One-Piece Floor Jumper with Resilient Section for Electrical Bridging
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Solution Overview
Problem
Existing floor jumpers face issues such as tilting during insertion, leading to shearing and impaired functionality, complex production processes, high production and storage costs, and unsuitability for small distance connections due to material and processing tolerances.
Innovation Solution
A one-piece floor jumper design combining a conductive section for electrical bridging and a resilient section, made from copper materials, with bulges for secure insertion and contact establishment, and an optional non-conductive section for easy insertion and removal, featuring stops to limit spring travel and ensure stable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If floor jumpers are made with a two-part structure (conductive section and resilient section separate), then production flexibility is improved, but the risk of shearing during insertion increases and reliability deteriorates
Solution Approach 1:
The patent combines the conductive section and resilient section into a single one-piece component. The conductive section extends from one end of the resilient section to the other, creating an integrated structure that eliminates the risk of shearing at connection points while maintaining production efficiency through single-step manufacturing processes
2Reliability
If classic connection techniques (soldering) are used to connect the conductive section, then the risk of shearing is minimized, but production costs increase and error probability increases
Solution Approach 1:
The conductive section is integrated directly into the resilient section as a one-piece component, eliminating the need for separate connection techniques like soldering. This integration maintains strong electrical connection while reducing production complexity and cost
Solution Approach 2:
The material properties of the resilient section are optimized to provide both mechanical resilience and adequate electrical conductivity, allowing the component to function as both structural support and electrical conductor without requiring separate connected parts
3Adaptability or versatility
If multi-part components are used, then adaptability to different configurations is improved, but storage costs for basic parts during production increase
Solution Approach 1:
By integrating multiple functions into a single one-piece component, the patent reduces the number of separate parts that need to be stored and managed during production, while the resilient section's ability to spring and the conductive section's continuous path maintain adaptability to different installation configurations
4Length of moving object
If known floor bridges are used with small distance connections, then compactness is improved, but manufacturing precision requirements increase due to processing and material tolerances
Solution Approach 1:
The resilient section's spring properties are designed to compensate for small variations in dimensions and positioning tolerances. The elastic deformation capability allows the component to accommodate manufacturing variations while maintaining reliable contact, enabling production of compact connectors without requiring extremely tight precision control
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 design prevents shearing, simplifies production, reduces costs, and allows secure electrical contact even in tight spaces, while being easier to install and maintain, with the resilient section acting as both a conductive and non-conductive component.
Implementation Method 1
bulges are provided on the resilient section so that they can spring when inserted and thus enable insertion on the one hand, and on the other hand in the respective end position ensure that contact is established safely
Data Source
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AI summary
The invention relates to a floor bridge for electrically bridging two superimposed contacts in a holder. The floor bridge comprises a conductive section (3) for electrically bridging the two superimposed contacts and a resilient section (4) which facilitates insertion and secure retention. The conductive section (3) and the resilient section (4) of the floor bridge are formed in one piece. Furthermore, the invention proposes a method for manufacturing floor bridges, which includes the step of stamping (100) a metallic material to produce a one-piece metallic floor bridge blank (8).