Bus Bar Insert Molding for Terminal Deformation Control

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Solution Overview

Problem

Tuning fork terminals in battery direct-attachment fuse terminals (BFTs) are prone to deformation due to external forces applied during manufacturing steps, compromising dimension precision.

Innovation Solution

The manufacturing method involves insert molding the housing with the bus bar in a before-bending state where the standing terminals are on the same plane as the main plate parts, followed by bending the terminals after molding, and using protection walls and sub-housings to prevent deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the bus bar is transferred between manufacturing steps or welding operations are performed while the standing terminals are in an erected state, then the manufacturing process can be completed, but the standing terminals are prone to deformation due to external forces, compromising dimension precision

Engineering Contradiction:

Improvedimension precision of standing terminalsVSAvoiddeformation of standing terminals

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by performing the housing insert molding operation before the standing terminals are bent into their final erected position. The bus bar is first molded with the housing while the terminals remain in a safe, non-erected state that is resistant to deformation. After molding is complete, the terminals are then bent to their final position, eliminating the risk of deformation during the critical molding process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing process is segmented into distinct sequential steps: first molding the bus bar with housing while terminals are flat, then separately performing the bending operation to erect the terminals. This segmentation allows each operation to be optimized independently, with the molding step free from terminal deformation risks and the bending step performed only after the housing provides structural support.

Inventive Principle:

Principle #1Segmentation

2Shape

If the standing terminals are bent before housing insert molding, then the terminals can be positioned correctly, but they are exposed to external forces during molding that can cause deformation

Engineering Contradiction:

Improveerected position of standing terminalsVSAvoiddimension precision of standing terminals

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent reverses the conventional sequence by performing the housing insert molding operation before the standing terminals are bent into their final erected position. The bus bar is first molded with the housing while the terminals remain in a safe, non-erected state that is resistant to deformation. After molding is complete, the terminals are then bent to their final position, eliminating the risk of deformation during the critical molding process.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If the standing terminals remain in the same plane as the main plate parts during molding, then deformation is prevented, but additional bending operations are required after molding

Engineering Contradiction:

Improvedimension precision of standing terminalsVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

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 prevents unnecessary deformation of the standing terminals, ensuring necessary dimension precision and protecting them post-molding, facilitating bending and cutting operations.

Implementation Method 1

a resin-made housing so insert molded as to cover other portions of the bus bar than the exposed portion thereof

Methodology Applied

Scientific EffectInsert molding:

Implementation Method 2

the base ends of the tuning fork terminals 221, 222 are bent 90° to erect the terminals 221, 222 to be orthogonal to the input side terminal 211 and output side terminals 212, 213

Methodology Applied

Scientific EffectBending:

Implementation Method 3

low meting metal, namely, tin chips 216, 217 are caulked and welded to the caulking pieces 214, 215 of the welding parts 218, 219 to complete the welding parts 218, 219

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10250002B2Method of manufacturing electrical connection block

Publication Date: 2019.04.02 YAZAKI CORP

AI summary

An electric connection block is provided with a bus bar formed from a press-formed product of a metal plate member and a resin-made housing insert molded integrally with the bus bar. The bus bar is provided with a flat plate-shaped main plate part and a standing terminal erected by bending a base end connected to a portion of the main plate part relative to the main plate part. The electric connection block is manufactured by insert molding the housing integrally with the bus bar in a before-bending state where the standing terminal is located on the same plane as the main plate part, and bending the base end of the standing terminal to thereby erect the standing terminal relative to the main plate part after the insert molding of the housing.