Connection Element With Segmented Busbar For Reliable Electrical Contact
Solution Overview
Problem
Existing connecting elements with clamping springs for electrical conductors and contact pins lack a compact and efficient design that ensures reliable and space-saving electrical contact with a short current path and easy insertion of components.
Innovation Solution
The connecting element features a busbar with a contact arc transitioning into a clamping section, forming a second contact point with the clamping spring, allowing the conductor to be pressed against the busbar and the contact pin to be clamped between the busbar sections, with a movable holding section and a contact leg that opens and closes the contact point, enabling independent insertion of conductors and pins with a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clamping spring is used to clamp both the electrical conductor and contact pin to a busbar, then reliable electrical contact is achieved, but the device becomes complex and insertion becomes difficult
Solution Approach 1:
The connection element is divided into separate functional sections: a first connection section for the electrical conductor with its own clamping spring, and a second connection section for the contact pin with a separate clamping mechanism. This segmentation allows each section to be optimized independently, simplifying the overall structure while maintaining reliable electrical contact in both sections.
2Reliability
If the contact pin is clamped between fixed busbar sections, then stable electrical contact is achieved, but insertion force becomes too high and insertion difficult
Solution Approach 1:
The holding section of the busbar is designed to be movable relative to the contact section, creating a dynamic clamping mechanism. When the contact pin is inserted, the holding section moves to accommodate the pin and establish contact, reducing the insertion force required compared to a fully fixed structure, while still providing stable contact once inserted.
3Ease of operation
If conductors and contact pins are inserted independently, then ease of assembly is improved, but interference between components occurs
Solution Approach 1:
The connection element is divided into separate functional sections: a first connection section for the electrical conductor with its own clamping spring, and a second connection section for the contact pin with a separate clamping mechanism. This segmentation allows each component to be inserted independently without interfering with the other, as each has its own dedicated connection area and clamping mechanism.
Solution Approach 2:
The busbar structure acts as an intermediary element that mediates between the electrical conductor and the contact pin. The first holding section and second holding section are designed to independently receive and secure their respective components, preventing interference while the busbar itself provides the structural framework that coordinates both connection points.
4Volume of moving object
If a compact design is achieved with short current path, then space is saved, but contact pressure on the contact pin increases
Solution Approach 1:
The holding section of the busbar is designed to be movable relative to the contact section, creating a dynamic clamping mechanism. When the contact pin is inserted, the holding section moves to accommodate the pin and establish contact, distributing the contact pressure more effectively and reducing peak pressures compared to a rigid fixed structure, while maintaining a compact overall 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
This design provides a compact, reliable electrical connection with a short current path, allowing for easy and repeated insertion of electrical conductors and contact pins without interference, while ensuring optimal contact and minimizing pressure on the contact pin.
Implementation Method 1
a clamping spring (13) for contacting the electrical conductor (100), wherein the clamping spring (13) has a clamping leg (14) with a clamping edge (15) pointing towards the contact section (7)
Implementation Method 2
the clamping spring (13) being set up for pressing the contact pin (5) against the clamping section (9) of the conductor rail (6)
Implementation Method 3
a busbar (6), the busbar (6) having a contact section (7) arranged between the inserted electrical conductor and the inserted contact pin
Data Source
Figure 1
Figure 2
AI summary
A description is given of a conductor connection terminal (1) having an insulating material housing (2), wherein the insulating material housing (2) has a conductor insertion opening (3) for the insertion of an electrical conductor and a contact pin insertion opening (4) for the insertion of a contact pin (5), having a busbar (6), wherein the busbar (6) has a contact section (7) arranged between the inserted electrical conductor and the inserted contact pin (5), having a clamping spring (13) for the clamped connection of the electrical conductor, wherein the clamping spring (13) has a clamping limb (14) having a clamping edge (15) oriented so as to point towards the contact section (7), a spring bow (16) and a bearing limb (17), wherein the clamping edge (15) and the contact section (7) form a first clamping point for the electrical conductor to be clamp-connected. The busbar (6) has a contact bow (8) that adjoins the contact section (7) and transitions into a clamping section (9) for the clamped connection of the contact pin (5), wherein the clamping section (9) and the contact section (7) of the busbar (6) form a second clamping point, and wherein a holding section (11) extending towards the contact section (7) and running past the contact section (7) protrudes from the clamping section (9) of the busbar, wherein the bearing limb (17) of the clamping spring (13) is mounted on the holding section (11) of the busbar (6).