Connector Partition Wall Liquid-Tight Seal for Busbar Isolation
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Solution Overview
Problem
Conventional connectors with busbars fastened using bolts face challenges in preventing unintended short-circuiting and forming partition-wall-separated terminal housing rooms, making it difficult to ensure electrical isolation between busbars.
Innovation Solution
A connector design featuring a housing with integrated busbars and a cover that includes partition walls with liquid-tight portions formed by engaging projections and recesses, ensuring separation and insulation between fastening target portions of busbars, even when terminal metal fittings are fastened using bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal metal fittings are fastened to busbars using bolts, then fastening strength and reliability are improved, but it becomes difficult to form partition-wall-separated terminal housing rooms and prevent unintended short-circuiting between busbars
Solution Approach 1:
The housing is divided into multiple housing rooms by partition walls, with each housing room accommodating a specific busbar and its terminal metal fittings. This segmentation physically isolates different busbars electrically while maintaining the bolt fastening connection for reliable electrical contact within each housing room.
Solution Approach 2:
Partition walls serve as intermediary structures between adjacent housing rooms, providing both mechanical support and electrical insulation. These partition walls enable the coexistence of bolt-fastened connections (requiring direct contact) while maintaining electrical isolation through their insulating properties.
2Reliability
If partition walls are added to separate housing rooms for electrical isolation, then unintended short-circuiting is prevented, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The partition walls are integrated directly into the housing structure, combining the functions of the housing and isolation barriers into a single molded component. This merging eliminates the need for separate isolation parts, reducing assembly steps and manufacturing complexity while maintaining effective electrical isolation between housing rooms.
3Ease of operation
If bolts and working spaces are provided for fastening terminal metal fittings to busbars, then fastening work can be performed, but available space for terminal housing rooms is reduced
Solution Approach 1:
The connector design utilizes three-dimensional spatial arrangement within each housing room, positioning the busbar, terminal metal fittings, and bolt fastening components in different spatial dimensions. This allows adequate working space for fastening operations while maximizing the utilization of available housing room volume.
Data Source
AI summary
A connector includes: a number of busbars; a housing holding of the busbars; and a cover mounted on the housing. The busbars each have a fastening target portion to connect a terminal metal fitting by using a bolt. The fastening target portion is housed in a housing room, and a number of the housing rooms is defined between the housing and the cover. One of the housing rooms corresponding to the fastening target portion of one of the busbars and another of the housing rooms corresponding to the fastening target portion of another of the busbars are separated with a partition wall, and at least part of the partition wall has a liquid-tight portion formed by engaging a projection of one of the housing and the cover with a recess of the other of the housing and the cover.