Flat Bus Bar Routing Board for Low-Height Electrical Connections
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Solution Overview
Problem
The existing electrical connection units have a high height that needs to be reduced for more compact designs, particularly in applications like in-vehicle devices.
Innovation Solution
A routing board design incorporating a first and second bus bar with insulating members and bent portions to minimize vertical space, allowing for a more compact electrical connection unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If bus bars are arranged in a standing posture in the housing, then electrical connection functionality is achieved, but the height of the electrical connection unit becomes large
Solution Approach 1:
The bus bars are changed from a standing posture (vertical arrangement) to a flat arrangement on the same plane. The first and second bus bars are disposed on the same plane and extend in plate shape, with the second bus bar positioned away from the first bus bar in the first direction. This dimensional change from vertical to horizontal arrangement significantly reduces the height of the electrical connection unit while maintaining electrical connection functionality.
Solution Approach 2:
The first and second bus bars are merged into the same plane rather than being stacked vertically. Both bus bars extend in plate shape and are positioned side-by-side in the first direction, combining their spatial occupation into a single horizontal plane. This merging approach reduces the overall height requirement while preserving all electrical connection functions.
2Length of moving object
If multiple bus bars are placed on the same plane, then height is reduced, but insulation between bus bars becomes more critical
Solution Approach 1:
An insulating member is introduced as an intermediary between the first and second bus bars. The insulating member includes a first cover portion in contact with the first bus bar and a second cover portion in contact with the second bus bar, with a bent portion connecting these cover portions. The bent portion is joined to the first insulating member, creating a complete insulation barrier that prevents electrical discharge between the bus bars while allowing them to be arranged on the same plane.
Solution Approach 2:
The insulating member utilizes a bent portion that can flexibly connect the first and second cover portions, adapting to the spatial arrangement of the bus bars. This flexible insulation structure effectively separates the bus bars on the same plane while maintaining insulation reliability, enabling the height reduction without compromising electrical safety.
3Length of moving object
If bus bars are arranged horizontally on the same plane, then height is reduced, but the complexity of insulation structure increases
Solution Approach 1:
The insulating member integrates multiple functions into a single structure: the first cover portion insulates the first bus bar, the second cover portion insulates the second bus bar, and the bent portion connects them while providing insulation between the bus bars. This merging of insulation functions into one component reduces the number of separate insulation parts needed, simplifying the overall structure despite the horizontal bus bar arrangement.
Solution Approach 2:
The insulating member is segmented into functional portions (first cover portion, second cover portion, and bent portion) that can be designed and manufactured separately but assembled as a single integrated component. This segmentation allows for optimized design of each portion while maintaining overall structural simplicity and reducing the complexity of the complete insulation system.
Data Source
AI summary
A routing board includes a first bus bar at least partially extending in a plate shape, a second bus bar located on the same plane as the first bus bar, disposed away from the first bus bar in a first direction, and at least partially extending in a plate shape, a first insulating member in contact with the first bus bar and the second bus bar from a second direction intersecting the first direction, a first cover portion that is a sheet-shaped member and is in contact with the first bus bar from a side opposite to the first insulating member, a second cover portion in contact with the second bus bar from the side opposite to the first insulating member, and a first bent portion bent from the first cover portion and the second cover portion toward the first insulating member.