Terminal Device Busbar Oblique End Section Thermal Expansion
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Solution Overview
Problem
Jumper terminals face issues with relative position changes due to different thermal expansion coefficients of components, leading to impaired electrical connections when exposed to changing environmental conditions.
Innovation Solution
A busbar with obliquely extending end sections that can move relative to contact parts, ensuring a secure electrical connection by allowing expansion without loosening the connection, with the oblique angle between 20° and 70°, preferably 30° to 45°, allowing the end section to be pressed into the gap between contact pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar is firmly connected to contact parts to ensure reliable electrical connection, then electrical reliability is improved, but the connection becomes vulnerable to thermal expansion mismatches between plastic housing and metal busbar
Solution Approach 1:
The busbar connection design transitions from a static fixed connection to a dynamic adaptable connection. The busbar is designed with an L-shaped configuration where the second leg can move relative to the contact part, allowing the connection to adapt dynamically to thermal expansion and contraction while maintaining electrical contact reliability.
Solution Approach 2:
The invention utilizes parameter changes in the geometric configuration of the busbar, specifically the L-shaped design with defined angles (20°-70° relative to contour line, 10°-30° relative to contact part). These parameter changes enable the busbar to accommodate thermal expansion differently than a straight rigid connection would, maintaining reliability while adapting to temperature variations.
2Productivity
If the busbar extends along a contour line to distribute potential, then electrical distribution function is improved, but thermal expansion causes position changes relative to contact parts
Solution Approach 1:
The busbar is segmented into functional sections: a first leg extending along the contour line for potential distribution, and a second leg forming an L-shape for reliable contact connection. This segmentation allows each section to perform its specific function while the overall structure compensates for thermal expansion effects.
Solution Approach 2:
The busbar connection is designed with angular dimensions (L-shape configuration) rather than just linear extension. The second leg extends at an angle (20°-70° to contour line, 10°-30° to contact part), adding dimensional complexity that enables thermal compensation while maintaining electrical connection stability.
3Adaptability or versatility
If compensation areas are added to busbars to handle thermal expansion, then thermal adaptability is improved, but device complexity and space requirements increase
Solution Approach 1:
The compensation function is merged into the basic L-shaped geometry of the busbar itself, rather than adding separate compensation mechanisms. The angular configuration serves both the electrical connection function and the thermal compensation function simultaneously, reducing overall device complexity.
Solution Approach 2:
The busbar design incorporates flexibility through its L-shaped geometry and controlled angles, allowing it to bend or shift position slightly to accommodate thermal expansion. This flexible geometric design replaces rigid compensation mechanisms, simplifying the overall structure while maintaining thermal adaptability.
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 provides a reliable and space-saving compensation for thermal expansion, maintaining a stable electrical connection between the busbar and contact parts, even under temperature changes, without compromising the electrical contact.
Implementation Method 1
temperature changes can occur on a clamping device, which leads to spatial expansion of the different components of the clamping device, which can be problematic in particular if different components expand in different ways due to different thermal expansion coefficients
Data Source
Figure 1~2
Figure 3~4
AI summary
A terminal device comprises a housing which has at least one slot, a contact part which is arranged at the at least one slot and to which at least one electrical line for making electrical contact with the contact part can be plugged, and at least one busbar which is arranged on the housing and is electrically connected to the contact part and a busbar section of which extends along an elevation line. In this case, provision is made for an end section (21, 22) to adjoin the busbar section (20), which end section extends along an oblique direction (S) at an oblique angle (ß) with respect to the elevation line (L1 - L8) and can be moved relative to the contact part (13) along the elevation line (L1 - L8). This provides a terminal device which makes it possible to compensate for relative positional changes on account of different coefficients of thermal expansion at components of the terminal device in a simple, cost-effective and space-saving manner and makes it possible to ensure a safe, reliable electrical connection between a busbar and associated contact parts at slots.