Canted Coil Coupler Structure for Secure Bus Bar Connection
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Solution Overview
Problem
Conventional power conductors, such as bus bars, are difficult to securely connect to electrical devices like printed circuit boards due to their composition and configuration, requiring complex and cumbersome connection assemblies.
Innovation Solution
A coupler with a chamber defined by two brackets and a row of canted coil contacts is used to facilitate the connection of power conductors, allowing for secure and efficient electrical contact through the projection of coil contacts into the chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection assemblies are used to connect power conductors, then secure electrical connection is achieved, but device complexity and ease of operation deteriorate due to cumbersome assemblies
Solution Approach 1:
The connection system is divided into separate functional components: the coupler with canted coil contacts and the power conductor with engagement features. This segmentation allows each component to be optimized independently while simplifying the overall connection process.
Solution Approach 2:
The canted coil contacts act as an intermediary element between the power conductor and the electrical device. These flexible contacts can deform to accommodate misalignment and ensure reliable electrical connection without requiring complex alignment mechanisms.
2Reliability
If conventional connection assemblies are used to connect power conductors, then secure electrical connection is achieved, but ease of operation worsens due to difficult insertion and connection processes
Solution Approach 1:
The canted coil contacts are designed to be dynamically flexible, allowing them to deform and adapt during the insertion process. This dynamic behavior enables easy insertion while maintaining secure connection, eliminating the need for complex alignment or fastening operations.
Solution Approach 2:
The physical state of the canted coil contacts changes during operation - they deform from their initial position upon insertion and then maintain a stable engaged state. This parameter change allows the system to transition from an easy insertion state to a secure connected state.
3Ease of operation
If canted coil contacts are used in the coupler, then ease of operation improves for connecting power conductors, but device complexity increases due to the specialized contact structure
Solution Approach 1:
The canted coil contacts are integrated directly into the coupler structure, merging the contact function with the housing. This integration eliminates the need for separate contact assemblies while providing the desired ease of operation through the inherent flexibility of the canted coil design.
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
The coupler enables easy and secure connections between power conductors and electrical devices, improving the efficiency and simplicity of power connections while maintaining electrical integrity.
Implementation Method 1
A row of canted coil contacts is secured to the second bracket so as to be partially disposed in the trough and project outwardly therefrom to contact the at least one power conductor
Data Source
AI summary
A coupler for connecting a pair of power conductors. The coupler includes a first bracket and a second bracket that are arranged to define one or more chambers in-between. The second bracket has a trough formed therein for each chamber. A row of canted coil contacts is at least partially disposed in each trough and is secured to the second bracket. In each chamber, the row of canted coil contacts presses against a power conductor when it is inserted into the chamber.