to the power distribution system. Modules can be easily swapped between different housing assemblies to adapt to changing application requirements, allowing the system to dynamically adjust its configuration without requiring new tooling or large-volume production runs for each customization scenario.
3Adaptability or versatility
If interchangeable modules are used for customization, then flexibility for smaller applications is improved, but sealing complexity increases
Solution Approach 1:
Rather than attempting to seal the entire power distribution assembly as a single complex unit, the invention applies sealing selectively at the critical interface between the module and housing. The sealing element is positioned only where the module inserts into the housing opening, providing adequate protection for the electrical components without requiring comprehensive sealing of the entire assembly, thus reducing overall sealing complexity while maintaining customization flexibility.
4Reliability
If a sealed design is implemented, then protection against contaminants is improved, but assembly complexity increases
Solution Approach 1:
The sealing element is pre-installed on the module before the module is inserted into the housing assembly. This preliminary action ensures that the sealing mechanism is already in place and properly positioned, eliminating the need for complex sealing operations during final assembly. The module is simply snapped into the housing opening, and the pre-installed sealing element automatically provides the seal, maintaining both contaminant protection and assembly simplicity.
Data Source
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AI summary
Provided are approaches for modularized power distribution. In one approach, an apparatus may include a module extending into an interior cavity of a housing assembly through an opening formed in a base section of the housing assembly. The module may include a component grid at one end for receiving one or more components (e.g., fuses, relays, circuit breakers, diodes, etc.), and a wiring alignment cover at an opposite end operable with a terminal. The apparatus may further include a mechanical sealing element disposed along one or more surfaces of the module to provide a seal between the module and the base section defining the opening. In another approach, a plurality of modules may be disposed within a plurality of openings formed in the base section. In another approach, the apparatus may include a bracket configured to releasably connect the base section and the cover.