Terminal Block Bracket Heat Radiation and Resin Locking
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Solution Overview
Problem
Conventional terminal blocks face issues with heat radiation efficiency and separation of the bracket and resin portion during bolt tightening, leading to ineffective heat transfer from conductive members to the motor case.
Innovation Solution
The terminal block design includes a bracket directly fixed to the metal case with a resin portion that locks the nut and bracket in place, using nut locking portions and partition walls to prevent separation, and incorporates heat radiation recesses and guiding portions for improved heat dissipation and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the bracket is directly fixed to the case to improve heat radiation, then heat radiation efficiency is improved, but the bracket and resin portion separate during bolt tightening
Solution Approach 1:
The bracket is divided into two functional zones: a first region directly contacting the case for heat radiation, and a second region embedded in the resin portion for mechanical bonding. This segmentation allows the bracket to simultaneously achieve thermal contact with the case and structural integration with the resin, resolving the contradiction between heat radiation efficiency and connection stability.
2Area of stationary object
If the covered part of the bracket by the resin portion is reduced to improve heat radiation, then heat radiation area is increased, but the resin portion is pulled toward the bolt and separation occurs
Solution Approach 1:
The bracket's cross-section is segmented into a first region with smaller area for heat radiation and a second region with larger area for resin embedding. This area segmentation enables the bracket to expose sufficient surface area for thermal contact while maintaining adequate embedded area for mechanical bonding strength.
Solution Approach 2:
Different regions of the bracket are given different functional qualities: the first region is optimized for heat radiation with direct case contact, while the second region is optimized for mechanical bonding with increased resin embedding. This local quality differentiation resolves the contradiction between maximizing heat radiation area and maintaining bonding strength.
3Reliability
If heat is transferred from conductive members to the nut and accumulated in the terminal block, then electrical connection is achieved, but heat accumulation causes temperature increase
Solution Approach 1:
The heat accumulation problem is solved by extracting the heat from the terminal block interior and transferring it to the case. The bracket serves as a thermal pathway that extracts heat from the nut and conductive members and conducts it to the case, thereby maintaining electrical connection while preventing heat accumulation and temperature increase.
Solution Approach 2:
The bracket acts as a thermal intermediary between the conductive members/nut and the case. It receives heat from the conductive members, transfers it through its structure, and dissipates it to the case, serving as a mediator that enables heat removal while maintaining the electrical connection integrity.
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 configuration enhances heat radiation properties while preventing the separation of the bracket and resin portion, ensuring reliable electrical connections and efficient heat transfer to the motor case.
Implementation Method 1
heat of the bracket can be radiated to the metal case from the mounting portion directly fixed to the metal case
Implementation Method 2
transfer heat transferred from the conductive members to the nut to the bracket via the insulating sheet and radiate this heat from the bracket to the case of the motor
Implementation Method 3
the resin portion includes first locking portions for locking screw grooves of screw holes provided on the mounting portion, and second locking portions for locking engaging portions provided on the embedded portion
Data Source
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AI summary
An object of the present invention is to prevent the separation of a bracket and a resin portion while improving a heat radiation property of the bracket. A terminal block 10 is for connecting terminals T connected to ends of enameled wires extending from a motor and busbars B extending from an inverter and includes nuts 20 on which the terminals T and the busbars B are to be placed from above and which fasten the terminals T and the busbars B together with bolts BT, a bracket 40 which is formed by aluminum die casting and arranged below the nuts 20, and a resin portion 50 which integrally fixes the nuts 20 and the bracket 40. The bracket 40 includes a mounting portion 42 exposed from the resin portion 50 and to be directly fixed to a metal motor case, and an embedded portion 41 embedded in the resin portion 50. The resin portion 50 includes first locking portions 57 for locking screw grooves 47A of screw holes 47 provided on the mounting portion 42 from below, and a second locking portion 58 for locking an engaging portion 49 provided on the embedded portion 41 from below.