Lever Connector Mechanism for Compact High-Force Wire Clamping
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Solution Overview
Problem
Current lever connectors for electrical conductors face limitations in lever opening forces, size constraints, and operational efficiency, particularly in connecting higher gauge and smaller diameter wires, and lack the ability to be shipped in an open configuration.
Innovation Solution
The design incorporates a lever mechanism with a resilient member and a busbar bridge, allowing for improved lever opening forces and a smaller form factor, enabling efficient electrical contact and connection of wires by using a housing with insulating material, a busbar, and a resilient member with a clamping section that moves under a lifting mechanism to secure the conductor against the busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional lever connector designs are used, then the structure is simple and easy to manufacture, but the lever opening force is insufficient and the size cannot be reduced
Solution Approach 1:
The patent implements a dynamic lever mechanism where the lever can rotate between open and closed positions, and the lifting mechanism dynamically adjusts the clamping section position along the busbar bridge. This dynamic operation enables improved lever opening force while maintaining manageable device complexity through controlled motion rather than static structural complexity.
Solution Approach 2:
The lifting mechanism introduces a new dimension of motion by sliding the clamping section along the busbar bridge in addition to the lever's rotational motion. This dimensional addition allows the force to be applied more effectively at multiple points, improving lever opening force without proportionally increasing overall device complexity.
2Volume of moving object
If traditional lever connector designs are used, then the structure is straightforward, but the size (height and width) cannot be reduced
Solution Approach 1:
The lifting mechanism is nested within the housing structure, with the clamping section sliding along the busbar bridge that is itself integrated into the housing. The lever mechanism is positioned to operate within the same compact envelope. This nesting arrangement reduces the overall height and width of the connector while containing the increased internal mechanism complexity within a smaller volume.
Solution Approach 2:
The dynamic sliding action of the lifting mechanism along the busbar bridge allows the clamping section to occupy a smaller average volume compared to traditional static designs. The mechanism only requires space for its range of motion rather than permanent structural elements throughout the entire connector volume, enabling size reduction.
3Reliability
If the lever connector is designed with improved clamping force, then the electrical contact is more reliable, but the lever opening force increases making operation harder
Solution Approach 1:
The resilient member acts as an intermediary between the lifting mechanism and the conductor. It stores and releases elastic energy to provide consistent clamping force on the conductor, ensuring reliable electrical contact. Simultaneously, the lever mechanism serves as an intermediary that amplifies the user's input force to overcome the resilient member's pre-load, making operation easier despite the high clamping force requirement.
Solution Approach 2:
The dynamic interaction between the lever mechanism and the resilient member creates a force multiplication effect. When the lever is closed, it overcomes the resilient member's elastic force to achieve initial contact. Once contact is made, the resilient member's elastic recovery provides sustained clamping force for reliable electrical contact, while requiring less force to maintain than traditional static designs.
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 configuration enhances the lever connector's ability to securely connect electrical conductors, provides improved lever opening forces, and allows for a smaller size, making it suitable for various applications, including splicing wires of different gauges and sizes, while enabling shipping in an open configuration.
Implementation Method 1
The resilient member may include a fixed section connected to the busbar bridge and a clamping section connected to the lifting mechanism. When the lever is actuated and lifted upwards and away from the housing, the lifting mechanism may move the clamping section of the resilient member to release away from the busbar base surface. When the lever is closed and pushed downward toward the housing, the lifting mechanism may move the clamping section of the resilient member downward to push the electrical conductor against the busbar base surface
Data Source
AI summary
A lever connector for contacting electrical conductors may include features and improvements over other lever connectors. The lever connector includes a housing, a busbar located within the housing, one or more lever mechanisms, and one or more resilient members that connect the lever mechanisms to the busbar. The lever mechanism includes a lever located on a near side of the busbar bridge and a lifting mechanism located on a far side of the busbar bridge opposite the near side of the busbar bridge. The resilient member includes a fixed section connected to the busbar bridge and a clamping section connected to the lifting mechanism. When the lever is actuated and lifted upwards and away from the housing, the lifting mechanism moves the clamping section of the resilient member to release away from the busbar base surface. When the lever is closed and pushed downward toward the housing, the lifting mechanism moves the clamping section of the resilient member downward to push the electrical conductor against the busbar base surface, thereby making electrical contact between the electrical conductor and the busbar.