Bus Bar Recess and Rib Engagement for Error-Proof Assembly

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Solution Overview

Problem

Existing bus bars and electrical connection boxes face challenges in improving assembly work efficiency, particularly due to issues with assembly interference and recognition of correct attachment posture.

Innovation Solution

The bus bar design incorporates protrusions and recesses on its sides, allowing for engagement with corresponding projections in the electrical connection box, facilitating easy recognition of the correct attachment posture and reducing interference during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a flat plate shape bus bar is formed by press punching, then manufacturing simplicity is maintained, but assembly work efficiency is insufficient

Engineering Contradiction:

Improveassembly work efficiencyVSAvoidbus bar configuration complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The bus bar is divided into multiple plate-shaped bodies stacked in the thickness direction, with each body having specific connection portions. This segmentation allows for modular assembly and improved work efficiency while maintaining manufacturing simplicity through standardized pressing processes for each layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Protrusions and recesses are asymmetrically positioned on the bus bar plate bodies to create a unique engagement pattern. This asymmetric design ensures correct assembly orientation and improves assembly efficiency by preventing erroneous connections, while the overall structure remains relatively simple.

Inventive Principle:

Principle #4Asymmetry

2Productivity

If multiple plate-shaped bus bar bodies are stacked, then assembly work efficiency is improved, but recognition of correct attachment posture becomes difficult

Engineering Contradiction:

Improveassembly work efficiencyVSAvoidrecognition of correct attachment posture

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The protrusions and recesses are positioned asymmetrically on each plate-shaped bus bar body, creating a unique mechanical engagement pattern. This asymmetry provides clear tactile and visual cues for the correct attachment posture, making it easy to recognize the proper assembly orientation while maintaining improved assembly efficiency.

Inventive Principle:

Principle #4Asymmetry

3Productivity

If protrusions and recesses are added for engagement, then assembly efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveassembly efficiencyVSAvoidbus bar manufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The protrusions and recesses are pre-formed as integral features of the plate-shaped bus bar bodies during the pressing manufacturing process. This preliminary action incorporates the engagement features into the base manufacturing step, avoiding additional complex post-processing operations while still achieving improved assembly efficiency.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20260051420A1Bus bar and electrical connection box

Publication Date: 2026.02.19 YAZAKI CORP

AI summary

A bus bar includes a plate-shaped bus bar body provided with a plurality of connection portions electrically connected to bus bars as connection partners being provided as connection portions, a first protrusion provided to protrude from one side plate face of the bus bar body, and a second protrusion provided to protrude from the other side plate face of the bus bar body. The bus bar body has a recess, and in a normal attachment posture in which the bus bar body is attached to an electrical connection box as an installation target having a rib as a projection, the recess and the rib are engaged.