Insert-Molded Bus Bar Unit Fixing for Low-Stress Assembly
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Solution Overview
Problem
Existing bus bar unit fixing methods do not effectively reduce the number of components, assembling steps, and space usage while minimizing stress in the connector unit, which are critical for cost reduction and efficient electrification of drive sources.
Innovation Solution
A bus bar unit fixing method that integrates a bus bar with a connector unit via insert molding, featuring bolt insertion holes for secure attachment to a fixing-object member, connection terminals, and cable connection, reducing the number of components and steps while absorbing manufacturing variations to minimize stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the bus bar unit uses a integrated connector unit molded by insert molding, then the number of components is reduced and assembling steps are simplified, but stress concentration may occur in the connector unit
Solution Approach 1:
The connector unit is molded to be integrated with the bus bar through insert molding, combining two previously separate components (bus bar and connector) into a single integrated unit. This reduces the total number of components and simplifies the assembly process while maintaining functional separation through distinct bolt insertion holes for different fastening purposes.
2Productivity
If the connector unit is fixed directly to the fixing-object member, then the number of assembling steps is reduced, but manufacturing variations may cause stress and reliability issues
Solution Approach 1:
The connector unit is pre-integrated with the bus bar through insert molding during manufacturing, creating a preliminary bonded state. This preliminary bonding absorbs manufacturing variations and prevents excessive stress during the final assembly step when the connector unit is fixed to the fixing-object member, thereby improving reliability while maintaining assembly efficiency.
3Volume of moving object
If the bus bar unit design integrates connector and bus bar, then space saving is achieved, but the fixing method must accommodate manufacturing variations
Solution Approach 1:
The insert molding process creates a bonded connection with specific mechanical properties that can accommodate dimensional variations within acceptable ranges. The bonding parameters (molding pressure, temperature, material selection) are optimized to provide flexibility that absorbs manufacturing variations while maintaining the compact integrated design for space saving.
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 method reduces the number of components, simplifies the assembly process, and achieves space savings while minimizing stress in the connector unit, enhancing the efficiency and cost-effectiveness of bus bar unit installation.
Implementation Method 1
a connector unit molded to be integrated with the bus bar by insert molding
Data Source
AI summary
A bus bar unit includes a bus bar including two ends and tending from a first end to a second end, and a connector unit molded to be integrated with the bus bar. A first bolt insertion hole is formed in the first end. A second bolt insertion hole is formed in the connector unit. The bus bar unit is fixed, by fixing the bus bar unit to a fixing-object member, connecting the first end to a connection terminal provided on an electronic component, and connecting a cable to the second end. A bus bar unit fixing method includes a step of inserting the first bolt through the first bolt insertion hole and fastening the first end of the bus bar to the connection terminal, and a step of inserting the second bolt through the second bolt insertion hole and fixing the connector unit to the fixing-object member.