Bus Bar Layout in Insulating Base for Low-Height Connections
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Solution Overview
Problem
The existing electrical connection units have a high height that needs to be reduced for more compact designs, particularly in applications like in-vehicle devices.
Innovation Solution
The electrical connection unit incorporates a base member with an insulating property and a flat surface portion that accommodates a bus bar, featuring openings to penetrate in a specific direction, allowing for a more compact design by integrating bus bars and electronic components efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If bus bars are attached to the housing in a standing posture, then electrical connectivity is maintained, but the height of the electrical connection unit increases
Solution Approach 1:
The bus bar is repositioned from a vertical standing posture to a horizontal layout within the housing. The accommodation portion provides a recessed space where the bus bar extends along the flat surface portion in the width direction of the housing, rather than standing upright in the height direction. This dimensional reorientation reduces the height of the electrical connection unit while maintaining electrical connectivity between components.
Solution Approach 2:
The bus bar is nested within the accommodation portion of the base member. The accommodation portion is formed as a recessed space in the flat surface portion, allowing the bus bar to be accommodated inside this nested structure. This nesting arrangement integrates the bus bar into the housing structure, eliminating the need for additional vertical space and reducing the overall height of the electrical connection unit.
2Length of stationary object
If bus bars are accommodated in a recessed space, then height is reduced, but manufacturing complexity increases
Solution Approach 1:
The accommodation portion is merged with the base member as an integrated structure. The recessed space is formed directly in the flat surface portion of the base member, combining the housing and bus bar mounting functions into a single integrated component. This merging approach simplifies manufacturing compared to using separate components, as the accommodation portion can be formed during the base member manufacturing process itself, such as through injection molding or other conventional forming techniques.
Data Source
AI summary
An electrical connection unit includes a first electronic component, a base member, and a first bus bar. The base member has an insulating property and includes a flat surface portion, and the flat surface portion includes an accommodation portion that is recessed in a first direction or penetrates the flat surface portion in the first direction in a case where a thickness direction of the flat surface portion is the first direction. The first bus bar is at least partially accommodated in the accommodation portion and extends along the flat surface portion, and the flat surface portion electrically connected to the first electronic component has an opening that penetrates the flat surface portion in the first direction and is disposed along at least one of a part of an outer shape of the bus bar and a part of an outer shape of the first electronic component.