Flexible Sheet Circuit Structure for Automotive Bus Bar Mounting
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Solution Overview
Problem
Existing circuit structures for electrical connection boxes in automobiles face difficulties in mounting electronic components due to the need for bending terminals to match the thickness of the circuit substrate, which is troublesome, especially for components with short terminals.
Innovation Solution
A circuit structure that includes a circuit substrate with bus bars and an electronic component straddling the bus bars, using a flexible sheet member with an adhesive layer, terminal conductor foil, and insulating layer to electrically connect the second terminal to the circuit pattern without direct connection, eliminating the need for terminal bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gate terminal is folded and displaced upward to connect to the circuit pattern, then electrical connection is achieved, but the mounting process becomes troublesome and complex
Solution Approach 1:
A flexible sheet member is introduced as an intermediary component between the gate terminal and the circuit pattern. This flexible sheet member includes a conductor portion that electrically connects the gate terminal to the circuit pattern, eliminating the need to fold and displace the gate terminal itself. The flexible sheet member can be easily positioned and fixed, simplifying the mounting process while ensuring reliable electrical connection.
2Reliability
If the gate terminal is bent to match substrate thickness, then proper electrical connection is achieved, but components with short terminals cannot be properly mounted
Solution Approach 1:
The flexible sheet member serves as a mediator that compensates for the discrepancy between the gate terminal length and the required connection point on the circuit pattern. The flexible sheet member can be adjusted in length and positioning, allowing components with various terminal lengths to be properly mounted and connected without requiring the terminal itself to be bent or extended.
3Reliability
If multiple separate components are used for connection and insulation, then electrical insulation is ensured, but the number of components increases
Solution Approach 1:
The flexible sheet member integrates multiple functions into a single component: it provides electrical connection through its conductor portion and electrical insulation through its insulator portion. This merged structure eliminates the need for separate connection elements and insulation elements, reducing the total number of components while ensuring both electrical connection and insulation requirements are met.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates easy mounting of electronic components on the circuit substrate, improves insulation, and reduces the number of components required, while maintaining electrical connections over time by absorbing thermal expansion and contraction.
Implementation Method 1
an adhesive layer that is fixed to the one bus bar
Implementation Method 2
an insulating layer that is interposed between the adhesive layer and the terminal conductor foil piece and insulates the one bus bar and the terminal conductor foil piece from each other
Implementation Method 3
a terminal conductor foil piece that electrically connects the second terminal and the circuit pattern to each other
Data Source
AI summary
A circuit structure includes a circuit substrate surface having a circuit pattern; a plurality of bus bars are fixed to another surface of the circuit substrate with an interval therebetween; an electronic component straddles an interval between two adjacent bus bars, a first terminal is electrically connected to one bus bar and a second terminal is electrically connected to the circuit pattern; and a flexible sheet member is fixed to the bus bar to insulate the bus bar and the second terminal from each other, while electrically connecting the second terminal and the circuit pattern. The flexible sheet member includes: an adhesive layer fixed to the bus bar; a terminal conductor foil piece electrically connecting the second terminal and the circuit pattern; and an insulating layer that is interposed between the adhesive layer and the terminal conductor foil piece insulating the bus bar and the terminal conductor foil piece.