Busbar Support Housing for PCB Tolerance Compensation
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Solution Overview
Problem
Conventional methods for fixing busbars on circuit boards fail to compensate for manufacturing tolerances and mechanical stresses during assembly, leading to potential damage from insertion forces.
Innovation Solution
A device with a housing that encloses busbars between the circuit board and a housing wall, featuring a conical supporting element and screw base for secure fixation, allowing for tolerance compensation and minimizing mechanical stress, while maintaining electrical isolation and using nonconductive materials for minimal weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If busbars are fixed directly to the circuit board with rigid components, then the position and arrangement of busbars are precisely defined, but manufacturing tolerances cannot be compensated and mechanical stresses occur during assembly
Solution Approach 1:
The patent employs a plastic housing with an integrated flexible support element that can elastically deform to accommodate manufacturing tolerances. The housing acts as a flexible intermediary between the rigid circuit board and busbar, absorbing dimensional variations while maintaining precise busbar positioning. This resolves the contradiction by providing both precision (through the structured housing) and adaptability (through the elastic support element).
Solution Approach 2:
The support element's elastic properties allow it to change its physical parameters (shape, position) in response to assembly variations. By designing the support element with specific elastic characteristics, the system can dynamically adjust to tolerance deviations during assembly, thereby compensating for manufacturing variations while maintaining accurate busbar positioning.
2Reliability
If busbars are fixed rigidly to the circuit board, then electrical connection stability is improved, but insertion forces cause mechanical stress and potential damage to the circuit board
Solution Approach 1:
The patent introduces a plastic housing with an elastic support element as an intermediary between the circuit board and the busbar. This intermediary absorbs the insertion forces through elastic deformation, preventing direct transmission of mechanical stress to the circuit board. The intermediary maintains reliable electrical connection stability while protecting the circuit board from damage during assembly.
Solution Approach 2:
The elastic support element is pre-designed to provide cushioning against insertion forces before assembly occurs. The element's elastic properties are calculated to absorb expected insertion forces, providing beforehand protection to the circuit board. This preemptive cushioning ensures that mechanical stresses are mitigated during the assembly process while maintaining connection reliability.
3Reliability
If conventional plastic components are used to fix busbars, then electrical isolation is achieved, but tolerance compensation is prevented and assembly stresses increase
Solution Approach 1:
The patent merges multiple functions into a single integrated plastic housing: electrical isolation, mechanical support, tolerance compensation, and stress absorption. The housing combines the isolating function with an elastic support element that simultaneously provides tolerance compensation and stress relief. This integration achieves electrical isolation while simplifying the assembly process through a single component that handles multiple requirements.
Solution Approach 2:
The housing is made from plastic material that combines electrical non-conductivity with elastic mechanical properties. This composite material approach allows the single component to provide both electrical isolation (through the plastic's insulating properties) and tolerance compensation (through the elastic deformation capability), thereby simplifying assembly while maintaining reliability.
4Reliability
If multiple separate components are used for busbar fixation, then functional requirements are met, but device complexity and production costs increase
Solution Approach 1:
The patent combines isolation, support, and fixation functions into a single integrated plastic housing with an embedded elastic support element. This merging eliminates the need for multiple separate components (isolation barriers, separate support elements, fixation devices), reducing device complexity while maintaining reliable busbar fixation. The integrated design simplifies production and assembly processes.
Solution Approach 2:
The plastic housing serves multiple functions simultaneously: electrical isolation of the busbar, mechanical support through the elastic element, tolerance compensation, and stress absorption. This multi-functionality replaces what would traditionally require multiple separate components, thereby reducing device complexity and production costs while ensuring reliable fixation.
Data Source
AI summary
The invention relates to a device for receiving and supporting busbars as electrical connection elements for a circuit board. The device is arranged in a gap between the circuit board and a housing wall, in contact with the circuit board and with the housing wall, and comprises a housing which receives at least one busbar and which, on a first end, is designed with a supporting element for holding the device on the housing wall. Here, the housing wall is designed with a screw base of a screw connection, and the supporting element is designed in the form of an eyelet such a manner that the supporting element encloses the screw base at least partially, and the circuit board is connected on a front side of the screw base to the housing wall.