Electrical Connection Box Bus Bar Stabilization
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Solution Overview
Problem
Existing electrical connection boxes face reliability issues due to potential deformation or separation of bus bars from heat dissipation plates and coils, leading to unreliable connections and increased temperatures.
Innovation Solution
An electrical connection box design featuring a bus bar, a case made of heat conductive material, a terminal connected to the bus bar, a fixing member, and a base member that overlaps the connection portion, ensuring stable contact between the bus bar and terminal, and effective heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is positioned higher to ensure contact with the coil, then the electrical connection reliability improves, but the bus bar may be pressed downward and deform, causing contact failure
Solution Approach 1:
The fixing member is positioned in advance at a location that overlaps the connection portion of the bus bar. When the terminal and bus bar are connected, the fixing member automatically moves to contact and secure the bus bar, preventing deformation before it can occur during operation.
Solution Approach 2:
The fixing member acts as an intermediary element between the terminal connection and the bus bar positioning. It provides mechanical support and stabilization to the bus bar connection portion, ensuring both electrical reliability and positional stability without requiring the bus bar itself to bear the full mechanical load.
2Stability of the object's composition
If the bus bar is positioned lower to prevent deformation, then the bus bar stability improves, but the bus bar may separate from the heat dissipation plate, causing temperature increase
Solution Approach 1:
The base member serves as an intermediary that provides mechanical support to the bus bar connection portion without interfering with the heat dissipation function. It stabilizes the bus bar position while allowing maintained contact with the heat dissipation plate, preventing both deformation and thermal issues.
Solution Approach 2:
The support function is segmented from the heat dissipation function. The base member handles mechanical support and positioning, while the heat dissipation plate continues to perform thermal management independently. This separation allows optimal positioning for both stability and heat dissipation.
3Manufacturing precision
If a fixed positioning structure is used to maintain bus bar position, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The fixing member is pre-positioned in the base member at a location that overlaps the bus bar connection portion. This preliminary positioning eliminates the need for complex adjustable mechanisms, achieving precise bus bar positioning through a simple, fixed structure that reduces overall device complexity.
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
The design provides high electrical connection reliability by maintaining stable contact between the bus bar and connected members, preventing failures and temperature increases, while enhancing heat dissipation through the use of a heat conductive case.
Implementation Method 1
the case may be a heat dissipation member made of a heat conductive material. Such a configuration improves heat dissipation of the case because the heat generated in the bus bar is dissipated to the outside of the case via the heat dissipation member due to the heat dissipation function of the case.
Implementation Method 2
The electronic component may be a coil. Such a configuration makes it possible to prevent an increase in the temperature of the electrical connection box because the heat generated in the coil is transmitted to the bus bar.
Data Source
AI summary
An electrical connection box includes a bus bar, a case to which the bus bar is fixed, a terminal that is connected to the bus bar, a fixing member that fixes a connection portion at which the terminal and the bus bar are connected to each other, and a base member that holds the fixing member. The fixing member and the base member are disposed at a position at which the fixing member and the base member overlap the connection portion of the bus bar, and when the connection portion at which the terminal and the bus bar are connected to each other is fixed, the base member moves in a direction in which the base member comes into contact with the bus bar.