Lead Block Bus Bar Layout for Insulated Rotary Cable Connections
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Solution Overview
Problem
Existing rotary connector devices with lead blocks do not effectively manage the alignment and insulation of multiple bus bars and conductor connections, leading to potential electrical interference and inefficiencies in cable connections.
Innovation Solution
A lead block design featuring a first and second bus bar with insulated sections and connection pins, aligned in a specific direction, and a manufacturing method involving a flat plate punching, bending, and molding process to ensure precise alignment and insulation of bus bars, with a coupling portion that is later cut to isolate them electrically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple bus bars and conductor connection portions are arranged on the same plane in existing rotary connector devices, then the device structure is simplified, but electrical interference occurs and alignment precision deteriorates
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional spatial arrangement by extending connection pins in the thickness direction and positioning conductor connection portions on different planes. This dimensional change allows multiple bus bars to be electrically isolated while maintaining a compact structure, resolving the contradiction between structural simplicity and electrical interference prevention.
Solution Approach 2:
The lead block is segmented into multiple insulated sections, each housing a separate bus bar and its associated connection pins. This segmentation electrically isolates different conductors while maintaining organizational structure, preventing electrical interference without significantly increasing overall device complexity.
2Ease of manufacture
If conventional lead block manufacturing methods are used, then production is straightforward, but alignment precision and insulation reliability deteriorate
Solution Approach 1:
Connection pins are preliminarily positioned and fixed within the lead block body before the final molding process. This preliminary action ensures precise alignment of conductor connection portions with bus bars, guaranteeing manufacturing precision while maintaining ease of production through a systematic molding sequence.
Solution Approach 2:
The lead block body acts as an intermediary structure that precisely positions and electrically isolates multiple bus bars and connection portions. This intermediary component ensures accurate alignment during manufacturing while maintaining insulation reliability, bridging the gap between ease of manufacture and manufacturing precision.
3Ease of manufacture
If connection pins are arranged without specific alignment, then manufacturing is easier, but electrical connection reliability and cable connection efficiency worsen
Solution Approach 1:
Connection pins are arranged asymmetrically with specific directional orientations (first connection pins in a first direction, second connection pins in a second direction). This asymmetric arrangement optimizes electrical connection reliability for specific cable routing configurations while maintaining manufacturing feasibility through standardized molding processes.
Data Source
AI summary
A lead block includes a lead block body, a first bus bar, and a second bus bar. The first bus bar includes at least one first insulated section, a first connection pin and a first conductor connecting portion extended from the second insulated section to be exposed from the lead block body to be electrically connected to the first conductor of the electric cable. The second bus bar includes a second connection pin and a second conductor connecting portion extended from the second insulated section to be exposed from the lead block body to be electrically connected to the second conductor of the electric cable.