Overlapping Bus Bar Terminal Block Routing Space
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Solution Overview
Problem
Conventional conductive paths using bus bars require significant routing space, especially when connecting multiple paths, making complex routing structures difficult and inefficient.
Innovation Solution
A terminal block configuration with overlapping bus bars and insulating covers, where terminals are exposed radially from the overlap portions, reduces routing space and prevents short circuits by using a single routing path shared by multiple conductive paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one bus bar is disposed inside one cover, then the bus bar is insulated and protected, but it is difficult to achieve complex routing structure and requires large routing space when connecting multiple conductive paths
Solution Approach 1:
Multiple bus bars are merged into a single cover structure, allowing multiple conductive paths to be integrated within one terminal block. This combining approach maintains insulation protection while reducing the overall routing space required compared to using separate covers for each bus bar.
Solution Approach 2:
Multiple bus bars are nested within a single cover, with each bus bar positioned in a specific arrangement. This nesting structure allows complex routing to be achieved within a compact space, as the bus bars are contained within the same protective enclosure rather than requiring separate covers.
2Reliability
If multiple conductive paths are used to connect ends of conductive paths, then electrical connection is achieved, but a large routing space is required
Solution Approach 1:
Multiple conductive path connections are merged into a single terminal block structure. The ends of multiple conductive paths are connected to terminals on the same bus bars within one cover, eliminating the need for multiple separate covers and reducing routing space while maintaining reliable electrical connections.
3Area of stationary object
If bus bars are overlapped to reduce routing space, then routing space efficiency is improved, but short circuit risk increases due to closer proximity of conductive elements
Solution Approach 1:
An insulating middle cover is introduced as an intermediary element between overlapping bus bars. This middle cover maintains electrical insulation between the bus bars while allowing them to be positioned in a compact overlapping arrangement, thus achieving routing space efficiency without compromising short circuit prevention.
Solution Approach 2:
Insulation is applied locally at the overlap regions where bus bars are in close proximity. The insulating middle cover is positioned specifically between the overlapping portions, providing targeted insulation where it is most needed while allowing other areas to maintain compact routing.
4Reliability
If multiple separate covers are used for multiple bus bars, then insulation is ensured, but the number of components and manufacturing complexity increases
Solution Approach 1:
Multiple covers are merged into a single integrated cover structure that houses multiple bus bars. This single cover design reduces the number of components from multiple separate covers to one unified structure, simplifying assembly and reducing part count while maintaining insulation through the insulating middle cover between overlapping regions.
Data Source
AI summary
A terminal block includes a lower bus bar and an upper bus bar that overlap each other at overlap portions and an insulating middle cover disposed between the overlap portion of the lower bus bar and the overlap portion of the upper bus bar. The lower bus bar and the upper bus bar are provided with their respective ones of first to fourth terminals exposed from the middle cover, at positions different from the overlap portions and the first to fourth terminals are disposed at positions radially spaced apart from the overlap portions.