Bus Bar Module Wire Routing for Mid-Section Take-Out

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Solution Overview

Problem

The existing bus bar modules face bulkiness issues in the electric wire take-out portion when drawing out multiple electric wires in the middle of the longitudinal direction, leading to potential damage and increased height due to the need for folding and routing of wires.

Innovation Solution

The bus bar module incorporates parallel electric wire routing grooves and passing portions, with an electric wire take-out portion in the middle, allowing wires to be routed through these passages to reduce the number of wires drawn from the opposite end, and an electric wire holding cover to guide and hold the wires, minimizing bulkiness and height.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electric wires are drawn out from the middle of the bus bar module in the longitudinal direction, then the drawing-out position can be adapted to installation conditions, but the electric wire take-out portion becomes bulky in height due to folding and bending requirements

Engineering Contradiction:

Improvedrawing-out position adaptabilityVSAvoidelectric wire take-out portion height

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The patent introduces a second electric wire routing groove portion extending in the width direction, creating a two-dimensional routing network. Wires can enter from the middle take-out portion, route through the second groove in the width direction, pass through the passing portion, and exit from the first groove, transforming a one-dimensional folding problem into a two-dimensional routing solution that minimizes height.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The routing path is segmented into distinct sections: the first electric wire routing groove portion for longitudinal routing, the second electric wire routing groove portion for width-direction routing, and the electric wire passing portion for transfer between grooves. This segmentation allows wires to change direction systematically rather than folding within a single confined space, reducing the take-out portion height.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If multiple electric wires are bundled and drawn out from one end side, then the structure is simple, but it cannot meet installation conditions requiring middle position drawing-out

Engineering Contradiction:

Improverouting structure simplicityVSAvoiddrawing-out position flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The electric wire routing groove portions are designed to serve multiple functions: the first groove handles wires drawn from one end, the second groove handles wires drawn from the middle take-out portion, and the passing portions enable transfer between routing paths. This multi-functional design allows a single bus bar module to accommodate different drawing-out positions (one end or middle) without requiring fundamentally different structures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If electric wires are folded back in the electric wire take-out portion, then middle position drawing-out is achieved, but the wires may be damaged when bent to the minimum radius of curvature

Engineering Contradiction:

Improvemiddle position drawing-out capabilityVSAvoidelectric wire integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The second electric wire routing groove portion acts as an intermediary routing path that receives wires from the middle take-out portion and guides them through the width direction to the passing portion. This intermediary groove provides a gentle, controlled routing path with adequate bend radius, eliminating the need for sharp folding and bending at the take-out portion, thus protecting wire integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12142791B2Bus bar module

Publication Date: 2024.11.12 YAZAKI CORP

AI summary

A bus bar module includes: a case extending from a first end to a second end; a bus bar; and electric wires. The case includes first and second electric wire routing groove portions provided in parallel, electric wire passing portions bridged between the first and second electric wire routing groove portions, and an electric wire take-out portion which is provided in the first electric wire routing groove portion and from which the electric wires are drawn toward the second end. At least a part of the electric wires is routed from a position of the second electric wire routing groove portion closer to the second end than the electric wire take-out portion, through an electric wire passing portion provided closer to the one end than the electric wire take-out portion, to the electric wire take-out portion.