Intermediate Busbar Structure for Vibration-Stable Connections
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Solution Overview
Problem
Existing structures using Z-shaped springs to connect busbars and terminals generate noise and risk damage in vibration environments.
Innovation Solution
A structure comprising a fastening member, first and second busbars, and an intermediate structure with a resiliently deformable terminal and housing, where the terminal's coupling portion absorbs positional variations and presses against the housing to stabilize the connection, reducing noise and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a Z-shaped spring is used to connect the busbar and terminal, then misalignment between components is absorbed, but noise is generated and damage occurs in vibration environments
Solution Approach 1:
The patent introduces an intermediate structure comprising a housing and terminal as a mediator between the busbar and connector. The housing with side walls and accommodation portion provides a stable mounting platform, while the terminal with resilient coupling portion absorbs misalignment. This intermediary structure isolates the vibration-prone spring elements from direct connection, reducing noise and damage in vibration environments while maintaining misalignment absorption capability.
Solution Approach 2:
The connection system is divided into separate functional segments: the housing provides structural support and mounting, the terminal with coupling portion handles misalignment absorption, and the spring elements manage connection flexibility. This segmentation allows each component to perform its specific function optimally, with the housing protecting against vibration damage while the coupling portion handles positional variations.
2Stability of the object's composition
If the terminal is rigidly connected to the housing, then structural stability is improved, but positional variations cause stress concentration and potential damage
Solution Approach 1:
The coupling portion of the terminal is designed with changed physical parameters - it is resiliently deformable rather than rigid, allowing it to flex and absorb positional variations. The side walls of the housing provide structural stability while the deformable coupling portion accommodates movement, distributing stress and preventing concentration at connection points.
3Adaptability or versatility
If the coupling portion is made resiliently deformable, then positional variations are absorbed, but the structure becomes more complex
Solution Approach 1:
The coupling portion is designed as a flexible, resiliently deformable element that can bend and flex to accommodate positional variations. This flexible design absorbs misalignment and movement without requiring complex mechanical adjustment mechanisms, achieving adaptability through material and geometric flexibility rather than complex structural systems.
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
The structure effectively reduces noise and minimizes damage to busbars and terminals by absorbing positional variations and stabilizing the connection, even in vibration environments.
Implementation Method 1
The coupling portion is resiliently deformable and couples the first connection portion and the second connection portion together
Implementation Method 2
the pressed portion at least partially bites the side wall in the second direction
Data Source
AI summary
A structure comprises an intermediated structure, a first busbar, a second busbar and a fastening member. The intermediated structure comprises a housing having a side wall and a terminal held by the housing. The terminal has a first connection portion, a second connection portion and a coupling portion. Under a fastened state where the fastening member is fastened, the first connection portion is connected to the first busbar, and the second connection portion is connected to the second busbar. The coupling portion is resiliently deformable and couples the first connection portion and the second connection portion together. One of the second busbar and the terminal has a pressed portion. Under the fastened state, the pressed portion bites the side wall in the second direction.