Nested U-Shaped Connecting Bridge for High-Clamping Busbar Contact
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Solution Overview
Problem
Existing connecting bridges for electrically conducting components, such as busbars, lack optimized connection and secure current transmission due to limitations in contacting properties and clamping forces, particularly when using wire elements.
Innovation Solution
A novel connecting bridge featuring nested U-shaped cross-connectors made of electrically conducting sheet metal with spring legs and a holding device, allowing for improved contact and clamping forces through a nested design and overmoulding with plastic, enabling secure and efficient current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wire elements are used for connecting bridges, then the structure is simple, but the contacting properties and clamping forces are insufficient
Solution Approach 1:
The patent applies nesting by arranging multiple U-shaped cross-connectors concentrically within each other, with each cross-connector having a smaller dimension than the previous one. This nested configuration allows multiple contact points to be integrated into a compact structure, significantly increasing clamping forces while maintaining space efficiency and manageable structural complexity.
Solution Approach 2:
The patent employs composite construction by combining electrically conducting sheet metal for the cross-connectors with plastic material for the housing and insulation elements. This composite approach enables the connecting bridge to achieve both mechanical strength for clamping and electrical conductivity for current transmission, while the plastic components provide insulation and structural support.
2Reliability
If single cross-connector design is used, then the device is simple, but the current transmission reliability is insufficient
Solution Approach 1:
The patent implements nesting by placing multiple U-shaped cross-connectors concentrically within each other, creating multiple parallel current paths between busbars. This nested arrangement ensures that if one contact path fails, current can still flow through alternative paths, significantly improving transmission reliability while keeping the overall device compact.
Solution Approach 2:
The patent divides the connecting bridge into multiple segmented cross-connectors rather than using a single solid connector. Each cross-connector acts as an independent current path segment, and their nested arrangement creates redundant pathways for current flow, enhancing reliability through distribution of current across multiple segments.
3Reliability
If sheet metal cross-connectors with contours are used, then the contacting properties are optimized, but the manufacturing complexity increases
Solution Approach 1:
The patent applies nesting by configuring multiple U-shaped cross-connectors with varying dimensions to fit concentrically within each other. This nested design allows standardized sheet metal components with simple U-shapes to be manufactured efficiently while achieving optimized contacting properties through their arranged configuration, rather than requiring complex single-piece contours.
Solution Approach 2:
The patent segments the connecting function into multiple identical or similar U-shaped cross-connector components rather than one complex contoured piece. This segmentation enables standardized manufacturing of simple U-shaped sheet metal elements, which are then assembled in a nested pattern to achieve the desired contacting properties, simplifying the manufacturing process.
4Strength
If multiple cross-connectors are arranged nested, then the clamping forces are increased, but the device volume increases
Solution Approach 1:
The patent resolves this contradiction by nesting multiple cross-connectors concentrically within each other, similar to Russian dolls. This arrangement allows multiple clamping elements to occupy the same spatial envelope, multiplying clamping forces without proportionally increasing the external dimensions or volume of the connecting bridge device.
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 enhanced contacting properties and increased clamping forces, ensuring reliable current transmission with reduced contact resistance and scalability, while accommodating tolerance variations and material properties like high tensile strength and elasticity.
Implementation Method 1
A spring leg of a metallic component has, up to a certain degree of deformation, an elasticity with the formation of a restoring force.
Implementation Method 2
The cross-connectors are formed from an electrically conducting sheet metal so that the cross-connectors can be provided with contours
Data Source
AI summary
A connecting bridge for the transmission of an electrical current between two electrically conducting components has at least two U-shaped cross-connectors each composed of electrically conductive sheet metal which are arranged nested in one another. An arrangement includes the connecting bridge and at least one busbar.