Connector Bus Bar Protrusions for Thermal Displacement Control
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Solution Overview
Problem
The housing of existing connectors made from synthetic resin experiences dimensional changes due to temperature variations, leading to displacement between the bus bar and terminals, which can cause increased friction, plating peeling, and potential rust or elevated electric resistance.
Innovation Solution
A connector design where the bus bar includes contact pieces and support portions with protrusions that are aligned with the contact points and locking positions in the longitudinal direction of the housing, reducing the impact of volume changes and maintaining a stable contact state between the bus bar and terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing is made from synthetic resin, then the connector can be manufactured with ease and cost-effectiveness, but the housing experiences dimensional changes due to temperature variations causing displacement between bus bar and terminals
Solution Approach 1:
The patent introduces protrusions on the bus bar that align with recesses in the housing to create a mechanical interlocking structure. This changes the positional parameters of the bus bar relative to the housing, preventing displacement caused by thermal expansion of the synthetic resin housing while maintaining ease of manufacture through simple structural modifications.
Solution Approach 2:
The bus bar is divided into functional segments: contact pieces for electrical connection, support portions for structural integrity, and protrusions for positional stabilization. This segmentation allows each part to perform its specific function independently, with the protrusions specifically addressing the thermal expansion issue without affecting other functions.
2Reliability
If the contact pieces and locking positions are aligned in the longitudinal direction, then displacement is suppressed, but the structure becomes more complex
Solution Approach 1:
The patent combines multiple functions into the bus bar structure: the protrusions serve both as positioning elements for preventing displacement and as integral parts of the bus bar itself. This merging approach avoids adding separate locking mechanisms, thereby suppressing displacement while minimizing increases in device complexity.
Solution Approach 2:
The protrusions on the bus bar serve multiple purposes: they provide mechanical interlocking with the housing to prevent displacement, maintain alignment during assembly, and work together with the support portions to distribute mechanical loads. This multi-functionality addresses reliability concerns without requiring additional dedicated components.
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 effectively suppresses displacement between the bus bar and terminals, preventing plating peeling, rust, and increased electric resistance, thereby enhancing the reliability and stability of the connector.
Implementation Method 1
protrusions provided in support portions of the bus bar and locked to the bus bar receiving chamber of the housing
Implementation Method 2
contact pieces inserted into electric connection portions are pressed against elastic arms which are contact point portions folded back on inner sides of the electric connection portions
Data Source
AI summary
A connector (10) includes terminals (12), a bus bar (11), and a housing (14). Electric wires (19) are connected to the terminals (12). The bus bar (11) electrically connects the terminals. The housing (14) has terminal receiving chambers (16) and a bus bar receiving chamber (15). The terminals (12) are received in the terminal receiving chambers (16). The bus bar (11) is received in the bus bar receiving chamber (15). The bus bar has contact pieces (24), a coupling portion (25), and support portions (26). The support portions (26) extend from both end portions of the coupling portion. A position where the contact pieces make contact with contact point portions and a position where protrusions (29a, 29b) provided in the support portions are locked to the bus bar receiving chamber are aligned with each other in a longitudinal direction of the housing.