Segmented Busbar Connector With Elastic Joints for Tolerance Compensation
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Solution Overview
Problem
The assembly of electronic modules, such as inverters in motor vehicles, with large conductive bars is challenging due to tolerance issues, requiring precise positioning of the conductive bars on the support, which can lead to improper assembly if not met.
Innovation Solution
An electrical connection device comprising a body with electric conductors in the form of conductive bars, divided into multiple plate parts linked by elastically deformable junctions, allowing for relative displacement and compensation of tolerance issues during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the common part carrying conductive bars has large dimensions, then it can accommodate more conductors, but it requires precise positioning zones which increases assembly difficulty and tolerance constraints
Solution Approach 1:
The common part is divided into multiple plate parts (first plate part, second plate part, third plate part) that are connected through elastically deformable junctions. This segmentation allows each plate part to be positioned independently on the support, reducing the overall positioning precision requirements while maintaining the ability to accommodate multiple conductors.
Solution Approach 2:
The junctions between plate parts are designed to be elastically deformable, allowing them to change their physical state from rigid to flexible during assembly. This enables the plate parts to adapt to tolerance variations in the positioning zones through elastic deformation, compensating for manufacturing tolerances without requiring high precision.
2Quantity of substance
If the common part has large dimensions, then it can carry more conductive bars, but it becomes more sensitive to tolerance variations in positioning zones
Solution Approach 1:
By dividing the common part into separate plate parts, each carrying some conductive bars, the system can accommodate multiple conductors while reducing the sensitivity to tolerance variations. Each segment can be assembled independently, improving assembly reliability.
Solution Approach 2:
The elastically deformable junctions introduce dynamic flexibility to the structure, allowing the plate parts to move and adapt during assembly. This dynamic capability enables the system to compensate for tolerance variations, maintaining reliable assembly even with larger dimensions and more conductive bars.
3Manufacturing precision
If positioning zones are placed precisely on a large common part, then proper assembly is achieved, but manufacturing complexity and tolerance constraints increase
Solution Approach 1:
The common part is segmented into multiple plate parts, each with its own positioning zones. This reduces the complexity of positioning zone placement on a single large part, as each smaller plate part can be positioned independently with simpler tolerance requirements.
Solution Approach 2:
The elastically deformable junctions allow the plate parts to adapt to positioning variations through deformation, reducing the need for extremely precise positioning zone placement. This decreases manufacturing complexity while maintaining proper assembly.
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 use of elastically deformable junctions between plate parts of the electrical connection device allows for tolerance compensation, facilitating precise assembly and reducing the risk of improper connections in electronic modules.
Implementation Method 1
these parts being linked together by at least one elastically deformable junction so as to allow placement of one of the parts relative to the other part with play
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to an electrical connection device (1) configured to be assembled with a support (101) of an electronic module (100), in particular an inverter, this electrical connection device (1) comprising a body (2), in particular made of plastic, and electrical conductors (3), in particular in the form of conductive bars which are carried by the body (2), the body comprising at least two plate parts (5, 6, 7) each carrying at least one of the conductors, each plate part (5, 6, 7) comprising at least one positioning zone (10) of the electrical connection device (1) on the support (101), and these plate parts (5, 6, 7) being linked together by at least one elastically deformable junction (12) so as to allow one of the plate parts (5, 6, 7) to be placed with respect to the other part with a clearance, when the electrical connection device (1) is assembled on the support (101) of the electronic module.