Angled Busbar Plug-In Connector with Single-Step Bending
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing angled plug-in connectors with overmolded busbar stacks are inefficient, as they require complex bending and twisting procedures that are not reproducible, leading to installation challenges in compact spaces like vehicle wheel suspensions.
Innovation Solution
A method involving the temporary connection of busbars with separating webs, followed by injection molding with non-conductive plastic to form bridges, severing the webs, and bending the busbars to create angled connections, which are then overmolded with a housing, allowing for a single bending procedure and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex bending and twisting procedures are used to produce angled plug-in connectors, then the connectors can achieve angled connections, but the manufacturing process becomes non-reproducible and difficult to install
Solution Approach 1:
The busbars are pre-formed with integrated bending regions and transition regions that enable angular deformation. The separating webs are pre-positioned to define precise bending locations, allowing the busbars to be deformed into angled configurations through a single, reproducible bending operation rather than complex multi-step procedures
Solution Approach 2:
The busbar structure is segmented into distinct regions: straight sections, bending regions with defined neutral axes, and transition regions. This segmentation allows each region to serve its specific function during deformation, enabling controlled angular bending while maintaining structural integrity and electrical conductivity
2Manufacturing precision
If busbars are temporarily connected with separating webs and then bent, then angled connections are achieved, but the manufacturing process requires additional steps
Solution Approach 1:
Multiple busbars are temporarily connected via separating webs in a preliminary arrangement that defines their relative positions and bending locations. This pre-arrangement enables subsequent single-shot bending operations that deform all busbars simultaneously into their final angled configurations, ensuring precision while maintaining efficiency
Solution Approach 2:
Separating webs serve as temporary intermediary elements that hold busbars in predetermined positions during manufacturing. These webs define the exact locations where bending should occur and are removed after the bending process, leaving precisely positioned angled busbar connections
3Reliability
If busbars are overmolded with non-conductive plastic, then insulation is ensured, but the busbar positions must be fixed beforehand
Solution Approach 1:
The busbars are temporarily connected with separating webs that define their precise positions and spacing before overmolding. This preliminary positioning ensures correct spatial arrangement is maintained during the injection molding process, eliminating the need for additional position fixation mechanisms while ensuring reliable insulation
Solution Approach 2:
Separating webs act as temporary positioning intermediaries that maintain busbar spacing and alignment during manufacturing. These webs are integrated into the molding process and removed afterward, having served their purpose of ensuring correct positioning for reliable insulation without requiring complex fixation systems
4Ease of manufacture
If a single bending procedure is used to produce angled busbars, then manufacturing is simplified, but the busbar geometry must be pre-designed with bending regions
Solution Approach 1:
The busbar geometry is pre-designed with integrated bending regions, transition regions, and neutral axes in the flat material before cutting. This preliminary geometric design enables the busbars to be deformed into angled configurations through a single, simple bending procedure without requiring complex manufacturing steps
Solution Approach 2:
The busbar design incorporates specific geometric parameters including bending regions with defined neutral axes, transition regions with specific curvature radii, and angular relationships between straight sections. These pre-defined parameters enable controlled deformation during bending while maintaining structural integrity and electrical performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of angled plug-in connectors with interlinked busbars in two spatial directions, facilitating efficient electrical connections and compact designs suitable for limited spaces, while ensuring reliable insulation and protection of the busbars.
Implementation Method 1
the busbars are connected to at least one bridge using a first injection molding tool, which bridge is made from an electrically non-conductive plastic material
Implementation Method 2
the busbars are deformed at the bending regions using a bending tool, wherein the end regions of the busbars are folded out of the reference plane through a folding angle at the bending line
Implementation Method 3
between the start region and the end region, using a second injection molding tool, the prefabricated busbar stack is overmolded with a housing made from an electrically non-conductive plastic material
Data Source
AI summary
A method is disclosed for producing an angled plug-in connector, which has an insert-molded, prefabricated busbar stack that has at least two busbars which are next to one another, are spaced apart by an insulating gap, and are made of an electrically conductive planar material. Each of the busbars includes a starting region which is in a reference plane and oriented in a reference direction, an end region which is bent out of the reference plane about a creasing angle and oriented in a transverse direction, a curved transition region from the reference direction into the transverse direction, and a bending region oriented along a bending line. The bending line is oriented, with respect to the reference direction, at a bending line angle, and the busbar stack is insert moulded between the starting region and the end region having a housing made of an electrically non-conductive plastics material.