Straight Busbar Block Terminal for Hybrid Motors

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Solution Overview

Problem

The existing block terminals for hybrid electric vehicle motors have complex shapes, leading to increased insulation coatings, assembly processes, and component numbers, which limit design freedom, increase costs, and require separate busbar designs for different vehicle models, making them costly and difficult to share.

Innovation Solution

A block terminal manufactured through insert injection molding with a straight busbar structure, reduced components, and simplified assembly processes, featuring a block base, busbar, bushings, and fixing nuts, where the busbar and bushings are integrally formed and the fixing nuts are insert-mounted, reducing the number of components and assembly steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the busbar is configured with a complex bent structure to position nuts and accommodate connections, then the mechanical connection function is improved, but the device complexity and number of components increase

Engineering Contradiction:

Improvemechanical connection functionVSAvoidbusbar structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of bending the busbar to achieve positioning, the invention inverts the approach by using a straight busbar structure and positioning it through the block base design. The block base includes positioning structures that locate the straight busbar, eliminating the need for complex busbar bending while maintaining mechanical connection functionality.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention divides the system into functionally independent components: a straight busbar for current conduction, a block base for positioning and support, and separate insulation coatings. This segmentation allows each component to perform its specific function optimally without the busbar needing to assume both conduction and positioning roles through complex bending.

Inventive Principle:

Principle #1Segmentation

2Reliability

If multiple insulation coatings and assembly components are used to ensure electrical insulation and mechanical stability, then the reliability is improved, but the number of assembly processes and manufacturing complexity increase

Engineering Contradiction:

Improveelectrical insulation and mechanical stabilityVSAvoidnumber of assembly processes

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention combines multiple functions into integrated components. The block base integrates positioning structures, support functions, and insulation features into a single molded part. The busbar is directly positioned and fixed within this integrated base, reducing the need for separate assembly steps for positioning and insulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The block base is pre-formed with integrated positioning structures and insulation features before the busbar assembly. This preliminary action of creating an integrated base with built-in positioning and insulation capabilities eliminates the need for subsequent assembly steps to add separate positioning components and insulation coatings.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a complex busbar shape with multiple insulation coatings is used, then the electrical insulation performance is improved, but the material costs and investment costs increase

Engineering Contradiction:

Improveelectrical insulation performanceVSAvoidmaterial costs and investment costs

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention merges the insulation function into the block base structure itself, which is molded as an integrated component with built-in insulation features. This eliminates the need for multiple separate insulation coatings on the busbar, reducing material usage and manufacturing costs while maintaining electrical insulation performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts the insulation function from the busbar and places it in the block base structure. Instead of applying multiple insulation coatings to the busbar, the block base is designed with integrated insulation features that provide the necessary electrical isolation, thereby reducing the number of insulation materials required and lowering overall material costs.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This approach enhances vibration resistance, decreases the volume and complexity of the block terminal, allows for sharing of designs, and lowers material and investment costs by simplifying the structure and reducing the number of molds and assembly processes.

Implementation Method 1

a block terminal for a motor, which is manufactured through insert injection molding to improve vibration resistance performance

Methodology Applied

Scientific EffectInsert injection molding:

Data Source

PatentUS11165176B2Block terminal for motor and method of manufacturing same

Publication Date: 2021.11.02 HYUNDAI MOBIS CO LTD

AI summary

A block terminal for a motor includes a block base, a busbar, bushings, and fixing nuts. The busbar is disposed in the block base and includes end portions protruding outward from the block base. The end portions include coupling holes. The bushings are mounted on sides of the block base. The fixing nuts are insert-mounted in the coupling holes of the busbar.