Busbar Connector with Dual Plug Contacts for Thermal Expansion
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Solution Overview
Problem
Current busbar connector systems require labor-intensive installation and skilled personnel for alignment and electrical connection of current-carrying profiles, with potential issues of oxide layer formation and high-impedance connections due to thermal expansion and fretting corrosion.
Innovation Solution
A busbar connector system with dual plug contact areas, where the first plug contacts are designed for vertical plugging onto current-carrying profiles to ensure immovable contact and the second plug contacts provide an axial interface for reliable, long-term connection, using blade and fork contacts with spring tongues for secure contact and accommodating thermal expansion through movable mounting within the insulating housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbar connectors are inserted axially into busbar profiles, then electrical connection is established, but alignment precision and installation complexity increase
Solution Approach 1:
Instead of inserting the connector axially into the busbar profile as in prior art, the patent inverts the approach by having the connector approach from the top surface. The plug contacts project laterally to contact the conductors on the side walls, eliminating the need for precise axial alignment while maintaining reliable electrical connection.
Solution Approach 2:
The patent transitions from one-dimensional axial insertion to a combination of vertical placement (perpendicular to busbar extension) and lateral contact. This dimensional change allows the connector to be positioned more easily on the top surface while the plug contacts reach out to establish electrical connection with the conductors.
2Reliability
If busbar connectors use fixed plug contacts, then electrical connection is stable, but thermal expansion and fretting corrosion cause high-impedance connections
Solution Approach 1:
The patent applies spring-loaded plug contacts that can move dynamically within their mounting positions. This dynamic capability allows the contacts to accommodate thermal expansion and contraction of the busbar conductors while maintaining continuous pressure for stable electrical connection, preventing fretting corrosion and oxide layer formation.
Solution Approach 2:
The spring-loaded mechanism changes the contact pressure parameter dynamically in response to thermal expansion. The spring force automatically adjusts to maintain optimal contact pressure under varying thermal conditions, ensuring stable electrical connection without excessive force that could cause deformation.
3Manufacturing precision
If busbar connectors require skilled personnel for installation, then connection quality is high, but installation time and labor cost increase
Solution Approach 1:
The connector design incorporates self-aligning features and snap-fit mounting that allow the connector to automatically position itself correctly on the busbar profile. The lateral plug contacts naturally engage with the conductors on the side walls, eliminating the need for skilled alignment operations and reducing installation to simple placement and engagement actions.
Solution Approach 2:
The plug contacts are pre-configured in the insulating housing at predetermined positions and orientations. This preliminary arrangement ensures that when the connector is placed on the busbar, the contacts are already positioned to engage with the conductors, eliminating the need for field adjustment or complex alignment procedures during installation.
4Device complexity
If busbar connectors use single plug contact area, then device complexity is low, but connection reliability under thermal expansion is poor
Solution Approach 1:
The connector is divided into two distinct plug contact areas: one for vertical placement on the top surface and another for lateral electrical contact with the conductors. This segmentation allows each contact area to be optimized for its specific function while working together to provide stable long-term connection under thermal expansion conditions.
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
Enables a reliable, long-term stable electrical connection between current-carrying profiles with reduced risk of oxide layer formation and improved contact reliability, allowing for easy installation and reduced dependency on profile alignment, while compensating for thermal expansion and preventing relative movement-induced corrosion.
Implementation Method 1
using blade and fork contacts with spring tongues for secure contact and accommodating thermal expansion through movable mounting within the insulating housing
Data Source
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AI summary
A busbar connector (1, 1a, 1b) for electrically connecting conductors (22) to webs (7) of a busbar profile (6), which has a top surface (O) from which the conductors (22) are accessible via the spaces (12) between the webs (7), is described. The busbar connector (1, 1a, 1b) has an insulating housing (2) and a plurality of first and second plug-in contacts (4, 9) electrically connected in pairs. A first plug-in contact area (4) with the first plug-in contacts (5) for plugging onto the top surface (O) perpendicular to the longitudinal direction (E) of the busbar profile (6) in a first plug-in direction (S1) and for plugging in the conductors (22) of the busbar profile (6) is provided.Furthermore, a second plug-in contact area (8) is provided on an end face of the insulating housing (2), wherein the second plug-in contact area (8) has the second plug-in contacts (9) for plugging in a complementary connector (1, 1a, 1b) in a plug-in direction (S2) corresponding to the longitudinal extension direction (E) of the current-carrying profile (6). The plane which spans the top (O) is at an angle to a plane spanning the end face.