Offset Bus Bar Connection Layout for Compact High-Current Units

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The increase in size of the electrical connection unit due to increased current capacity tends to increase the electrical connection unit, the increase in the size of the electrical connection unit with an increase in current capacity.

Innovation Solution

The electrical connection unit includes a terminal at a component end in a second direction, a routing board with a flat surface portion, and a bus bar held by the flat surface portion, with a connection component that electrically connects the terminal to the bus bar, where the position of the second attachment hole is shifted from the first attachment hole to reduce the overall size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the current capacity of the electrical connection unit is increased, then the electrical connection unit can handle higher currents, but the size of the electrical connection unit increases

Engineering Contradiction:

Improvecurrent capacityVSAvoidsize of electrical connection unit

Core Design Contradiction:

PowerVSVolume of stationary object

Solution Approach 1:

The patent repositions the second attachment hole in the connection component from a conventional aligned position to a shifted position in the plan view. This spatial rearrangement in the horizontal plane allows for more compact packaging of the connection component, thereby reducing the overall size of the electrical connection unit while maintaining its current handling capacity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The connection component features an asymmetric configuration where the second attachment hole is deliberately positioned at a shifted location rather than being symmetrically aligned with the first attachment hole. This asymmetric layout optimizes the internal space utilization and enables a more compact design that reduces the unit's overall footprint.

Inventive Principle:

Principle #4Asymmetry

2Ease of manufacture

If the connection component uses a conventional aligned position for attachment holes, then the assembly is simple, but the electrical connection unit occupies more space

Engineering Contradiction:

Improveassembly simplicityVSAvoidsize of electrical connection unit

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

Instead of changing the vertical stacking arrangement, the patent utilizes the horizontal plane by shifting the second attachment hole's position in the plan view. This dimensional approach allows for compact packaging without complicating the assembly process, as the shifted position still accommodates standard mounting operations.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250372983A1Electrical connection unit

Publication Date: 2025.12.04 YAZAKI CORP

AI summary

An electrical connection unit includes an electronic component including a terminal at a component end in a second direction, a routing board including a base member and a bus bar, and a connection component including a first portion having a first attachment hole and having a posture of standing in the first direction with respect to a first surface, and a second portion having a second attachment hole and protruding along the first surface from an end of the first portion on a first surface side, in which the position of the second attachment hole is shifted from the position aligned in the second direction with respect to the position of the first attachment hole in a plan view viewed from the first direction.