Press-Fit Block Terminal Assembly Without Bolt Fastening
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Solution Overview
Problem
Existing block terminals require time-consuming bolt-fastening processes, leading to increased manufacturing costs and potential warpage and insulation degradation due to bolting torque.
Innovation Solution
A block terminal design featuring press-fit pins and a housing cover that allows for easy detachment without bolts, improving vibration resistance and insulation performance through an insert injection manufacturing process, with a reduced number of components and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolt-fastening is used to connect terminals, then connection strength is improved, but assembly time increases and manufacturing cost increases
Solution Approach 1:
The patent removes the bolt-fastening process entirely from the terminal connection system. Instead of using bolts and press-fit nuts, the invention uses a press-fit pin that is directly inserted into the terminal hole, extracting the unnecessary fastening components and steps while maintaining connection strength through the press-fit mechanism alone.
Solution Approach 2:
The patent replaces the mechanical bolt-fastening system with a press-fit pin system. The press-fit pin utilizes elastic deformation and interference fit mechanics to achieve secure connection without requiring threading, tightening, or multiple fastening components, thereby dramatically reducing assembly time and complexity.
2Strength
If bolt-fastening is used to connect terminals, then connection strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates multiple components (bolts, press-fit nuts, washers) from the assembly, reducing the bill of materials and simplifying the manufacturing process. The press-fit pin is a single integrated component that performs both connection and fastening functions, lowering material costs and assembly complexity.
Solution Approach 2:
The patent merges the functions of multiple components into a single press-fit pin. The pin combines the fastening function, the connection function, and the positioning function that were previously distributed across bolts, nuts, and alignment features, thereby reducing component count and manufacturing cost.
3Strength
If bolt-fastening is used to connect terminals, then connection strength is improved, but terminal warpage occurs due to fastening torque
Solution Approach 1:
The patent replaces the torque-based mechanical fastening system with a press-fit insertion system. The press-fit pin is inserted into the terminal hole and secures through interference fit and elastic deformation, eliminating the need for rotational tightening that applies uneven torque and causes warpage to the terminal material.
Solution Approach 2:
The patent removes the torque-application mechanism (bolt tightening) from the connection process. By using a press-fit pin that is simply inserted and secured through friction and elastic recovery, the harmful torque that causes terminal warpage is completely eliminated while maintaining secure connection.
4Strength
If bolt-fastening is used to connect terminals, then connection strength is improved, but insulation performance degrades
Solution Approach 1:
The patent extracts and removes the metal bolt and press-fit nut components that create conductive paths between adjacent terminals. By replacing these with non-conductive press-fit pins and incorporating insulating materials in the housing, the risk of dielectric breakdown and insulation failure is eliminated while maintaining mechanical connection strength.
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
The solution simplifies assembly, reduces manufacturing costs, and enhances insulation and vibration resistance by eliminating the need for bolt-fastening, while maintaining effective electrical connections.
Implementation Method 1
Press-fit pins, which are configured to be elastically deformed to cause overlapping of a terminal of a high-voltage connector and a terminal of a stator terminal which are adjacent to each other
Implementation Method 2
The block base may be insert-injection molded in a state in which the plurality of bus bars are disposed to be spaced apart from each other
Data Source
AI summary
A block terminal including a plurality of bus bars including ring-shaped connection terminals at both ends thereof; a block base formed to surround bodies of the plurality of bus bars excluding the connection terminals and provided with a slit passing through a surface thereof; and a housing cover formed to surround a surface of the block base and detachably attached to the block base.