Integrated Busbar Clamp Terminal for Uninterrupted Current Flow
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Solution Overview
Problem
The related-art busbar clip-type connectors require additional processes like welding or riveting to fix two independent elastic pieces, which can adversely affect current transmission.
Innovation Solution
A clamp terminal design with a connecting rib integrally connected between two elastic pieces, allowing them to be overlapped and adhered without additional fixing, ensuring seamless contact and uninterrupted current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two independent elastic pieces are used to form the clamp terminal, then the manufacturing difficulty is reduced (can be formed separately), but additional welding or riveting processes are required which adversely affect current transmission
Solution Approach 1:
The patent merges the two independent elastic pieces by integrally forming them into a single clamp terminal structure. The first and second elastic pieces are formed as one integrated component, eliminating the need for separate welding or riveting processes while maintaining the ability to manufacture the complex multi-arm structure. This resolves the contradiction by combining manufacturing steps into a single integral formation process that ensures good electrical contact without additional joining operations.
2Stability of the object's composition
If additional welding or riveting processes are used to fix the elastic pieces, then the structural stability is improved, but the current transmission is adversely affected
Solution Approach 1:
The elastic pieces are integrally formed as a single structure, providing inherent structural stability through their unified construction. The integral formation ensures that the first and second elastic pieces are firmly connected without requiring additional welding or riveting, thereby maintaining good electrical contact and current transmission while achieving the required structural stability.
3Reliability
If the clamp terminal is formed as a single integral structure, then the current transmission is maintained, but the manufacturing complexity increases due to multiple elastic arms needing to be arranged closely
Solution Approach 1:
The clamp terminal is segmented into multiple functional regions within a single integral structure. The first and second elastic pieces are divided into multiple elastic arms that are arranged closely side by side, with each arm serving specific clamping functions. This segmentation allows the complex multi-arm structure to be manufactured as one piece while maintaining good electrical contact and current transmission through the integral formation.
Data Source
AI summary
A busbar clip-type connector includes an insulating body and two clamp terminals mounted on the insulating body. The clamp terminal includes a first elastic piece, a second elastic piece, and a connecting rib. The first elastic piece includes a first plate, first elastic arms, and first gaps. The second elastic piece includes a second plate, second elastic arms, and second gaps. The first and second elastic arms protrude from the first and second plates. Each first gap is defined between two adjacent first elastic arms. Each second gap is defined between two adjacent second elastic arms. The first and second elastic pieces are folded through the connecting rib connected between the first and second plates. The first and second plates are overlapped and adhered to each other. The first elastic arms are inserted in the second gaps, and the second elastic arms are inserted in the first gaps.