Bus Bar Module Hinge Cover Bending Design
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Solution Overview
Problem
Conventional bus bar modules with resin cases have limited flexibility in arranging hinge covers and corresponding hinge parts, restricting the forms in which these components can be configured to protect the bus bar and electric wires effectively.
Innovation Solution
A bus bar module with a metallic body and a synthetic resin case, featuring multiple hinge covers and hinge parts made of synthetic resin, where each hinge cover is bent at a predetermined angle to cover corresponding parts, allowing for increased flexibility in arrangement and protection without undercuts in the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hinge covers and hinge parts are made of synthetic resin and integrally formed with the case, then manufacturing complexity is reduced and flexibility in locating forms is enhanced, but the structural strength and durability may be compromised
Solution Approach 1:
The hinge cover, hinge part, and case are made of synthetic resin and integrally formed as a single piece, eliminating the need for separate components and assembly steps. This merging of parts simplifies manufacturing while maintaining sufficient structural strength through the integral construction.
Solution Approach 2:
The patent uses synthetic resin material for the hinge cover, hinge part, and case, creating a composite structure that provides both manufacturing flexibility and adequate structural strength. The resin material allows for integral forming while maintaining the necessary mechanical properties.
2Reliability
If multiple hinge covers are bent at predetermined angles to cover protected parts, then protection effectiveness is improved, but the mold configuration complexity increases
Solution Approach 1:
The hinge cover is divided into multiple segments or sections, each bent at predetermined angles to cover specific protected parts. This segmentation allows each section to be optimized for its specific protective function while the entire structure remains integrally formed, reducing mold complexity.
Solution Approach 2:
The hinge cover employs three-dimensional bending at multiple predetermined angles rather than simple planar folding. This dimensional approach allows the cover to conform to complex protective requirements while maintaining a single-piece construction that simplifies molding.
Data Source
AI summary
A bus bar module has a body part, first to third hinge covers, first to third hinges, and first and second parts. The first to third hinge covers are directly or indirectly connected through the first to third hinge parts to the case of the body part. The first to third hinge covers and the first to third hinges are integrally formed with the case of the body part. In an initial state of the bus bar module, the case of the body part, the first to third hinge covers and the first to third hinge parts have no undercut. The first to third hinge covers are bent at the first to third hinge parts, respectively, so that at least a part of the second hinge cover covers the first part and at least a part of the third hinge cover covers the second part.