Busbar Regulating Portion Prevents Resin Case Scratching
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Solution Overview
Problem
The existing methods for fabricating synthetic resin base plates with busbars, such as insert molding, are complex, time-consuming, and labor-intensive, leading to increased production costs and potential conduction failures due to burrs generated during the shear cutting process, which can cause resin powder to scratch the resin case and result in conduction failures.
Innovation Solution
A busbar configuration with a regulating portion to prevent burrs from scratching the resin case, featuring a metal plate with a burr extending opposite to the insertion direction for positioning and a connected portion with a burr in the insertion direction to avoid contact with the case, along with a resin case design incorporating tapered guides for accurate busbar placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If insert molding is used to fabricate synthetic resin base plates with busbars, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
The fabrication process is divided into separate steps: busbar preparation (with press punching and shear cutting) and subsequent assembly into the resin base plate. This segmentation allows each component to be manufactured independently with optimized processes, reducing overall device complexity while maintaining positioning precision through dedicated fixtures and guide structures.
Solution Approach 2:
The busbar is prepared in advance with press punching and shear cutting operations that create specific geometries and burr patterns. These preliminary actions on the busbar enable simplified assembly into the resin base plate, as the pre-formed features guide positioning and reduce the complexity of the molding process itself.
2Productivity
If shear cutting is used to cut the busbar, then productivity is improved, but harmful factors increase due to burr generation
Solution Approach 1:
The burrs generated by shear cutting, which are typically harmful, are utilized beneficially by designing the busbar to position these burrs away from the resin case interior. The burrs on the outer surfaces serve as positioning features or are directed outward, converting the harmful byproduct into a functional element that maintains electrical connection integrity.
Solution Approach 2:
Different regions of the busbar are designed with different burr characteristics. The shear cutting is controlled to create burrs on specific surfaces (outer surfaces) while keeping other surfaces (inner surfaces facing the resin case) burr-free or with minimal burrs. This local differentiation ensures high productivity through shear cutting while preventing harmful burr contact with the resin case.
3Ease of manufacture
If busbars are positioned without regulation, then ease of manufacture is improved, but reliability decreases due to conduction failures
Solution Approach 1:
The busbar design incorporates self-positioning features where the geometry of the busbar itself (including burr locations and press-punched features) automatically guides correct positioning within the resin base plate during assembly. This self-service mechanism ensures reliable electrical connections without requiring complex external positioning devices or regulations, maintaining ease of manufacture while improving reliability.
Data Source
AI summary
A busbar for being accommodated in a case includes a metal plate, a regulating portion and a connected portion. The regulating portion is provided at a part of an edge of the metal plate. The regulating portion has a burr extending in a direction opposite to an inserting direction in which the busbar is inserted into the case. The regulating portion is adapted to come in contact with a part of an inner wall of the case so as to regulate a position of the busbar. The connected portion is provided at a part of the edge of the metal plate. The connected portion has a burr extending in the inserting direction. The connected portion is adapted to be disposed so as not to contact the inner wall of the case.