Terminal Block Cover Sealing for Foreign Matter Prevention
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Solution Overview
Problem
In on-vehicle power conversion devices, gaps and holes between components allow conductive foreign matter to enter, causing short-circuits during assembly, repair, and inspection, which can damage control circuit boards and power semiconductor elements.
Innovation Solution
The design includes a terminal block with a mounting hole and bore, covered by a swing-side interlock connector and a cover that fits over the protruding portion, preventing foreign matter from entering the housing by sealing the gap and holes around the protruding portion of the swing-side housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a swing-side interlock connector is mounted to the terminal block with snap-fit, then the interlock connector can be easily fixed, but a gap and hole are created that allow conductive foreign matter to enter
Solution Approach 1:
The sealing function is segmented from the interlock connector assembly and implemented as a separate cover component. The cover is fitted over the protruding portion of the swing-side housing, creating a dedicated sealing element that closes the gap and hole without interfering with the snap-fit mounting mechanism of the interlock connector.
Solution Approach 2:
The cover acts as an intermediary component between the swing-side housing and the external environment. It mediates by providing a sealing barrier that prevents conductive foreign matter from entering through the gap and hole, while allowing the interlock connector to function normally through the cover-fitted structure.
2Object-affected harmful factors
If a cover structure is added to seal the gap and hole, then entry of conductive foreign matter is prevented, but device complexity increases
Solution Approach 1:
The cover is integrated with the existing terminal block and interlock connector assembly as a unified protective structure. The cover fits over the protruding portion of the swing-side housing, merging the sealing function with the existing mechanical assembly without requiring separate complex sealing mechanisms or additional fastening components.
Solution Approach 2:
The cover functions as a thin protective shell that seals the gap and hole around the protruding portion. This thin-film approach provides effective sealing against conductive foreign matter entry while adding minimal structural complexity and maintaining a compact overall device design.
Data Source
AI summary
In an electrical device, a terminal block includes a mounting hole portion formed so as to be opened in a bottom surface and a mounting bore which is formed so as to be opened in a top surface, and connects the mounting hole portion and an outside of the top surface to each other, the swing-side interlock connector includes a swing-side housing which is mounted inside the mounting hole portion, and protrudes from the mounting bore, a cover is placed on the top surface of the terminal block by fitting a fitting hole to a protruding portion (31a) of the swing-side housing protruding from the mounting bore, and a gap portion which is formed around the protruding portion (31a), and connects the mounting hole portion and the outside of the top surface to each other is covered with the cover as viewed from the side of the housing opening portion.