Insert-Molded Connector Bus Bar Positioning for Reliable Fastening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors face challenges in maintaining positional accuracy of bus bars due to flow pressure during the molding process, leading to potential displacement and improper connection between terminals and bus bars.
Innovation Solution
The connector design incorporates recessed portions on the bus bars engaged with the molding die's inner surface, reducing positional deviation and enhancing accuracy, while the bus bars are insert-molded in a housing with grooves to minimize resin shrinkage and maintain precise gap dimensions between fastened portions and nuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are insert-molded in housing during molding process, then electrical connection reliability is improved, but positional deviation of bus bars occurs due to flow pressure of molten resin
Solution Approach 1:
Positioning protrusions are provided on the bus bars before the insert molding process. These positioning protrusions engage with corresponding positioning recesses in the molding die, establishing precise positions in advance before the molten resin is injected, thereby preventing positional deviation during the molding process
Solution Approach 2:
The positioning protrusions and positioning recesses act as intermediary elements between the bus bars and the molding die. These intermediaries transmit and constrain the position of the bus bars, ensuring they remain at the correct positions while withstanding the flow pressure of the molten resin during injection molding
2Manufacturing precision
If positioning protrusions are provided on bus bars, then positional accuracy is improved, but device complexity increases
Solution Approach 1:
The positioning protrusions are integrated directly onto the bus bars as part of their structure, and the positioning recesses are formed in the molding die. This merging of positioning functions into existing components avoids adding separate positioning devices, thereby minimizing the increase in device complexity while still achieving improved positional accuracy
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
A connector includes a resin housing to be assembled to a wall portion of a box-shaped body, a bus bar held by the housing and having a fastened portion that is disposed inside the wall portion and is to be connected to a terminal fitting by fastening using a bolt, and a nut held by the housing with a gap between the nut and the fastened portion, the gap allowing insertion of the terminal fitting and engaged with the bolt to fasten the fastened portion and the terminal fitting inserted into the gap together. In the bus bar, a recessed portion recessed such that the bus bar is cut off is provided inside the wall portion. The recessed is exposed to an outside of the housing without being covered with a resin constituting the housing.