Bus Bar Bending for Compact Electronic Component Assembly
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Solution Overview
Problem
Conventional electronic component assemblies, such as relays, require increased housing space due to the height dimensions of the relay main body and the holding member, leading to a larger fitting direction for terminal portions and terminal fittings.
Innovation Solution
An electronic component assembly with bus bars bent at a right angle and attached to a resin member, where the other ends of the bus bars are opposite to the side surfaces of the component main body, reducing the overall height and allowing for a more compact connection structure with terminal fittings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the relay main body and holding member are arranged in the fitting direction of the terminal portion and terminal fitting, then the electrical connection function is ensured, but the housing space and height dimensions increase
Solution Approach 1:
The bus bar is bent at a right angle to extend in the width direction rather than the height direction, changing the spatial dimension of arrangement. This allows the terminal fitting to be positioned adjacent to the side surface of the relay main body, reducing height dimensions while maintaining electrical connection functionality
Solution Approach 2:
The bus bar is divided into multiple sections with different orientations: one end extends in the height direction for connection to the terminal portion, while the other end bends at a right angle to extend in the width direction for connection to the terminal fitting. This segmentation allows optimized spatial arrangement of different connection points
2Reliability
If the bus bar extends in the fitting direction to connect terminal portions and terminal fittings, then electrical connection is achieved, but the height dimension and housing space increase
Solution Approach 1:
The bus bar changes direction by bending at a right angle, transitioning from height direction extension to width direction extension. This dimensional change maintains electrical connection reliability while significantly reducing the height dimension and overall housing space requirements
Solution Approach 2:
Different sections of the bus bar have different spatial orientations tailored to their specific connection requirements: the first section extends in the height direction to reach the terminal portion, while the second section bends at a right angle to extend in the width direction to reach the terminal fitting, optimizing local connection quality
Data Source
Figure 1
Figure 2
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AI summary
Provided is an electronic component assembly that can reduce a housing space in a fitting direction of a bus bar and a terminal fitting. An electronic component assembly (1) includes a relay (2), a diode (3), a plurality of bus bars (6), and a plate-shaped resin member (7). The relay (2) has a relay main body (20) having a rectangular parallelepiped outer shape, and a plurality of terminal portions (21) protruding from a bottom surface (20b) of the relay main body (20). The plurality of bus bars (6) is configured such that one end (6a) side is soldered to a terminal portion (21) of the relay (2) or a terminal portion (31) of the diode (3), and the other end (6b) is fitted to a terminal fitting. The one end (6a) sides of the plurality of bus bars (6) are embedded in the resin member (7). Furthermore, the plurality of bus bars (6) protrudes from the two opposing side surfaces of the resin member (7) and is bent at a right angle to a top surface (20a) side of the relay main body (20). For this reason, the other ends (6b) of the bus bars (6) are opposite to the two opposing side surfaces (20c, 20d) of the relay main body (20).