Modular Connection Assembly Using Bonded Intermediary Connectors
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Solution Overview
Problem
Conventional assemblies for electrical equipment require dedicated matching of connection devices for interlocking, limiting variability and flexibility in configuring different connection functionalities on a circuit board.
Innovation Solution
A connecting element with a main body and connecting portion is used to connect adjacent connection devices via material-to-material bonding, allowing for variable configuration of connection devices with different housing contours through adhesive bonding or welding, providing electrical insulation and a strong connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If snap-fit connections or dovetail tongue/groove combinations are used to interlock adjacent connection devices, then the connection strength and stability are improved, but the adaptability and versatility are worsened due to dedicated matching requirements
Solution Approach 1:
A connecting element is introduced as an intermediary component between adjacent connection devices. This connecting element features a connecting portion with bonding surfaces that enable material-to-material bonding to housings of different contours, while its main body provides electrical insulation. This mediator allows connection devices with different housing designs to be securely connected without requiring dedicated interlocking features, thus resolving the contradiction between connection strength and adaptability.
2Reliability
If dedicated matching of connection devices is used for interlocking, then the reliability of connection is improved, but the device complexity increases due to multiple specialized components
Solution Approach 1:
The connecting element is designed as a universal component that can connect different types of connection devices regardless of their specific housing contours. The connecting portion features bonding surfaces configured to bond with various housing designs through material-to-material bonding, while the main body provides electrical insulation. This universal design reduces the need for multiple specialized interlocking components, thereby reducing device complexity while maintaining reliable connections.
3Object-affected harmful factors
If intermediate plates are used for electrical insulation between adjacent terminal arrangements, then the electrical insulation is improved, but the connection strength and structural integrity are worsened
Solution Approach 1:
The connecting element merges two previously separate functions into a single integrated component: electrical insulation and mechanical connection. The main body of the connecting element is made of electrically insulating material that provides electrical insulation between adjacent connection devices, while the connecting portion with bonding surfaces provides strong material-to-material bonding to the housings. This combined design eliminates the need for separate intermediate plates, maintaining electrical insulation while significantly improving connection strength.
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
Enables the creation of a variably configurable assembly for electrical equipment by allowing connection devices with different designs and sizes to be securely attached, enhancing flexibility and functionality while maintaining electrical insulation.
Implementation Method 1
the connecting element is connectable via the connecting portion to the housing of at least one of the two adjacent connection devices by material-to-material bonding
Implementation Method 2
allowing for variable configuration of connection devices with different housing contours through adhesive bonding or welding
Implementation Method 3
the connecting element is formed of an electrically insulating material
Data Source
AI summary
An assembly for electrical equipment includes: a plurality of connection devices to be modularly arranged side-by-side in a row along a row direction, each having a housing and at least one termination point for connecting at least one electrical conductor; and a connecting element having a main body and a connecting portion formed on the main body, the connecting element connecting together two of the plurality of connection devices which two connection devices are adjacent to each other along the row direction. The connecting element is connectable via the connecting portion to the housing of at least one of the two adjacent connection devices by material-to-material bonding.