Bus Bar and Cable Connection Structure Using Nested Ultrasonic Welding
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Solution Overview
Problem
The existing connection structure of a bus bar and a cable forms unnecessary space due to its stepped configuration, increasing the overall size when the bus bar and core wire are joined, especially when protected by an insulating cylindrical member.
Innovation Solution
A connection structure that includes a bus bar serving as an external terminal, a cable with an exposed core wire cut to form a flat joining surface, and an insulating cylindrical protective member covering the joined portion, where the bus bar and core wire are connected via ultrasonic welding, reducing the vertical thickness and overall size by fitting the bus bar into the cut core wire portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bus bar and core wire are connected in a stepped state, then the joining is simple, but a space that has no use is formed and the entire structure is increased in size
Solution Approach 1:
The bus bar is inserted into the core wire to form a nested configuration where the bus bar fits within the hollow interior of the core wire. This nesting eliminates the stepped configuration and unused space, creating a compact integrated structure while maintaining ease of manufacturing through simple insertion and welding operations
2Reliability
If the joining portion is covered with an insulating cylindrical protective member, then insulation is provided, but the overall size of the structure is increased
Solution Approach 1:
The protective member is integrated with the nested bus bar-core wire assembly, forming a unified compact structure. The nested configuration allows the protective member to cover only the necessary joining portion without adding excessive overall dimensions, as the nested arrangement minimizes the space required for the connection itself
3Ease of operation
If the bus bar is placed on top of the core wire, then the joining is straightforward, but unnecessary space is formed in the vertical direction
Solution Approach 1:
Instead of placing the bus bar on top of the core wire (external arrangement), the bus bar is inverted into the core wire (internal arrangement). This inversion eliminates vertical gaps and unnecessary space, reducing the overall vertical thickness while maintaining straightforward joining through insertion and welding
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
This configuration effectively minimizes the space between the bus bar and the protective member, reducing the overall size of the connection structure while allowing for easy joining and enhanced sealing properties.
Implementation Method 1
The bus bar and the core wire of the cable are joined by means of ultrasonic welding
Data Source
AI summary
A connection structure of a bus bar and a cable has: a bus bar that serves as an external terminal; a cable that has a core wire exposed from an insulation sheath at a terminal, the core wire being joined with the bus bar; a protective member that covers at least a joining portion of the bus bar and the core wire of the cable; and a cut portion that is formed in the core wire at the joining portion with the bus bar.