Bus Bar Base Structure for Durable Electrical Connections
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Solution Overview
Problem
Existing electrical connection units lack durability, particularly in harsh environments such as vehicles, leading to potential failure and reduced reliability.
Innovation Solution
The electrical connection unit incorporates a metal plate, a first electronic component, and a first bus bar connected to a first base member with specific structural configurations to enhance durability, including a first portion extending from a flat surface and supported by the metal plate, improving the unit's structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple housing structure with bus bar attached in standing posture is used, then device complexity is reduced, but durability deteriorates
Solution Approach 1:
The base member is divided into multiple functional portions: a flat surface portion for holding the bus bar, a first portion extending in the thickness direction for structural support, and a second portion for fixing to the housing. This segmentation allows each portion to optimize its function while maintaining overall structural integrity and durability.
Solution Approach 2:
The first portion of the base member extends in the thickness direction of the housing, adding a vertical dimension to the structural support. This dimensional extension reinforces the connection between the bus bar holding function and the housing fixation, improving durability without significantly increasing planar complexity.
2Ease of manufacture
If the bus bar is held without additional support structures, then ease of manufacture is improved, but strength deteriorates
Solution Approach 1:
The base member integrates multiple functions into a single component: it holds the bus bar on its flat surface portion, provides structural reinforcement through the extended first portion, and fixes to the housing via the second portion. This merging eliminates the need for separate support structures while maintaining manufacturing simplicity and structural strength.
Data Source
AI summary
An electrical connection unit includes a metal plate, a first electronic component, a first bus bar, and a first base member. The first bus bar is electrically connected to the first electronic component. The first base member includes: a first flat surface portion having a plate shape, having a first surface and a second surface, and holding the first bus bar, the first surface facing the first electronic component, the second surface being located on a side opposite to the first surface and facing the metal plate; a first portion having a plate shape and extending from the first flat surface portion in a first direction intersecting the first surface; and a second portion supported by the first portion, disposed at a position different from the first surface in the first direction, and fixed to the metal plate.