Top-Down Power Distribution Box Busbar Mounting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing bottom-up Power Distribution Box (PDB) design is costly and complicated due to the need for a protector plate to separate wires from the busbar, making assembly and service difficult, as the busbar is attached to the underside of the frame, requiring additional components and steps for access and rework.

Innovation Solution

A top-down PDB design where the busbar is attached to the top side of the frame, eliminating the need for a protector plate, allowing unobstructed wire insertion and easy access for service, with the busbar and current control devices securely isolated and integrated into a wedge structure for simplified assembly and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the busbar is attached to the underside of the frame with a protector plate, then wire protection is achieved, but system cost increases and assembly complexity increases

Engineering Contradiction:

Improvewire protection from electrical contactVSAvoidassembly complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent removes the protector plate from the system entirely by changing the busbar orientation to the top side of the frame. This extraction of the unnecessary component simplifies the assembly process while maintaining wire protection through the natural structural arrangement of the frame and busbar configuration.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent inverts the traditional bottom-up assembly approach by implementing a top-down configuration where the busbar is attached to the top side of the frame rather than the underside. This inversion eliminates the need for the protector plate and simplifies the overall assembly process.

Inventive Principle:

Principle #13The other way round (Inversion)

2Object-affected harmful factors

If the busbar is attached to the underside of the frame, then wire separation is achieved, but serviceability deteriorates

Engineering Contradiction:

Improvewire separation from busbarVSAvoidserviceability

Core Design Contradiction:

Object-affected harmful factorsVSEase of repair

Solution Approach 1:

By inverting the busbar attachment location from the underside to the top side of the frame, the patent improves serviceability. Technicians can now access and service the busbar and connected components from the top and sides of the frame without needing to remove protective plates or disconnect wires, while wire separation is maintained through the structural design.

Inventive Principle:

Principle #13The other way round (Inversion)

3Object-affected harmful factors

If the busbar is attached to the underside of the frame, then electrical isolation is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveelectrical isolationVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent extracts the protector plate component from the manufacturing process, reducing part count and assembly steps. The electrical isolation function is maintained through the top-down busbar configuration where wires connect to the busbar from below without requiring an additional protective plate, thereby reducing manufacturing costs.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If a protector plate is used to separate wires from the busbar, then safety is improved, but assembly time increases

Engineering Contradiction:

ImprovesafetyVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent removes the protector plate from the assembly process, reducing the number of components that need to be installed. Safety is maintained through the top-down configuration where the busbar is positioned on the top side of the frame, allowing wires to connect from below without requiring an additional protective plate, thereby reducing assembly time.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By inverting the traditional assembly approach and attaching the busbar to the top side of the frame rather than the underside, the patent eliminates the need for the protector plate. This inversion maintains safety through proper electrical isolation while significantly reducing assembly time by removing an entire component and its associated installation steps.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS7371080B1Power distribution box

Publication Date: 2008.05.13 LEAR CORP

AI summary

A Power Distribution Boxes (PDBs), such as but not limited to the type employed in vehicles and other devices to distribute power from a primary power source to a number of loads. The PDB may include top-down constructions in so far as the main components are laid one on top of the other. Wires used to distribute energy from a primary source to a number of loads may be connected from an underside of the PDB.