Bus Bar Conductive Unit With Molded Insulation Support

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Solution Overview

Problem

Existing conductive units for rotary electric machines require additional fixing portions for the insulating members, which increases costs and weight while compromising insulation properties.

Innovation Solution

A conductive unit design where the insulating member is supported only by a molded member integrated with the conductive members, eliminating the need for additional fixing portions and enhancing insulation properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the insulating member is supported by the motor case with additional fixing portions, then the insulating member can be securely fixed, but the cost and weight increase

Engineering Contradiction:

Improvefixing reliabilityVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The insulating member is merged with the molded member to form an integrated structure. The molded member, which is already present as part of the conductive member assembly, is designed to simultaneously provide both mechanical support and electrical insulation functions, eliminating the need for separate fixing portions and reducing overall weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molded member is designed to serve multiple functions: it acts as both a structural support element and an insulating member. By making the molded member multi-functional, the patent eliminates the need for additional dedicated fixing components, thereby reducing weight and cost while maintaining securing reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If the insulating member is supported by the motor case with additional fixing portions, then the insulating member can be securely fixed, but the cost increases

Engineering Contradiction:

Improvefixing reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating member and molded member are merged into a single integrated component. This reduces the total number of parts that need to be manufactured, stored, and assembled, thereby reducing manufacturing costs while maintaining the securing function through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molded member is designed to perform multiple functions including structural support, electrical insulation, and mechanical securing. This multi-functionality reduces the bill of materials and assembly complexity, leading to cost reduction while maintaining fixing reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Weight of stationary object

If the insulating member is supported only by the molded member, then cost and weight are reduced, but the insulation properties must be ensured

Engineering Contradiction:

ImproveweightVSAvoidinsulation property

Core Design Contradiction:

Weight of stationary objectVSReliability

Solution Approach 1:

The molded member is constructed from composite materials that combine mechanical strength properties with electrical insulation properties. This allows the single molded member to simultaneously provide structural support for securing the insulating member while maintaining the required insulation performance between conductive members.

Inventive Principle:

Principle #40Composite materials

4Weight of stationary object

If the insulating member is supported only by the molded member, then cost and weight are reduced, but the fixing reliability must be maintained

Engineering Contradiction:

ImproveweightVSAvoidfixing reliability

Core Design Contradiction:

Weight of stationary objectVSReliability

Solution Approach 1:

The support and fixing functions are merged into the molded member design. The molded member is shaped to provide both mechanical support and securing features, eliminating the need for separate fixing portions while maintaining fixing reliability through the integrated structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molded member is designed as a multi-functional component that simultaneously provides structural support, mechanical securing, and electrical insulation. This universal design reduces weight by eliminating redundant components while maintaining fixing reliability through the combined functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12294268B2Conductive unit

Publication Date: 2025.05.06 HONDA MOTOR CO LTD

AI summary

A conductive unit, includes a U-phase conductive member, a V-phase conductive member and an insulating cover. The U-phase conductive member include a U-phase bus bar and a molded member molded integrally with the U-phase bus bar. The V-phase conductive member includes a V-phase bus bar and not including the molded member. The insulating cover separates the U-phase bus bar from the V-phase bus bar apart and is supported only by the molded member.