Joint Connector Bus Bar Pattern Identification via Resin Sealed Holes

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Solution Overview

Problem

Conventional joint connectors cannot easily determine or identify bus bar patterns when multiple bus bars are accommodated, as visual identification is challenging and continuity testing methods do not effectively distinguish between different patterns.

Innovation Solution

The joint connector incorporates continuity check holes positioned between adjacent bus bars, with at least one formed in a resin-sealed part filled with insulating resin, allowing for visual differentiation and a method using continuity test pins to identify patterns based on conductivity, where pins corresponding to resin-sealed parts become non-conducting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple bus bars are accommodated in the joint connector, then the functionality and versatility of the connector is improved, but the ability to visually identify and determine bus bar patterns becomes difficult

Engineering Contradiction:

Improvecapability to accommodate multiple bus barsVSAvoiddifficulty of visual identification of bus bar patterns

Core Design Contradiction:

Adaptability or versatilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent applies visual differentiation through color coding or marking on the bus bars and corresponding housing features. Different bus bar patterns are associated with distinct visual characteristics (colors, markings, or configurations) that enable easy identification. This resolves the contradiction by maintaining multiple bus bar configurations while providing clear visual cues for pattern recognition.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The housing is divided into multiple bus bar accommodating parts, each capable of holding different bus bar patterns. By segmenting the housing into distinct accommodating regions with unique visual identifiers, the system can accommodate multiple bus bar types while enabling easy visual differentiation between them.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If conventional continuity testing methods are used, then the testing process is simple, but the ability to effectively distinguish between different bus bar patterns is insufficient

Engineering Contradiction:

Improvesimplicity of continuity testingVSAvoidaccuracy of bus bar pattern identification

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent introduces an intermediary identification system that bridges the gap between simple continuity testing and accurate pattern identification. This intermediary mechanism (visual markers, color codes, or positional indicators) works in conjunction with continuity testing to provide both operational simplicity and measurement precision for distinguishing bus bar patterns.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bus bars and housing are pre-configured with visual identification features before the continuity testing is performed. This preliminary action of marking or configuring visual identifiers enables the operator to quickly identify the bus bar pattern without complex testing procedures, maintaining simplicity while improving identification accuracy.

Inventive Principle:

Principle #10Preliminary action

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

Enables easy visual determination and swift identification of bus bar patterns, facilitating the manufacturing of wire harnesses with the joint connector by distinguishing resin-sealed parts and ensuring accurate pattern recognition through conductivity tests.

Implementation Method 1

at least one of the continuity check holes is formed in a resin-sealed part filled with an insulating resin material

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS9214775B2Joint connector and method for identifying bus bar pattern in joint connector

Publication Date: 2015.12.15 YAZAKI CORP

AI summary

A joint connector includes a bus bar and a housing. The bus bar juxtaposes plural tab pieces to be connected to mating terminals. The housing has a bus bar accommodating part accommodating the bus bar, and includes plural terminal receiving chambers for receiving the mating terminals. The housing is formed with plural continuity check holes at a back end of the housing so as to expose a back end of the bus bar. In a case where the plural bus bars are accommodated in the bus bar receiving parts, at least one of the continuity check holes is positioned between the adjacent bus bars, and the at least one of the continuity check holes is formed in a resin-sealed part filled with an insulating resin material.