Multi-Hinge Electrical Jumper Clamps for Uneven Surface Bonding
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Solution Overview
Problem
Electrical devices with conductive chassis or frames at different potentials can cause injuries or equipment damage, and existing methods for equipotential electrical connection, such as using threaded fasteners, are limited in holding strength and flexibility, especially when dealing with uneven surfaces and non-conductive layers.
Innovation Solution
An electrical jumper with interlacable multi-hinge fingers provides superior holding strength and conductivity by using clamps that extend from a body, allowing independent movement and better penetration through non-conductive layers, eliminating the need for manufacturer-provided holes and enabling bonding to uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded fasteners are used for electrical bonding, then the connection is secure, but the holding strength is limited and flexibility is reduced
Solution Approach 1:
The clamp uses hinged fingers that can dynamically adjust their position and angle to accommodate uneven surfaces and different geometries, transitioning from a rigid threaded fastener system to a flexible adaptive clamping mechanism
Solution Approach 2:
The hinge mechanism allows the clamp to change its geometric parameters (angle, position) to adapt to different bonding surfaces, enabling the same clamp to work on various surface conditions without modification
2Adaptability or versatility
If manufacturer-provided holes are used for electrical bonding, then the bonding location is fixed, but the ability to bond to uneven surfaces is limited
Solution Approach 1:
The clamp is segmented into multiple hinged fingers that can independently adjust, allowing the overall structure to adapt to uneven surfaces while maintaining precise electrical contact through the conductive body
Solution Approach 2:
The hinged fingers act as intermediaries between the fixed clamp body and the uneven bonding surface, absorbing geometric mismatches while ensuring reliable electrical connection
3Device complexity
If single-hinge clamps are used, then the structure is simple, but fatigue and failure occur after multiple uses
Solution Approach 1:
The single hinge is segmented into multiple hinge portions distributed along the finger, distributing the mechanical stress and fatigue across multiple points rather than concentrating it at a single location
Solution Approach 2:
The multi-hinge structure provides built-in compliance and stress distribution that cushions against fatigue loads before they can cause failure, extending the service life of the clamp
4Ease of operation
If clamping pressure is not sufficient, then installation is easy, but penetration through non-conductive oxide and anodizing layers is poor
Solution Approach 1:
The hinge mechanism provides compliant, curved movement paths that allow the clamp to conform to the surface and distribute pressure evenly, ensuring sufficient penetration through non-conductive layers while maintaining ease of installation
Data Source
AI summary
This disclosure discusses an electrical jumper for equipotential electrical connection between devices. The electrical jumper may include a body and clamps optionally positioned on opposite ends of the body. The clamps include a series of interlacable multi-hinged fingers. Downward-facing fingers and upward-facing fingers extend away from the body. The downward-facing fingers may interlace with the upward-facing fingers when unclamped. When clamped, downward-facing fingers may interlace with the upward-facing fingers may alternate. The ends of the upward-facing fingers and downward-facing fingers may face inward toward the body. The fingers may move and hinge independently of one another along multiple hinges.