Clamping Cage and Busbar Segmentation for Edge Connector
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Solution Overview
Problem
Existing connection modules for electrical conductors are costly due to the use of highly conductive materials like copper and generate significant waste during one-piece production, with a large distance required between adjacent modules.
Innovation Solution
The connection module is designed with a clamping cage and busbar produced independently from flat strips with good conductivity, where the clamping cage and busbar are attached via a linear seam, preferably by welding, allowing for material savings and closer module placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clamping cage and busbar are produced as one piece from highly conductive material, then current-carrying capacity is improved, but material waste increases and production cost increases
Solution Approach 1:
The connection module is divided into separate components: the clamping cage is produced from one flat strip and the busbar from another flat strip. These separate components are then joined together through welding, allowing each part to be optimized independently and reducing material waste compared to one-piece production.
2Stability of the object's composition
If the clamping cage and busbar are produced as one piece, then structural stability is improved, but production complexity increases
Solution Approach 1:
The clamping cage and busbar are manufactured separately as stamped parts from flat strips, which simplifies the production process for each component. The structural stability is then achieved by welding these separate parts together, combining the benefits of simplified manufacturing with stable assembly.
3Ease of manufacture
If one-piece production is used, then manufacturing steps are reduced, but material cost increases
Solution Approach 1:
By producing the clamping cage and busbar separately from flat strips and joining them through welding, the patent enables independent optimization of material usage. This segmentation allows for reduced material waste and lower material costs while the welding process adds only a moderate number of manufacturing steps.
4Quantity of substance
If the clamping cage is made from thin-walled material to reduce cost, then production cost is reduced, but mechanical stability deteriorates
Solution Approach 1:
The clamping cage is produced separately from the busbar, allowing the cage to be made from thinner, less expensive material while the busbar provides the necessary structural support and stability. This separation enables cost reduction in the clamping cage without compromising overall mechanical stability.
5Ease of manufacture
If busbar and clamping cage are produced in one piece, then assembly is simplified, but distance between adjacent modules increases
Solution Approach 1:
The separate production of clamping cages and busbars allows for more compact module design. The modular nature of separately produced components enables closer spacing between adjacent connection modules, reducing the overall distance required between them compared to one-piece production.
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 design reduces material waste and production costs while enabling a closer arrangement of connection modules, maintaining mechanical stability and current-carrying capacity.
Implementation Method 1
The clamping cage and the busbar are attached via a linear seam, preferably by welding
Data Source
Figure 1a~1b
Figure 1c~1e
Figure 2~3
AI summary
A connection module (1) for an electrical connection apparatus (10) for connecting an electrical conductor to an electrical assembly, comprising a. at least one clamping cage (2), b. and a busbar (3), c. which are each produced from an electrically conductive flat strip (200, 300), wherein each flat strip (200, 300) has in each case two mutually opposite broad sides (220, 320) and narrow sides (210, 310) connecting said broad sides, d. wherein the narrow sides (310) of the flat strip (300) of the busbar (3) are narrow sides (31) of the busbar (3), and the narrow sides (210) of the flat strip (200) of the clamping cage (2) are narrow sides (21) of the clamping cage (2), e. wherein the clamping cage (2) has at least three walls (221-223) which are arranged at an angle with respect to one another and which each have an extension component (601) parallel to a conductor insertion direction (8), and f. wherein either the clamping cage (2) is fastened undetachably on one narrow side (31) of the busbar (3) or g. the busbar (3) is fastened undetachably on one narrow side (21) of the clamping cage (2).