Pivoting Contact Clamp for Photovoltaic Connectors
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Solution Overview
Problem
Existing contact clamps for photovoltaic modules are cumbersome, require special tools for crimping, and lack flexibility in handling and secure connections, especially under tensile forces, with suboptimal force distribution and reliability.
Innovation Solution
A contact clamp with a pivoting clamping leg and a V-shaped spring design that allows for easy insertion and secure clamping of conductor ends, enabling manual operation without tools, flexible handling, and secure connections against tensile forces, using a holding frame with a contact plate and a clamping spring that can be opened and closed to accommodate conductor ends both when open and closed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a spiral spring with a long load arm is used to close the clamp, then the clamp can be closed, but the clamp becomes large and unwieldy and requires a relatively large amount of force to close
Solution Approach 1:
The clamp leg is designed to pivot about a pivot axis, transforming the closing action from a static spring compression to a dynamic rotational movement. This allows the clamp to be closed with less force by leveraging the pivot mechanism rather than directly compressing a long-load-arm spring.
Solution Approach 2:
The invention changes the geometric parameters of the spring mechanism by replacing the long load arm with a pivot-based system. The spring force is applied at a different location and angle, optimizing the force-to-size ratio by changing how the spring interacts with the clamp leg.
2Reliability
If the contact clamp is designed to be permanently closed after insertion, then connection security is improved, but flexibility in handling and ability to disconnect are lost
Solution Approach 1:
The clamp leg pivots between an open position (for insertion and removal) and a closed position (for secure connection). This dynamic positioning allows the same mechanism to provide both flexibility during handling and reliability during operation, resolving the contradiction between permanent fixation and adaptability.
Solution Approach 2:
The spring is pre-loaded to automatically close the clamp leg after insertion, providing preliminary securing action. However, the pivot mechanism allows this closing action to be reversed by applying force to the clamp leg, enabling disconnection when needed while maintaining automatic security during normal use.
3Device complexity
If the pivot axis runs parallel to the direction of insertion, then the clamp structure is simplified, but tensile forces on the conductor create opening forces on the load arm that require high preload or impair contact reliability
Solution Approach 1:
The pivot axis is positioned asymmetrically relative to the spring force application point and the clamp leg geometry. This asymmetric arrangement creates a mechanical advantage where tensile forces on the conductor are converted into closing forces on the pivot mechanism rather than opening forces, eliminating the need for high preload while maintaining contact reliability.
4Reliability
If crimping is used to connect the conductor, then a secure electrical connection is achieved, but special tools are required and the connection cannot be detached
Solution Approach 1:
The invention replaces the irreversible crimping mechanical system with a reversible pivot-based clamping system. The electrical connection security previously achieved only through crimping is now achieved through the spring-loaded pivot mechanism, which provides comparable contact pressure while allowing tool-free operation and detachment.
Solution Approach 2:
The clamp leg with pivot mechanism provides self-closing action through the spring force, eliminating the need for special crimping tools. The conductor is automatically clamped when the clamp leg pivots to the closed position, and can be released by simply pivoting the clamp leg open, providing tool-free attachment and detachment while maintaining secure electrical connection.
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 a user-friendly, secure, and permanent electrical connection that can be easily assembled and disassembled, ensuring reliable contact even under tensile forces, with adjustable force and insertion requirements, suitable for outdoor use and various conductor types.
Implementation Method 1
the clamping leg running obliquely in the direction of insertion towards the contact plate or base of the holding frame... with elastic springing of the terminal leg or the entire clamping spring into the target contact position
Data Source
Figure 1~4
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Figure 9~11
AI summary
The invention relates to a contact clamp for connecting a conductor end to an electrical contact and with an insertion side from which the conductor end can be inserted into the contact clamp, which comprises a holding frame with a contact section with which the conductor end can be contacted, and a clamping leg which is pivotably mounted in the holding frame and can pivot back and forth between an open pivot position (Fig. 1) and a closed pivot position (Fig. 2), and the clamping leg in the closed pivot position clamps the conductor end against the contact section when the conductor end is in the desired contact position (Fig.11) is inserted into the contact clamp to establish electrical contact between the conductor end and the contact section, and the clamping leg in the open pivot position is pivoted away from the contact section and releases the contact area in the contact clamp, so that the conductor end in the open pivot position can be inserted into the contact clamp on the one hand and is released for removal from the contact clamp on the other hand, and the clamping leg in the closed pivot position runs obliquely (γ) towards the contact section and is designed to be spring-loaded, such that the conductor end in the closed pivot position can be inserted into the contact clamp in the desired contact position under elastic spring action of the clamping leg.