Deformable Pressure Plate for Electrical Connector Force Stability
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Solution Overview
Problem
Existing electrical connector devices face issues with maintaining a consistent clamping force over time due to thermal cycling and material creep, leading to increased contact resistance between main and branch conductors, and they often have complex assembly processes and large dimensions.
Innovation Solution
The device incorporates a deformable pressure plate with varying flexural rigidity sections, allowing elastic deformation during assembly to maintain contact force, and features a rigid stop to prevent overstretching, ensuring high force transmission without increasing device size, and simplifies assembly with symmetrical design and locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a rigid pressure plate is used to maintain clamping force, then the contact force is initially high, but the device cannot compensate for settlement due to thermal cycling or material creep
Solution Approach 1:
The pressure plate is designed with elastically deformable sections that allow it to dynamically adjust and maintain constant contact force despite settlements caused by thermal cycling or material creep, transforming a static rigid structure into a dynamic adaptive one
Solution Approach 2:
The pressure plate's flexural rigidity is varied across different sections, with some sections being more elastic than others, allowing selective deformation in specific areas to maintain overall clamping force stability under varying conditions
2Force
If a helical spring is used to maintain clamping pressure, then the contact force is maintained, but the threaded bolt overhang causes shedding and assembly difficulties
Solution Approach 1:
The separate spring element is extracted and replaced by integrating the spring function directly into the pressure plate structure itself, eliminating the need for a threaded bolt overhang and associated assembly problems
Solution Approach 2:
The pressure plate combines the function of a connecting or reinforcing element with that of a spring element into a single integrated component, eliminating the need for separate spring elements and reducing assembly complexity
3Force
If the pressure plate is made fully rigid to transmit high forces, then force transmission is high, but the device size increases
Solution Approach 1:
The pressure plate has different sections with varying flexural rigidity - some sections are rigid for force transmission while others are elastically deformable for compensation, allowing high force transmission without increasing overall device size
Solution Approach 2:
The pressure plate is divided into multiple sections with different geometric configurations and flexural rigidities, allowing each section to perform its specific function optimally while maintaining a compact overall structure
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 solution provides a permanent and secure electrical connection with reduced contact resistance and simplified assembly, maintaining force over long-term use while minimizing material usage and assembly complexity.
Implementation Method 1
at least one section of the pressure plate is deformable in a force-storing manner... there is an elastic deformation of the pressure plate in a predetermined area
Implementation Method 2
The force stored in the pressure plate is introduced into the device after the tightening has ended... the contact force for the electrical connection is thus maintained to a high degree over the long term
Implementation Method 3
the pressure plate has a rigid stop... by which the spring deflection of the pressure plate and in particular of a resiliently deformable section of the pressure plate is limited
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The device (1) has a housing with parts (10, 20) that are connectable by a screw connection (22). A pressure plate (30) stands in effective connection with the screw connection and is deformable during tightening of the screw connection. A force retained by the elastic deformation is introduced in the device after completion of the tightening process for maintaining the contact force for the electrical connection between prime conductors (2, 4, 6, 8) and shunt conductors (12, 14, 18).