Routing Board Bus Bar Layout for Low-Height Electrical Connections
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Solution Overview
Problem
The challenge is to reduce the height of electrical connection units while maintaining their functionality and efficiency, particularly in applications such as in-vehicle devices.
Innovation Solution
The design incorporates a routing board with a base member and bus bars that are integrated through insert molding, featuring a first bus bar extending in a plate shape along the insulating base portion and a second bus bar overlapping it, allowing for a three-dimensional routing structure that reduces overall height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If bus bars are arranged in a standing posture on the housing, then electrical connection functionality is achieved, but the height of the electrical connection unit increases
Solution Approach 1:
The bus bars are transitioned from a vertical standing posture to a horizontal plate shape configuration on the routing board. This dimensional change allows the bus bars to extend in the planar direction rather than vertically, thereby reducing the height of the electrical connection unit while maintaining electrical connection functionality through the plate-shaped configuration that provides sufficient surface area for connections.
Solution Approach 2:
The routing board integrates multiple bus bars (first bus bar and second bus bar) into a single planar structure where they overlap when viewed from the thickness direction. This merging of multiple electrical connection elements into a compact plate shape configuration reduces the overall height requirement while maintaining all necessary electrical connection points and routing paths.
2Ease of manufacture
If bus bars are integrated through insert molding, then manufacturing efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The bus bars are pre-positioned and fixed to the routing board before the final housing assembly process. This preliminary action allows the bus bars to be accurately positioned and secured in their plate shape configuration, ensuring proper alignment and electrical connection points are established before the housing is closed, thereby reducing the precision requirements for the final assembly step.
Data Source
AI summary
A routing board includes a base member having an insulating base portion, a first bus bar that is held by the insulating base portion and includes a routing portion routed from a first part to a second part of the insulating base portion, and a second bus bar held by the first part, in which a part of the first bus bar passes through a region overlapping the second bus bar when viewed from a thickness direction of the insulating base portion, at least a part of the first bus bar extends in a plate shape along the insulating base portion, and at least a part of the second bus bar extends in a plate shape along the insulating base portion.