Resin Molded Component Busbar Positioning via Insert Molding
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Solution Overview
Problem
Riveting a busbar to a resin molded component is challenging due to positional variability under pressure and temperature changes, leading to incorrect mounting of electronic components and potential capacitance loss when using a flat cable as a intermediary.
Innovation Solution
A resin molded component with an integrated metal plate, where the busbar is insert-molded and held by forming dies during resin molding, ensuring accurate positioning and eliminating the need for intermediary wires by fixing the busbar directly to the electronic component's terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a busbar is fixed to a resin molded component by inserting and squeezing a resin rib through a through hole, then the busbar can be connected to the component, but the fixed position of the busbar varies due to changes in pressure and temperature during squeezing
Solution Approach 1:
The busbar is positioned and fixed to the resin molded component before the riveting process. The resin rib is inserted through the through hole and squeezed to secure the busbar in its correct position, ensuring that the busbar is already firmly attached when the electronic component is riveted to it. This preliminary positioning action eliminates position variations during subsequent manufacturing steps.
Solution Approach 2:
The connection structure is divided into separate functional elements: the resin molded component with through holes, the resin ribs for positioning, and the busbar with mounting holes. This segmentation allows each element to be optimized independently - the resin ribs can be precisely shaped for accurate positioning, while the busbar can be designed with appropriate hole locations for both component mounting and electronic component attachment.
2Productivity
If the busbar and electronic component are connected forcibly by riveting without proper positioning, then the connection can be made, but the electronic component is fixed at a position displaced from the originally set mount position
Solution Approach 1:
The busbar is pre-positioned and firmly attached to the resin molded component using the resin rib insertion and squeezing method before the riveting process begins. This preliminary action ensures that the busbar remains stationary and maintains its correct position during the subsequent riveting operation, allowing the electronic component to be mounted at the precisely intended location without displacement.
Solution Approach 2:
The resin rib structure provides a cushioning or buffering effect that absorbs positioning errors and prevents them from being transmitted to the busbar and electronic component connection. By having the resin rib already in place and secured, any variations in riveting pressure or position are cushioned, preventing displacement of the electronic component from its intended mount position.
3Ease of manufacture
If a flat cable is interposed between the busbar and electronic component to enable connection, then the connection can be made, but the number of parts increases and capacitance decreases
Solution Approach 1:
The busbar and electronic component are directly connected through the resin molded component structure, merging the electrical connection function into the mechanical mounting structure. The resin molded component serves simultaneously as the structural base, the positioning mechanism (through resin ribs), and the electrical connection medium, eliminating the need for a separate flat cable intermediary and preserving capacitance.
Solution Approach 2:
The resin molded component is designed with multi-functionality: it provides structural support, contains through holes for resin rib insertion and positioning, serves as the electrical connection path between busbar and electronic component, and integrates the mounting function. This universal design eliminates the need for separate flat cable components while maintaining all necessary functions.
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 ensures precise positioning of the busbar and electronic components, preventing displacement and unnecessary stress, while maintaining capacitance by eliminating the need for intermediary wires, thus enabling reliable and cost-effective riveting connections.
Implementation Method 1
a resin molded portion (20) insert-molded to be integral to the metal plate (10)
Implementation Method 2
The exposed portion of the busbar is held tightly between a pair of forming dies during the insert-molding of the resin molded portion
Implementation Method 3
The electronic component is held on a surface of the metal plate by riveting or otherwise fixing
Data Source
AI summary
A sensor unit (1) has a metal plate (10), a resin molded portion (20) and an oil temperature sensor (2). Busbars (4) made of a metal are arranged in the resin molded portion (20). Since the busbars (4) are insert-molded while having the exposed ends (4A) thereof tightly held by a pair of forming dies, a distance between the exposed ends (4A) and the placing surface 10A is held constant. Further, gate marks (5D) of the oil temperature sensor (2) are accommodated in recesses (10B) of the placing surface (10) and engaging grooves (9) and engaging projections (26A) are engaged. Thus, the oil temperature sensor (2) can be held in a proper posture. Additionally, the oil temperature sensor (2) can be held on the placing surface (10A) by riveting the exposed end (4A) and a terminal (8) of the oil temperature sensor (2).