Bus Bar Connection on Printed Circuit Board

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for connecting bus bars to printed circuit boards, such as soldering, are inadequate in withstanding vibrations and impacts, leading to potential disconnection issues, especially in vehicle applications where stress is significant.

Innovation Solution

A dual connection method where bus bars are both soldered and screwed to the printed board, ensuring mechanical strength and electrical connectivity, with conductive bolts enhancing current flow and reducing thermal stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bus bar is connected to circuit board by soldering only, then electrical connectivity is achieved, but connection reliability deteriorates under vibrations and impacts

Engineering Contradiction:

Improveconnection reliabilityVSAvoidvibrations and impacts

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent combines two connection methods (soldering and screwing) into a unified connection structure. The bus bar is both soldered to the circuit board and mechanically fixed with screws, creating a hybrid connection that leverages the electrical conductivity of soldering and the mechanical strength of screwing to resist vibrations and impacts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection structure uses composite joining methods combining metallurgical bonding (soldering) and mechanical fastening (screwing). This composite approach creates a multi-mode connection that simultaneously provides electrical continuity and mechanical robustness against external stresses.

Inventive Principle:

Principle #40Composite materials

2Strength

If dual connection method (soldering + screwing) is used, then connection strength is improved, but device complexity increases

Engineering Contradiction:

Improveconnection strengthVSAvoidconnection structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The connection function is segmented into two distinct components: soldering for electrical connectivity and screwing for mechanical fixation. This segmentation allows each method to perform its specialized function optimally while maintaining overall structural integrity and simplifying the design rationale.

Inventive Principle:

Principle #1Segmentation

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 approach provides a robust and reliable connection that resists vibrations and impacts, maintaining electrical integrity and reducing the risk of disconnection, making it suitable for vehicle use.

Implementation Method 1

the bus bar is soldered to a wiring pattern

Methodology Applied

Scientific EffectSoldering: Soldering

Implementation Method 2

the bus bar is screwed to the printed board

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Data Source

PatentUS11178753B2Switch device

Publication Date: 2021.11.16 SANYO ELECTRIC CO LTD

AI summary

Bus bars are soldered to a wiring pattern of a printed board to which the bus bars are connected, and the bus bars are screwed to the printed board. Tips of bolts passing through holes in the bus bars and holes in the punted board may be tightened using nuts. The holes in the printed board may be electrically connected to the wiring pattern.