Electrical Appliance Wiring Structure for Stable Busbar Protrusion
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Solution Overview
Problem
The existing wiring structure of electrical appliances experiences instability in the positional accuracy of busbars due to the reaction force from the seal member, affecting solderability as the busbar protrusion from the control board is not stabilized, leading to issues with soldering and electrical performance.
Innovation Solution
A wiring structure that incorporates a gasket inserted between the connector's outer peripheral portion and the housing's inner peripheral portion to create an axial seal, which generates a reaction force perpendicular to the busbar's protrusion direction, stabilizing the busbar's length and improving solderability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a seal member is compressed in the surface direction to seal between the outer housing and inner housing, then water resistance is improved, but the busbar positional accuracy deteriorates due to reaction force
Solution Approach 1:
The patent transitions from a two-dimensional surface seal to a three-dimensional axial seal by positioning the gasket axially between the connector and housing. This dimensional change redirects the sealing action perpendicular to the busbar extension direction, eliminating the reaction force that previously affected busbar positioning while maintaining effective water sealing.
Solution Approach 2:
The sealing function is segmented into two independent components: the axial gasket handles water sealing between the connector and housing, while the inner housing maintains its original sealing function. This segmentation separates the sealing responsibilities, allowing the busbar position to remain stable while achieving effective water resistance through the axial gasket compression.
2Manufacturing precision
If the connector is sealed in the axial direction only, then busbar positional accuracy is improved, but the sealing effectiveness in surface direction may be insufficient
Solution Approach 1:
The patent enhances sealing by adding the axial dimension to the sealing strategy. The gasket compressed in the axial direction creates effective sealing between the connector and housing, while the inner housing provides additional surface sealing, achieving comprehensive water protection without compromising busbar positioning.
3Reliability
If the busbar protrusion amount is not stabilized due to reaction force, then solderability deteriorates, but changing the seal structure may affect water resistance
Solution Approach 1:
The patent resolves the conflict between solderability and water resistance by changing the sealing dimension. The axial gasket compression perpendicular to the busbar extension direction stabilizes busbar protrusion for reliable soldering while maintaining effective water sealing through the axial sealing mechanism working in conjunction with the inner housing seal.
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 solution effectively stabilizes the busbar's protrusion from the control board, enhancing solderability and reducing electrical resistance and inductance, thereby improving the overall performance and reliability of the electrical connections.
Implementation Method 1
a gasket (6) which is attached by insertion between an outer peripheral portion (4c) of the connector (4) and an inner peripheral portion (2a) of the housing (2) which faces the outer peripheral portion (4c) of the connector (4), and seals a gap between the connector (4) and the housing (2)
Data Source
AI summary
The present application is to provide a wiring structure of an electrical appliance which can stabilize the amount of protrusion of a busbar from a control board.The wiring structure of the electrical appliance includes: a connector fixed to a housing and has an outer connector housing and an inner connector housing; a busbar in which one side is arranged in the outer connector housing of the connector and the other side is extended to the outside of the inner connector housing of the connector; and a control board through which the other side of the busbar passes. Then, the wiring structure of the electrical appliance includes a gasket which is attached by insertion between an outer peripheral portion of the connector and an inner peripheral portion of the housing which faces the outer peripheral portion of the connector, and seals a gap between the connector and the housing.