Conductor Module Fixing Member Plastic Deformation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional conductor modules face challenges in miniaturization due to the need for a locking mechanism that restricts the busbar's movement, requiring additional height in the accommodation case for the locking portion, which hinders the reduction of the module's overall height.

Innovation Solution

The conductor module employs a fixing member with plastic deformation capabilities, using fixing legs that insert into through holes and fixing holes to securely attach the connection conductors to the accommodation case, eliminating the need for the case to perform the locking function, thus allowing for a reduced height design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a locking portion is formed in the accommodation case wall to restrict busbar movement, then the busbar is securely fixed, but the accommodation case height increases

Engineering Contradiction:

Improvebusbar fixation reliabilityVSAvoidaccommodation case height

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The locking function is extracted from the accommodation case and transferred to a separate fixing member. The fixing member includes locking portions that engage with both the busbar and the accommodation case, removing the requirement for the case itself to have integrated locking structures, thereby reducing case height.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fixation system is segmented into distinct components: the accommodation case, the busbar, and a separate fixing member. This segmentation allows each component to have optimized dimensions for its specific function, with the fixing member providing the necessary locking mechanism without increasing the case height.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If the locking portion is made elastically deformable to enable busbar insertion, then the busbar can be inserted and locked, but additional height is required for the elastic deformation space

Engineering Contradiction:

Improvebusbar insertion easeVSAvoidaccommodation case height

Core Design Contradiction:

Ease of operationVSLength of stationary object

Solution Approach 1:

The elastic locking mechanism is extracted from the accommodation case and placed in the separate fixing member. The fixing member's locking portions can be elastically deformable to facilitate busbar insertion, while this deformation space does not increase the accommodation case height since the fixing member is a separate component.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If soldering or welding is used to connect the detection conductor to the busbar, then reliable electrical connection is achieved, but the process complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The electrical connection method is replaced from thermal processes (soldering/welding) to a mechanical connection system. The fixing member provides both mechanical fixation and electrical connection through conductive portions that contact the busbar and detection conductor, eliminating the need for soldering or welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The fixing member is designed to perform multiple functions simultaneously: mechanical fixation of the busbar, electrical connection between the detection conductor and busbar, and structural support. This multi-functionality reduces manufacturing complexity by consolidating multiple operations into a single component installation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enables the miniaturization of the conductor module by allowing the busbar, power cable terminal, and detection terminal to be reliably fixed without the need for extensive accommodation case height, promoting a more compact design.

Implementation Method 1

the fixing legs are capable of plastic deformation by an external force

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20180175535A1Conductor module

Publication Date: 2018.06.21 YAZAKI CORP

AI summary

A conductor module includes a busbar, an accommodation case, and a fixing member. The accommodation case has two or more fixing holes that pass through a fixing body first surface and a fixing body second surface. The fixing member includes a main body and fixing legs. The fixing legs are associated with the respective fixing holes, and have a part of the busbar interposed therebetween. The fixing legs are capable of plastic deformation by external force, are inserted in the respective fixing holes from a side of the fixing body first surface to protrude from a side of the fixing body second surface, and, under a fixed condition in which the busbar is fixed to the accommodation case by the fixing member, have leading ends disposed on an outside in a radial direction with respect to the fixing holes as viewed in an axial direction of the fixing holes.