Conductive Strip Design for Junction Block Material Reduction
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Solution Overview
Problem
Existing electrical connection systems for junction blocks are inefficient in terms of material usage and manufacturing complexity, often resulting in excess material waste and geometric constraints that complicate the integration of conductive strips and support rails.
Innovation Solution
A conductive strip with a U-like shape, comprising two portions that can be folded from a base sheet metal, combined with a clamping device like a leaf spring or screw, to securely connect electrical conductors and support rails, optimizing material usage and adaptability within compact geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate conductive parts are used to connect electrical conductors and support rails, then the electrical connection functionality is achieved, but the manufacturing complexity increases and material waste increases
Solution Approach 1:
The patent combines multiple separate conductive parts into a single integrated conductive strip with multiple connection points. This single strip serves both as the electrical conductor connector and the support rail connector, eliminating the need for multiple separate components and reducing material waste from producing and assembling separate parts
2Productivity
If the junction block geometry is optimized to accommodate multiple sockets, then the electrical connection capacity is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The conductive strip is designed as a multi-functional component that can connect to multiple support rails at different angles and positions. The strip includes multiple connection points that can accommodate various electrical conductor configurations, allowing a single component design to serve multiple connection purposes without requiring complex customized geometries for each socket arrangement
3Reliability
If a rigid conductive structure is used to ensure stable electrical connection, then the connection reliability is improved, but the adaptability to geometric constraints decreases
Solution Approach 1:
The conductive strip incorporates flexible sections with predetermined bend radii that allow the strip to be bent and adapted to different geometric configurations while maintaining stable electrical connections. These flexible sections enable the rigid conductive portions to be positioned at various angles and locations, providing both connection stability and geometric adaptability
Data Source
AI summary
The invention relates to an electrical connection system (7) for an electrical device, such as an electrical terminal block, said electrical connection system (7) comprising: a conductive bar (21) including an electrical contact region (45) arranged to cooperate with a conductive portion (13′) of an electrical conductor (13) in a connected position, and an engagement zone (35) arranged to engage with a portion (15′) of a support rail (15) in an engaged position; a leaf spring (23); and a retaining device (49) arranged to retain the support rail (15) in the engaged position, the conductive bar (21) consisting of a conductive strip.