Conductive Member Connection Terminals Bending
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Solution Overview
Problem
Existing connection structures for electrical component assemblies in vehicle brake hydraulic pressure control apparatuses result in size increases and reduced production yield due to the need for space to accommodate rising connection terminals, leading to increased material loss and manufacturing inefficiencies.
Innovation Solution
A connection structure where the connection terminal sections of electrically conductive members are bent towards the side of the electrical component assembly, with one terminal section positioned off-axis relative to the other, allowing for a more compact design and reduced material waste during manufacturing, and incorporating a housing with embedded connection terminals and a wire bonding section with a gap for improved workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection terminal sections rise along the axis direction of the coil, then electrical connection is achieved, but size increase occurs in the assembled apparatus
Solution Approach 1:
The connection terminal sections are bent to protrude in a direction substantially perpendicular to the axis direction of the coil, changing the dimensional orientation from axial to radial/protruding direction. This allows electrical connection to be achieved without increasing the apparatus size in the coil axis direction.
Solution Approach 2:
One connection terminal section is positioned at a location deviated in the axis direction of the coil relative to the other connection terminal section, creating an asymmetric arrangement that optimizes space utilization and enables compact assembly while maintaining electrical connectivity.
2Reliability
If connection terminal sections rise along the axis direction of the coil, then electrical connection is achieved, but material loss increases during manufacturing
Solution Approach 1:
By bending the connection terminal sections to protrude perpendicular to the coil axis rather than rising axially, the press punching operation can be performed more efficiently with reduced material waste, as the terminals utilize the plate material more effectively in the bent configuration.
3Strength
If intermediate wall encloses entire circumference of electrical component assembly, then structural support is provided, but housing weight and cost increase
Solution Approach 1:
The intermediate wall is designed with an opening that allows the electrical component assembly to pass through, rather than enclosing the entire circumference. This extraction of the enclosed structure reduces the amount of resin material needed while still providing necessary structural support through the remaining wall portions.
Data Source
AI summary
A method for producing a pair of electrically conductive members assembled into an electrical component assembly provided with a coil. The method includes: forming connection terminal sections provided in the pair of electrically conductive members by arranging them alternately opposite to each other and then performing press punching; and after the press punching, bending the connection terminal sections in the pair of electrically conductive members toward a side departing from the coil into a protruding form.