Busbar-to-Terminal Case Positioning for Jig-Free Laser Welding
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Solution Overview
Problem
The challenge of reducing the size of electric devices is hindered by the need for space to accommodate jigs that hold the relative positions of electronic components and busbars, which is exacerbated by the denser packing of components.
Innovation Solution
The electric device incorporates a case with overlapping terminals of electronic components and busbars, utilizing sandwiching portions on the case to hold relative positions without needing a jig, allowing laser welding through an opening in the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dedicated jig is used to hold the relative positions between the terminal of the electronic component and the busbar during laser welding, then the manufacturing precision is improved, but the device complexity increases and the size cannot be reduced
Solution Approach 1:
The patent extracts the positioning function from a separate dedicated jig and integrates it into the case structure itself. The case includes positioning protrusions that directly hold the relative positions of the terminal and busbar, eliminating the need for an external jig while maintaining positioning accuracy during laser welding
Solution Approach 2:
The case is designed to combine multiple functions: it serves as both the housing structure and the positioning device. The positioning protrusions are integrated into the case, merging the support function and positioning function into a single component, thereby reducing device complexity
2Manufacturing precision
If a dedicated jig is used to hold the relative positions between the terminal of the electronic component and the busbar, then the manufacturing precision is improved, but the volume increases
Solution Approach 1:
The positioning function is extracted from a separate jig and integrated into the case structure. The positioning protrusions are formed as integral parts of the case, eliminating the need for additional positioning components that would increase device volume
Solution Approach 2:
The case is designed as a multi-functional component that simultaneously serves as the housing, the support structure, and the positioning device. This universality eliminates the need for separate positioning jigs, thereby reducing the overall device volume
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 enables a reduction in device size by eliminating the need for a jig and optimizing space utilization, while ensuring precise alignment and connection of components.
Implementation Method 1
a busbar disposed in the case and laser-welded to the terminal of the electronic component
Data Source
AI summary
An electric device includes: a case; an electronic component having a terminal and disposed in the case; and a busbar disposed in the case and laser-welded to the terminal. The terminal of the electronic component and the busbar overlap each other, the case has an opening portion, and one or both of the terminal of the electronic component and the busbar are exposed to the outside of the case through the opening portion. The case has a first sandwiching portion configured to come into contact with one of the terminal of the electronic component and the busbar, and a second sandwiching portion configured to come into contact with the other of the terminal of the electronic component and the busbar, and relative positions of the terminal of the electronic component and the busbar are held as a result of sandwiching by the first sandwiching portion and the second sandwiching portion.