Electrical Connection Unit Assembly with Recessed Bus Bar Mounting
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Solution Overview
Problem
Existing electrical connection units face challenges in assemblability, particularly in integrating bus bars and electronic components efficiently.
Innovation Solution
A method of manufacturing an electrical connection unit involves forming an assembly by fixing a connection target component to a bus bar using fastening members, with a routing board having a base member and bus bar accommodated in an accommodation portion, and electrically connecting the components using additional fastening members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bus bar and electronic components are integrated using traditional separate mounting methods, then manufacturing flexibility is maintained, but assemblability and manufacturing efficiency deteriorate
Solution Approach 1:
The patent merges the bus bar and electronic components into a single integrated assembly where the bus bar is formed with integrated mounting structures (such as clips, tabs, or recesses) that directly accommodate the electronic components. This consolidation eliminates the need for separate mounting operations and reduces the number of discrete parts, thereby improving assemblability while the modular design keeps integration complexity manageable.
Solution Approach 2:
The bus bar is pre-formed with integrated mounting features and pre-assembled with electronic components during manufacturing. This preliminary integration allows the complete assembly to be installed as a single unit, reducing on-site assembly complexity and improving overall assemblability without requiring complex integration procedures during final installation.
2Productivity
If multiple separate components are used for bus bar and electronic components, then manufacturing flexibility is maintained, but manufacturing efficiency deteriorates
Solution Approach 1:
By combining the bus bar and electronic components into a single integrated assembly, the patent reduces the total number of parts that need to be handled, moved, and assembled. This merging enables batch processing during manufacturing and allows for rapid installation as a complete unit, significantly improving manufacturing efficiency and reducing assembly time compared to separate component installation.
Solution Approach 2:
The integrated assembly is prepared in advance during manufacturing, with all connections and mounting features pre-configured. This preliminary action eliminates time-consuming on-site assembly operations, allowing for quick installation while maintaining manufacturing flexibility through standardized assembly processes.
Data Source
AI summary
A method of manufacturing an electrical connection unit includes preparing a routing board, forming an assembly, and electrically connecting a connection target component to a bus bar. The routing board includes a base member and a bus bar, the base member having a flat surface portion, and the bus bar being held by the flat surface portion. The flat surface portion includes an accommodation portion recessed or penetrating the flat surface portion in a first direction (thickness direction of the flat surface portion). Part of the bus bar is accommodated in the accommodation portion. The forming of the assembly includes fixing a connection component to the connection target component with a first fastening member. The electrically connecting the connection target component to the bus bar includes connecting the connection component included in the assembly to the bus bar with a second fastening member after forming the assembly.