Bus Bar Connection Member With Heat-Sealed Waterproof Interface
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Solution Overview
Problem
Conventional electric connection members face issues with water ingress due to gaps between the primary and secondary molded portions, leading to compromised waterproofness, as the core is not directly held by the molds during secondary molding, allowing resin injection pressure to cause shifting.
Innovation Solution
An electric connection member design featuring a bus bar with a primary molded portion exposed and a secondary molded portion, where a seal member is embedded and heat-sealed around the exposed portion to prevent water entry, with the seal member being press-fitted into a housing cavity for secure attachment and enhanced manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core is not directly held by the fixed mold or upper mold during secondary molding, then the manufacturing process is simpler, but the core may shift under injection pressure leading to gaps and water ingress
Solution Approach 1:
The patent applies preliminary action by pre-forming the primary molded portion with the core in a first molding process, establishing precise positioning features before the secondary molding process. This preliminary structuring ensures that when secondary molding occurs, the core and primary molded portion are already configured to receive and maintain the seal member, preventing gaps and water ingress while maintaining manufacturing simplicity
2Stability of the object's composition
If the core is directly held by the fixed mold or upper mold during secondary molding, then positioning stability is improved, but the held portion is exposed to the outside and may allow water entry through gaps
Solution Approach 1:
The patent introduces a seal member as an intermediary element between the primary molded portion and the secondary molded portion. This seal member fills and seals the gap or groove formed at the interface, acting as a mediator that prevents water ingress while allowing the core to be directly held by the molds for stable positioning during secondary molding
3Adaptability or versatility
If there is a gap between the primary molded portion and secondary molded portion, then manufacturing flexibility is improved, but water proofness deteriorates
Solution Approach 1:
The patent employs a seal member with flexible sealing properties that can accommodate manufacturing variations and gaps between the primary and secondary molded portions. This flexible sealing element adapts to the interface geometry while maintaining water tightness, thus preserving both manufacturing flexibility and water proofness
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 design effectively prevents water from entering through the exposed portions by ensuring a gap-free seal, thereby improving the waterproofness of the electric connection member and maintaining the primary molded portion's stability during secondary molding.
Implementation Method 1
a boundary portion of the seal member to the secondary molded portion is heat sealed to the secondary molded portion
Data Source
AI summary
An electric connection member including: a bus bar that has at least one terminal portion; a primary molded portion formed in one piece with the bus bar in a state where the terminal portion is exposed; a secondary molded portion formed in one piece with the primary molded portion; and a seal member embedded in the secondary molded portion, wherein the primary molded portion includes an exposed portion that is exposed from an opening portion provided in the secondary molded portion, the seal member is shaped to surround the circumference of the exposed portion without a gap, and a boundary portion of the seal member to the secondary molded portion is heat sealed to the secondary molded portion.