Bus Bar Module Manufacturing via Integral Molding and Junction Cutting
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Solution Overview
Problem
The manufacturing of bus bar modules for power supply control apparatuses is hindered by poor workability and high costs due to the difficulty in accurately positioning and shaping multiple conductive bus bars, which requires multiple molds and increases production expenses.
Innovation Solution
The bus bar module is manufactured by integrating multiple bus bars with junctions into a single assembly through insert molding, followed by cutting off the junctions to create independent bus bars, allowing for easier assembly and reducing the need for individual molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple bus bars are manufactured separately using multiple molds, then each bus bar can have the required specific shape, but the manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent merges multiple separate bus bar manufacturing processes into a single integrated mold that can produce multiple bus bars simultaneously. The mold includes multiple cavities arranged in layers, allowing one molding operation to create several bus bars with different shapes and configurations, thereby reducing the total number of molds required and simplifying the manufacturing process
Solution Approach 2:
The mold is segmented into multiple cavities organized in different layers, with each cavity designed to produce a specific bus bar shape. This segmentation allows the single mold to handle diverse bus bar requirements while maintaining the advantage of unified manufacturing control and reduced equipment complexity
2Manufacturing precision
If multiple bus bars are positioned separately during insert molding, then each bus bar can be accurately shaped, but positioning accuracy becomes difficult to maintain and handling properties deteriorate
Solution Approach 1:
The patent combines multiple bus bars into a single integrated assembly during the insert molding process. The bus bars are pre-assembled in a fixed configuration and inserted together as one unit, eliminating the need to handle and position each bus bar separately. This approach maintains precise relative positioning between bus bars while significantly improving handling properties during manufacturing
Solution Approach 2:
The bus bars are pre-positioned and pre-assembled into a complete assembly before the insert molding process begins. This preliminary action ensures that all bus bars are correctly positioned relative to each other prior to being embedded in the resin, guaranteeing manufacturing precision without requiring complex positioning mechanisms during the molding operation
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 simplifies the manufacturing of bus bar modules, reduces production costs, and facilitates the assembly of power supply control apparatuses by enabling the use of a single mold for the bus bar assembly, thereby lowering the overall cost of the power supply control apparatus.
Implementation Method 1
The bus bar module is manufactured by integrally molding a bus bar assembly including a plurality of bus bars connected to each other by junctions and a resin member
Implementation Method 2
making the bus bars to be independent by cutting off the junctions after the integral molding
Data Source
AI summary
A power supply control apparatus includes: a control board that is configured to control a voltage of a battery module; and a bus bar module that is configured to electrically connect the control board to the battery module, the control board and the bus bar module are arranged in a stacked manner, and the bus bar module includes a plurality of bus bars that are made to be independent by cutting off junctions connecting the bus bars to each other and a resin member that supports the bas bars in a state where the junctions are exposed.