Electrical Connection Unit Layout for Easier Connector Assembly
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Solution Overview
Problem
The assemblability of electrical connection units, particularly those with bus bars and electronic components, is a challenge due to complex assembly processes and the need for improved connectivity and insulation.
Innovation Solution
An electrical connection unit design featuring a base member with a flat surface, a conductive bus bar, electronic components connected to a routing board via connection components, and a connector member with specific holding portions for improved assembly, including a connector member that facilitates easy attachment and detachment of connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex assembly structure is used to accommodate bus bars and electronic components, then the functionality and reliability are improved, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The electrical connection unit is divided into distinct functional modules: a base member for accommodating bus bars, a separate connector member for electronic components, and a cover member. This segmentation allows each module to be manufactured and assembled independently, simplifying the overall assembly process while maintaining functional integrity and reliability.
Solution Approach 2:
The base member serves multiple functions: it provides structural support, accommodates bus bars, and integrates connector holding portions. The cover member simultaneously protects internal components and provides a mounting surface. This multi-functionality reduces the number of separate parts needed, simplifying assembly while ensuring reliable electrical connections.
2Volume of moving object
If multiple connectors and electronic components are integrated in a compact arrangement, then the space efficiency is improved, but the assembly complexity increases
Solution Approach 1:
Electronic components are mounted on the connector member, which itself is integrated into the base member structure. The cover member then encloses these components, creating a nested arrangement where smaller elements are contained within larger structures. This nesting achieves compact volume while keeping assembly steps sequential and manageable.
Solution Approach 2:
The connector holding portions are integrated directly into the base member, combining the functions of support and connector retention in a single structural element. This merging reduces the number of separate components and assembly operations needed, achieving compact integration without proportionally increasing assembly complexity.
3Ease of operation
If connectors are made detachable for ease of connection and disconnection, then the ease of operation is improved, but the risk of connection errors or loose connections increases
Solution Approach 1:
The connector member is designed with detachable connectors that can be easily connected and disconnected when needed, providing operational flexibility. The dynamic design allows for easy assembly and disassembly while the integrated holding portions ensure that when connected, the connectors are securely retained, maintaining reliable electrical connections during normal operation.
Solution Approach 2:
The connector member acts as an intermediary between the base member and external connectors. It provides a standardized interface that ensures proper alignment and secure connection, reducing the risk of connection errors. The holding portions on the base member further mediate by providing additional retention, ensuring that detachable connectors remain securely connected during operation.
Data Source
AI summary
An electrical connection unit includes an insulating base member including a plate-shaped or sheet-shaped flat surface portion having a first surface and a second surface, a conductive bus bar held by the flat surface portion, an electronic component including a terminal and a connector connection portion, and a connector member including a first connector detachably connected to the connector connection portion, a second connector to which an external connector is detachably connected from outside, and a connector holding portion holding the first connector and the second connector, in which the connector holding portion includes a first portion holding the first connector and extending in the second direction in a state in which the first connector is connected to the connector connection portion, and a second portion holding the second connector, connected to the first portion, and extending to a first side in the first direction.