Busbar Spacer and Cover Latching for Tool-Free Assembly
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Solution Overview
Problem
Existing busbar systems face challenges in terms of increased strength requirements, longer assembly times, higher manufacturing costs, and the need for components to withstand various environmental conditions and mechanical stress, while also requiring easy installation, repair, and replacement without tools.
Innovation Solution
A busbar system design featuring a spacer with a fixing device that grips the cover element and busbar, utilizing a cross-member connected holding element with receiving openings and locking hooks, allowing for tool-free assembly and disassembly, and enabling secure, continuous operation across different climates and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional busbar systems use spacers and cover systems made of wood or corrosion-susceptible materials, then manufacturing costs are lower, but durability and strength are reduced
Solution Approach 1:
The spacer is constructed as a composite structure combining a plastic hollow body with integrated metal-free fixing devices and latching elements. This composite design provides corrosion resistance and adequate strength while maintaining cost-effectiveness through the use of engineered plastics that replace traditional metal components.
Solution Approach 2:
The invention changes the material parameters from traditional metal or wood to specialized plastic materials with enhanced mechanical properties. The plastic hollow body is designed with specific wall thicknesses, reinforcement structures, and integrated features that provide the necessary strength and durability without using corrosion-susceptible materials.
2Productivity
If busbar systems use complex assembly methods with multiple fastening elements, then connection strength is improved, but assembly time increases
Solution Approach 1:
The fixing devices are designed as self-contained units with integrated latching elements and clamping features that automatically engage with the busbar and cover elements. The self-closing bolts and snap-fit mechanisms enable the components to secure themselves without external tools or additional fastening operations, achieving both quick assembly and reliable connection.
Solution Approach 2:
The invention merges multiple functions into integrated components: the spacer combines structural support, positioning, and fastening functions; the cover elements integrate electrical insulation, protection, and clamping features; and the fixing devices combine mounting and securing operations. This functional integration eliminates the need for separate fastening elements and reduces assembly steps.
3Ease of repair
If busbar systems are designed for permanent installation, then structural stability is improved, but ease of repair and replacement is reduced
Solution Approach 1:
The fixing devices incorporate reversible latching mechanisms that can be easily engaged and disengaged. The self-closing bolts and snap-fit connections are designed to maintain stable structural attachment during operation but can be quickly released when repair or replacement is needed, providing dynamic adaptability between stable installation and easy maintenance states.
Solution Approach 2:
The busbar system is divided into modular components (spacer, cover elements, fixing devices) that can be independently removed and replaced. The latching elements and clamping features are designed as discrete, interchangeable parts that maintain structural integrity when assembled but allow for simple disassembly and replacement without affecting the overall system stability.
4Ease of operation
If busbar systems use traditional fastening methods, then manufacturing simplicity is maintained, but tool-free assembly is not achieved
Solution Approach 1:
The fixing devices are designed with self-actuating mechanisms including self-closing bolts that automatically engage and lock into place, and snap-fit connections that secure components through elastic deformation and geometric interlocking. These self-service features eliminate the need for external tools, screws, or complex fastening operations, enabling tool-free assembly while maintaining adequate connection strength.
Solution Approach 2:
The invention replaces traditional mechanical fastening systems (screws, nuts, welds) with integrated plastic-based securing mechanisms. The latching elements use elastic deformation and geometric constraints rather than threaded fasteners or adhesive bonds, enabling tool-free assembly while providing sufficient mechanical strength for the application.
Data Source
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AI summary
The invention relates to a busbar system, comprising at least one busbar (1), at least one cover element (2) and at least one spacer (3), the spacer (3) having at least one latching element (31, 32) which is connected to at least one clamping element (21, 22) of the cover element (2), connecting them, is operatively connected, wherein at least one carrier element (7) has a free end (5) which covers the conductor rail (1) and is arranged at a distance from it, the free end ( 5) of the carrier element (7) of the conductor rail (1) is arranged opposite, which is characterized in that the spacer (3) by at least one, via a traverse (4, 9), with at least one holding element (6, 6) connected, carrier element (7) is formed in that the spacer (3) has at least one fixing device (8) which overlaps at least one free end (23) of the cover element (2) and/or the busbar (1) in a fixing manner and which is in operative connection with the spacer (3) via at least one fixing element (83, 84).