Extensible Connector for Busbar Thermal Expansion
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Solution Overview
Problem
Existing expansion connectors for busbars are either structurally complex, space-consuming, or require extensive installation space and additional assembly steps to accommodate thermal expansion differences between metal and plastic materials, leading to insecure electrical connections.
Innovation Solution
A compact expansion connector design featuring a socket part with a longitudinal connecting opening and a plug part with a corresponding connecting plug, secured by a movable securing element that allows for longitudinal displacement up to a predetermined maximum expansion gap, ensuring secure electrical contact and length compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a connector designed as a connecting sleeve with two plastic halves is used to accommodate thermal expansion differences, then thermal expansion compensation is achieved, but the device becomes structurally complex and space-consuming
Solution Approach 1:
The connector is divided into two functional parts: a rigid connecting sleeve for electrical connection and a flexible sealing element for thermal expansion compensation. This segmentation allows each part to specialize in its function without adding overall complexity
Solution Approach 2:
The flexible sealing element acts as an intermediary between the rigid metal busbars and the plastic housing, absorbing thermal expansion differences while allowing the connecting sleeve to maintain a simple, compact structure for electrical connection
2Reliability
If a sliding system with conductive pins and pluggable connectors is used for expansion joints, then electrical connection is maintained, but the device requires extensive installation space and additional assembly steps
Solution Approach 1:
The electrical connection function and thermal expansion compensation function are merged into a single integrated connector assembly, eliminating the need for separate sliding systems and reducing installation space
Solution Approach 2:
The connecting sleeve serves multiple functions simultaneously: providing electrical connection through metal busbar contact, accommodating thermal expansion through the flexible sealing element, and maintaining mechanical alignment, thereby eliminating the need for dedicated sliding mechanisms
3Volume of moving object
If connector lugs are designed as cylindrical or prismatic plug pins inserted into recesses, then the current transfer cable fits within the busbar cross-section, but additional assembly steps are required and the structure becomes complex
Solution Approach 1:
The complex plug pin and recess structure is extracted and replaced with a simpler design where the flexible sealing element provides the necessary fit and sealing function, while the connecting sleeve provides direct electrical contact, reducing assembly complexity
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
The solution provides a quick, easy, and secure electrical connection between busbars while accommodating thermal expansion, reducing installation complexity and space requirements, and ensuring reliable operation.
Implementation Method 1
the plug part (13) is displaceable in the longitudinal direction (L) relative to the socket part (26) up to a predetermined maximum expansion gap in order to accommodate expansion of the busbars (4; 5) in the longitudinal direction (L)
Data Source
Figure 1~5
Figure 2~4
Figure 6~9
AI summary
The invention relates to an extensible connector (12) for connecting two busbars (4, 5) following each other in the longitudinal direction (L) of a contact line (1) and to a contact line (1) for supplying electric energy to an electric load that can be moved along the contact line (1) in the longitudinal direction (L), comprising at least one first and second busbar (4, 5) running in the longitudinal direction (L), wherein the busbars (4, 5) have a contact section (6) running in the longitudinal direction (L). The aim of the invention is to provide an extensible connector for connecting two busbars of a contact line, said extensible connector being easily and quickly installable, being as compact as possible, and allowing a reliable electric connection between two busbars following each other while simultaneously compensating for the length of the busbars. This is achieved by an extensible connector, which has a socket part (26) with a connection opening (31) running in the longitudinal direction (L) and a plug part (13) with a connection plug (21) running in the longitudinal direction (L), said connection plug (21) being pluggable into the connection opening (31) in the longitudinal direction (L) in order to establish an electric connection, and by a contact line, for which such an extensible connector (12) is provided for connecting the first busbar (4) and the second busbar (5).