Electrical Connector Assembly With Indented Contact Stab

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Solution Overview

Problem

Existing electrical connector assemblies in power distribution systems face challenges with retention force, leading to unintentional disconnection and poor electrical performance due to the use of separate fasteners and clip members that do not provide sufficient mechanical and electrical connection.

Innovation Solution

An electrical connector assembly featuring a contact stab with opposing indentations and a clip member with curved contact surfaces, where the clip member engages the indentations to increase retention force, ensuring a secure mechanical and electrical connection between the electrical apparatus and the bus member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If separate fasteners are used to mechanically couple electrical apparatus to bus members, then the connection can be achieved, but the installation process becomes time-consuming and requires separate tools

Engineering Contradiction:

Improveinstallation convenienceVSAvoidinstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent combines the fastening function and electrical connection function into a single integrated clip member. The clip member simultaneously mechanically couples the electrical apparatus to the bus member and provides electrical connection through its conductive structure, eliminating the need for separate fasteners and reducing installation steps

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If a simple clip member is used to mechanically couple electrical apparatus to contact stab, then the device complexity is reduced, but the retention force becomes insufficient

Engineering Contradiction:

Improveconnector structure simplicityVSAvoidretention force

Core Design Contradiction:

Device complexityVSForce

Solution Approach 1:

The patent introduces indentations at specific locations on the contact stab to create localized engagement points. These indentations concentrate the retention force at precise points where the clip member legs engage, enhancing the overall retention force without requiring a complete redesign of the clip member structure

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent incorporates curved contact surfaces on the clip member legs that engage with the indentations in the contact stab. The curved geometry allows for better force distribution and engagement, increasing the retention force while maintaining a simple overall structure

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Area of stationary object

If space constraints within electrical enclosure are considered, then the compact layout is achieved, but access to fasteners becomes difficult

Engineering Contradiction:

Improveenclosure space utilizationVSAvoidfastener accessibility

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

By integrating the fastening and electrical connection functions into a single clip member that is inserted from the front, the patent eliminates the need for separate fasteners that would be difficult to access in tight spaces. The combined structure can be installed and adjusted from the easily accessible front of the enclosure

Inventive Principle:

Principle #5Merging (Combining)

4Device complexity

If insufficient retention force is provided by the clip member, then the device simplicity is maintained, but unintentional disconnection occurs

Engineering Contradiction:

Improveconnector structure simplicityVSAvoidconnection reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The indentations in the contact stab create localized high-force engagement points that significantly enhance retention without requiring a more complex clip member structure. This localized enhancement prevents unintentional disconnection while maintaining overall structural simplicity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The curved contact surfaces on the clip member legs engage with the indentations to create a mechanical interlock that resists disconnection forces. The curved geometry provides better force distribution and engagement stability, improving connection reliability

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS7553175B1Power distribution system and electrical connector assembly therefor

Publication Date: 2009.06.30 EATON INTELLIGENT POWER LTD

AI summary

An electrical connector assembly is provided for electrically connecting an electrical apparatus, such as a circuit breaker, to an electrical bus member. The electrical connector assembly includes a contact stab extending outwardly from the electrical bus member. The contact stab includes first and second sides having first and second indentations, respectively, which are disposed opposite one another. A clip member mechanically couples and electrically connects the circuit breaker to the contact stab. The clip member includes a first leg and a second leg disposed opposite and distal from the first leg. The first leg engages the first indentation of the first side of the contact stab and the second leg engages the second indentation of the second side of the contact stab, thereby retaining the clip member on the contact stab.