Actuator Control Bus Bar Orientation for Mold Release Interference
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Solution Overview
Problem
The existing actuator control devices face challenges in miniaturization and cost due to interference issues between bus bars during resin molding, requiring shape changes that complicate manufacturing and increase costs.
Innovation Solution
The actuator control device incorporates a circuit device with a first and second bus bar, featuring large main flat-face portions and smaller sub flat-face portions, positioned to face each other in a direction different from the mold release direction, using at least one movable metal mold for resin molding, which prevents interference and allows for smaller device size without increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the main flat-face portions of bus bars are arranged to face each other in the mold release direction for resin molding, then the bus bars can be integrated with resin, but interference occurs between the bus bar in one mold and the other bus bar, making it difficult to hold the other bus bar
Solution Approach 1:
The patent changes the spatial arrangement of bus bars from facing each other in the mold release direction to facing each other in a direction different from the mold release direction. This dimensional repositioning eliminates interference between bus bars while maintaining their facing configuration for effective resin integration.
2Reliability
If the shape of bus bars is changed to secure the holding portion for the other bus bar, then the holding capability is improved, but the device size increases and manufacturing costs increase
Solution Approach 1:
Instead of modifying bus bar shapes to improve holding capability, the patent repositions the bus bars in space by changing the facing direction relative to the mold release direction. This allows standard bus bar shapes to be used while achieving secure holding, thereby preventing device size increase.
Solution Approach 2:
The patent enables a single bus bar shape design to serve multiple functions: maintaining holding capability while avoiding interference with other bus bars. The standardized bus bar shape can be used across different configurations without requiring custom modifications.
3Reliability
If the shape of bus bars is changed to secure the holding portion, then the holding capability is improved, but the manufacturing costs increase
Solution Approach 1:
The patent uses standardized bus bar shapes that can be manufactured using conventional processes. By avoiding custom shape modifications, the manufacturing cost is reduced while still achieving secure holding capability through optimized spatial arrangement.
Solution Approach 2:
The patent achieves improved holding capability through spatial repositioning rather than shape modification, allowing the use of standard bus bar components that can be manufactured cost-effectively using existing manufacturing processes.
Data Source
AI summary
An actuator control device includes a circuit device that is resin-molded by a plurality of metal molds including at least one movable metal mold to include a first bus bar and a second bus bar. The first bus bar and the second bus bar each include a flat plate-like portion that includes two main flat-face portions having large surface areas, and two sub flat-face portions that are adjacent to the main flat-face portions and have smaller surface areas than the surface areas of the main flat-face portions. One of the main flat-face portions of the first bus bar faces one of the main flat-face portions of the second bus bar. The facing direction differs from the mold release direction of the movable metal mold.