Connector With Rectangular Busbar For Cost Reduction
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Solution Overview
Problem
Existing connectors with busbars of complicated shapes increase manufacturing costs and are unsuitable for general use due to their specific shape and size requirements for connecting adjacent connectors.
Innovation Solution
A connector design that uses a simple rectangular busbar shape, allowing for easy insertion and connection between two connectors by moving the busbar along a specific orientation, with openings and receiving portions on the connector housing that accommodate the busbar ends, enabling connection without the need for complex shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a busbar of a complicated shape is used to connect two connectors, then the connection between adjacent connectors is achieved, but the manufacturing cost increases
Solution Approach 1:
The busbar is designed with a universal simple rectangular shape that can connect any two adjacent connectors regardless of their specific arrangement. The connector housing includes multiple openings (first opening, second opening) and receiving portions that accommodate the simple busbar shape, allowing one busbar design to serve multiple connection scenarios, thereby reducing manufacturing cost while maintaining connection capability.
Solution Approach 2:
Instead of adapting the busbar shape to fit the connector arrangement, the invention inverts the approach by making the connector housing adaptable to the simple busbar shape. The housing is designed with specific openings and receiving portions that guide and accommodate the simple rectangular busbar, reversing the traditional design logic where the connector would be customized to match complex busbar geometries.
2Adaptability or versatility
If a busbar of a complicated shape is used to connect two connectors, then the connection between adjacent connectors is achieved, but the busbar is unsuitable for general use
Solution Approach 1:
The simple rectangular busbar design serves as a universal connection element that can be used in various connector arrangements and positions. The connector housing is designed with multiple openings and receiving portions that accommodate this simple shape, enabling the same busbar design to be used across different applications and connector configurations, thereby achieving general suitability.
Solution Approach 2:
The invention changes the key parameter of busbar shape from complex to simple rectangular, and compensates by adjusting the connector housing parameters (openings, receiving portions) to accommodate the simplified busbar. This parameter transformation enables the busbar to become suitable for general use while maintaining effective connection capability.
3Ease of operation
If openings are formed on the housing to allow busbar insertion, then connection is enabled, but the housing structure becomes more complex
Solution Approach 1:
The housing is segmented with distinct openings (first opening, second opening) and receiving portions that are separately formed. This segmentation allows the busbar to be inserted through specific openings and guided into specific receiving portions, facilitating easy operation. The segmented structure, while adding some complexity, organizes the housing to clearly define insertion paths and contact regions.
Solution Approach 2:
The openings and receiving portions act as intermediary structures that mediate between the simple busbar and the connector internal components. These intermediaries guide the busbar insertion process and ensure proper positioning, making the operation easier while the complexity is confined to the housing structure rather than the entire connector system.
Data Source
AI summary
A connector comprises a first receiving portion formed with a first opening, a second receiving portion formed with a second opening, a first contact portion located inside the first receiving portion and a second contact portion located inside the second receiving portion. The first opening is visible both when the connector is seen along a first orientation and when the connector is seen along a third orientation perpendicular to the first orientation. The second opening is visible both when the connector is seen along a second orientation opposite to the first orientation and when the connector is seen along the third orientation. The first contact portion is in contact with a first busbar which is received in the first receiving portion through the first opening. The second contact portion is in contact with a second busbar which is received in the second receiving portion through the second opening.