Electrical Connector Direct Clamp Mounting

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Solution Overview

Problem

Existing electrical connectors face challenges in maintaining a stable relationship between the clamp and bus bar, particularly under thermal and mechanical stress, leading to potential disconnection of electrical conductors due to undesired deformation of the housing material, especially when handling flexible or twisted conductors.

Innovation Solution

The electrical connector features a directly mounted clamp to the bus bar using a snap-fit connection or integral mounting sections, eliminating the need for external support elements and reducing mechanical stress on the housing, ensuring a predefined relationship between the clamp and bus bar, and allowing for secure connection of various conductor types.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the clamp and bus bar are mechanically connected to the housing to maintain a predefined relationship, then the position stability is improved, but mechanical stress on the housing increases causing deformation

Engineering Contradiction:

Improveposition stability of clamp relative to bus barVSAvoidmechanical stress on housing

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The clamp is directly mounted to the bus bar, merging the clamp-bus bar-clamp system into a single integrated unit. This eliminates the need for separate housing connections and external support elements, allowing the components to maintain their predefined relationship through direct mechanical coupling rather than through the housing structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mounting system is segmented into independent mounting sections that are integral to the clamp itself. Each mounting section can independently secure the bus bar, distributing the mechanical load away from the housing and allowing the clamp-bus bar assembly to maintain its position through self-contained structural elements.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If the spring arm is moved against a restoring force to insert a conductor, then the conductor can be secured to the bus bar, but mechanical stress on the housing increases causing deformation

Engineering Contradiction:

Improveconductor insertion capabilityVSAvoidmechanical stress on housing

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The spring arm is integrated as part of the clamp assembly that is directly mounted to the bus bar. This merging allows the spring arm's movement and the clamp's securing function to occur as a unified mechanism, where the restoring force is contained within the clamp-bus bar assembly rather than being transmitted to the housing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring arm provides dynamic movement capability, allowing it to be displaced against the restoring force during conductor insertion and then return to its original position. This dynamic mechanism enables easy operation while containing the mechanical stress within the spring arm-clamp-bus bar system, preventing transmission to the housing.

Inventive Principle:

Principle #15Dynamics

3Stability of the object's composition

If external support elements are used to maintain the clamp-bus bar relationship, then position stability is improved, but device complexity increases

Engineering Contradiction:

Improveposition stability of clamp relative to bus barVSAvoidnumber of components

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The mounting sections are integrated directly into the clamp structure, merging the support function into the existing clamp component. This eliminates the need for separate external support elements while maintaining position stability, as the integral mounting sections provide the necessary structural support through the clamp's own geometry.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The clamp assembly serves multiple functions: it provides the clamping action to secure the conductor, houses the spring arm mechanism, and includes integral mounting sections that secure the bus bar. This multi-functionality eliminates the need for separate external support elements, reducing device complexity while maintaining stability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 maintains a stable connection between the clamp and bus bar, preventing unintended disconnection of electrical conductors, even under thermal and mechanical stress, and supports secure connection of diverse conductor types without external support, enhancing operational safety and reliability.

Implementation Method 1

The spring arm can be pre-loaded towards the bus bar so that an electrical conductor that is inserted into a gap between the bus bar and the spring arm can be mechanically secured

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11038289B2Electrical connector

Publication Date: 2021.06.15 APTIV TECHNOLOGIES AG

AI summary

An electrical connector for receiving at least one electrical conductor comprises a bus bar and at least one clamp, wherein the at least one clamp comprises a spring arm moveable relative to the bus bar. The spring arm cooperates with the bus bar to secure an electrical conductor to the bus bar when the spring arm is in a connecting position. The at least one clamp is directly mounted to the bus bar.