In-line Electrical Disconnect With Nested Enclosures
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Solution Overview
Problem
Existing electrical disconnects for high current applications are often bulky and inefficient in terms of material and space usage, and prior push-in disconnects are limited to low current ratings and inconvenient wire connectors.
Innovation Solution
A compact electrical disconnect design featuring push-in connections with male and female terminals, spring fingers, and a terminal holder that allows for high current handling (up to 20 amps) by aligning wire ends closely for minimal size and using resilient materials for mechanical integrity and non-conductive materials for housing, enabling easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional disconnects are designed for high current applications, then current handling capability is improved, but device size and material usage increase
Solution Approach 1:
The patent places the socket enclosure inside the plug enclosure, with the socket busbar nested within the plug housing. This nested arrangement allows the two enclosures to share common structural elements and mounting spaces, reducing the overall device volume while maintaining the current handling capability of both components
Solution Approach 2:
The patent combines the plug and socket into a single integrated device by mounting the socket enclosure within the plug enclosure. The busbars are also merged into a single assembly where the socket busbar is positioned adjacent to and integrated with the plug busbar, allowing shared mounting structures and reduced material usage
2Ease of operation
If push-in connections are used for convenient wire insertion, then ease of operation is improved, but current rating is limited to low values
Solution Approach 1:
The patent uses composite construction where spring fingers are made of resilient material for mechanical engagement and electrical contact is made of highly conductive material. This composite approach allows the push-in connection to handle high currents by separating the mechanical function (spring fingers) from the electrical conduction function (contact portions), enabling both convenience and high current capability
3Volume of stationary object
If terminal arrangements are optimized for compactness, then device size is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent divides the terminal arrangement into separate plug and socket enclosures that can be manufactured independently using standard molding processes. The busbars are segmented into plug busbar and socket busbar components that can be pre-fabricated and then assembled together, simplifying manufacturing while achieving compact integration
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 design provides a compact, safe, and efficient means for making and breaking electrical connections, allowing for high current handling while minimizing material and space usage, and facilitating easy replacement and maintenance in electrical circuits.
Implementation Method 1
The contact portions of both the male and female busbars have springs fixed thereto. The springs include flexible spring fingers adjacent an inserted conductor or wire. The spring fingers press the conductor into engagement with the associated contact portion.
Data Source
AI summary
An electrical disconnect has a pair of selectably engageable enclosures each including one or more terminals supported therein. Each terminal has a blade at a forward end thereof. The blades are releasably engageable in overlapping relation in an engagement zone. A terminal holder biases the overlapping blades into contact with one another.