Bus Bar Recessed Base Layout for Low-Height Electrical Connections
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Solution Overview
Problem
The challenge is to reduce the height of electrical connection units while maintaining their functionality and efficiency, particularly in applications such as in-vehicle devices.
Innovation Solution
The electrical connection unit incorporates a design with a first bus bar accommodated in a recessed or penetrating accommodation portion of an insulating base member, allowing the bus bar to protrude outside for connection, thereby reducing the overall height without compromising electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a bus bar is attached to the housing in a standing posture, then electrical connection functionality is ensured, but the height of the electrical connection unit increases
Solution Approach 1:
The bus bar is repositioned from a vertical standing posture to a horizontal layout within a recessed accommodation portion of the insulating base member. This dimensional change allows the bus bar to be accommodated within the planar footprint of the housing rather than extending vertically, thereby reducing the overall height while maintaining electrical connection functionality through the protruding connection portion.
Solution Approach 2:
The bus bar is nested within the recessed accommodation portion of the insulating base member. The accommodation portion is formed by recessing the insulating base member, creating a cavity that houses the bus bar. This nesting arrangement allows the bus bar to be integrated within the structure rather than attached externally, reducing height while preserving functionality.
2Length of stationary object
If the bus bar is accommodated in a recessed accommodation portion, then height is reduced, but manufacturing complexity increases
Solution Approach 1:
The accommodation portion is merged with the insulating base member as an integrated structure. The recessed accommodation portion is formed directly in the insulating base member, combining the base member and accommodation cavity into a single component. This integration reduces the number of separate parts and assembly steps, thereby reducing manufacturing complexity despite the recessed geometry.
3Reliability
If the bus bar protrudes from the first surface, then electrical connection is enabled, but height increases
Solution Approach 1:
The bus bar is configured with differentiated local qualities: the connection portion protrudes from the insulating base member to enable electrical connection, while the other portions are accommodated within the recessed accommodation portion. This localized protrusion only where needed allows electrical connectivity without requiring the entire bus bar to extend outward, thereby minimizing height increase.
Data Source
AI summary
An electrical connection unit includes a first electronic component, an insulating base member, and a first bus bar. The base member includes a plate-shaped or sheet-shaped flat surface portion having a first surface facing the first electronic component. In a case where a thickness direction of the flat surface portion is a first direction, the flat surface portion includes a first accommodation portion that is recessed in the first direction or penetrates the flat surface portion in the first direction. The first bus bar has a first connection portion electrically connected to the first electronic component, and at least part of the first bus bar is accommodated in the first accommodation portion and extends along the flat surface portion. At least the first connection portion of the first bus bar protrudes from the first surface to outside of the first accommodation portion in the first direction.