Bridging Element for Current Bars with Stable Contact
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Solution Overview
Problem
Existing bridging elements for electrically connecting current bars in housings suffer from decreased stability and contact force over time, leading to potential dislodgment and the need for hot caulking, which complicates multiple use.
Innovation Solution
A bridging element with a contact body made of electrically conductive material featuring two holding areas spaced along its length, allowing direct attachment and fastening to current bars, forming a stable metal-to-metal connection and enabling secure, detachable attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bridging element is fastened via the housing of the connection element using plastic material, then the bridging element can be attached to the housing, but the stability of the fastening decreases over time and the contact force decreases
Solution Approach 1:
The patent replaces the plastic-based mechanical fastening system with an electrical connection system. The bridging element is electrically connected to the current bars through conductive contact areas, eliminating reliance on plastic deformation and hot caulking. This substitution provides stable, long-term fastening without the degradation issues of plastic material.
Solution Approach 2:
The patent extracts the fastening function from the housing structure and relocates it to the current bars themselves. The bridging element is fastened directly to the current bars through electrical contact, rather than being fastened to the housing. This separation allows the fastening mechanism to be independent of the housing material and its associated problems.
2Reliability
If hot caulking of the bridging element is performed in the area of the bridge shaft with the insulating material of the housing, then the bridging element is securely fastened, but the effort for fastening significantly increases and multiple use becomes impossible
Solution Approach 1:
The patent replaces the thermal process of hot caulking with a simple electrical connection mechanism. The bridging element makes direct electrical contact with the current bars through conductive contact areas, eliminating the need for heating, melting, or chemical bonding processes. This results in a simple, tool-free fastening operation.
Solution Approach 2:
The patent enables the bridging element to be easily removed and reused by eliminating permanent fastening methods. The electrical connection through contact areas allows for simple disconnection and reconnection without damaging the bridging element or the current bars, facilitating multiple uses and recovery of components.
3Ease of manufacture
If the bridging element is attached via plastic material of the housing, then the bridging element can be fastened to the housing, but the contact force acting between the bridging element and the current bar decreases over time
Solution Approach 1:
The patent replaces the plastic-based mechanical fastening system with a direct electrical contact system. The contact force is generated and maintained through the electrical connection between the conductive contact areas of the bridging element and the current bars, rather than through plastic deformation or clamping forces. This ensures stable contact force over time.
4Ease of operation
If the bridging element is fastened to the housing via the bridge shaft, then the bridging element can be inserted and attached, but the bridging element can be unintentionally pressed out due to varying contact forces
Solution Approach 1:
The patent extracts the fastening function from the bridge shaft and housing structure and relocates it to the current bars. The bridging element is fastened directly to the current bars through electrical contact areas, making the fastening independent of the bridge shaft geometry and housing structure. This provides more reliable position stability.
Solution Approach 2:
The patent merges the electrical connection function and the fastening function into a single integrated mechanism. The same electrical contact areas that provide electrical connectivity also provide the fastening force to prevent unintentional dislodgment. This combination ensures that the bridging element remains securely positioned while maintaining electrical contact.
Data Source
Figure 1a~1c
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AI summary
The invention relates to a bridging element (100) for electrically connecting a first current bar (210) with at least one second current bar (211), with a contact body (110) which is made of an electrically conductive material and which has a first end section (111) and a second end section (112) arranged at a distance from the first end section (111), wherein the contact body (110) has between its first end section (111) and its second end section (112) a first retaining area (113) for holding the contact body (110) on the first current bar (210) and at least one second retaining area (114) for holding the contact body (110) on the second current bar (211), wherein the second retaining area (114) is formed at a distance from the second retaining area (114) along a longitudinal axis (A) of the contact body (110).