Lead Block Bus Bar Layout for Easier Cable Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lead blocks with bus bars and conductor connection portions on the same plane are difficult to assemble due to spatial alignment challenges.
Innovation Solution
The lead block design includes first and second bus bars with connection pins and conductor connecting portions arranged in different directions, allowing for easier alignment and assembly by utilizing protruding portions and cut surfaces for precise cutting and insulation, with a manufacturing method that involves punching, bending, and molding to ensure accurate alignment and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bus bars and conductor connection portions are arranged on the same plane, then the structure is simple, but assembly becomes difficult due to spatial alignment challenges
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional spatial arrangement. Connection pins are positioned at different heights (first connection pin at higher position, second connection pin at lower position), allowing bus bars to be arranged simply on the same plane while enabling easy assembly through vertical differentiation for spatial alignment.
2Ease of operation
If connection pins are arranged in different directions, then assembly alignment becomes easier, but the device structure becomes more complex
Solution Approach 1:
The patent employs asymmetric arrangement where the first connection pin and second connection pin are positioned at different heights, creating an asymmetric vertical profile. This asymmetric design simplifies alignment during assembly while maintaining a relatively simple overall structure by utilizing vertical rather than horizontal differentiation.
3Reliability
If conductor connecting portions are spaced apart in perpendicular direction, then insulation is improved, but the lead block size increases
Solution Approach 1:
Instead of spacing conductor connecting portions apart in the horizontal plane (which would increase area), the patent utilizes the vertical dimension by positioning connection pins at different heights. This achieves insulation and electrical separation through vertical stratification rather than horizontal expansion, maintaining compact lead block dimensions while ensuring proper insulation.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A lead block 30 includes a lead block body (31), a first bus bar (32A), and a second bus bar (32B). The first bus bar (32A) includes a first connection pin (33A) and a first conductor connecting portion (34A) exposed from the lead block body (31) to be electrically connected to the first conductor (71A) of the electric cable (71). The second bus bar (32B) includes a second connection pin (33B) and a second conductor connecting portion (72A) exposed from the lead block body (31) to be electrically connected to the second conductor (34B) of the electric cable (72).