Push-In Connector Busbar Daisy-Chain Design
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Solution Overview
Problem
Existing electrical connectors do not efficiently allow for the connection of multiple conductors to a single source in a daisy-chain design, nor do they facilitate easy removal of conductors, which is necessary for safe and efficient circuit operations.
Innovation Solution
A push-in wire connector with a 2-pole design featuring non-conductive housings and conductive contacts with spring elements and busbars, allowing for secure and daisy-chain style connections while preventing easy withdrawal of conductors, using male and female housings with specific structural features to ensure secure engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a known push-in connector is used to connect multiple conductors through a busbar, then the ability to connect multiple conductors together is improved, but the ease of removing conductors once inserted deteriorates
Solution Approach 1:
The connector employs a spring-loaded contact mechanism that dynamically adjusts its gripping force. During insertion, the spring compresses to allow conductor entry, then expands to provide secure retention. For removal, sufficient force compresses the spring to release the conductor, enabling controlled disconnection while maintaining secure connection during normal operation.
Solution Approach 2:
The connector is divided into modular components including individual contact elements, each with its own spring mechanism, and a common busbar structure. This segmentation allows independent operation of each conductor connection while maintaining the overall multi-conductor connection capability, enabling selective insertion and removal of individual conductors.
2Reliability
If a known disconnect is used for one-to-one conductor connection, then the safety of disconnecting conductors is improved, but the ability to connect multiple connectors in a daisy-chain design deteriorates
Solution Approach 1:
The connector is designed with universal compatibility features including standardized interfaces that can connect to both single and multiple connectors simultaneously. The busbar structure provides multiple connection points that can accommodate daisy-chain configurations while maintaining the same safety disconnect mechanism as single-conductor applications, enabling the connector to serve multiple functions.
Solution Approach 2:
The connector merges the safety disconnect mechanism with multi-conductor connection capability in a single integrated device. The common busbar combines multiple conductor connections while the unified housing and actuation mechanism provide simultaneous disconnect of all conductors, combining features that were previously separate in different connector designs.
3Ease of operation
If a connector allows easy removal of conductors, then the ease of operation is improved, but the reliability of maintaining secure electrical connection deteriorates
Solution Approach 1:
The spring-loaded contact provides dynamic retention force that maintains secure electrical connection during normal operation while allowing controlled removal when sufficient force is applied. The spring continuously exerts force to maintain contact pressure for reliable electrical connection, but this same mechanism allows the conductor to be removed by overcoming the spring force, providing both reliability and ease of operation.
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 secure and efficient connection of multiple conductors in a daisy-chain configuration, ensuring reliable electrical paths while allowing for controlled disconnection, thus addressing the need for safe and efficient multi-conductor connections.
Implementation Method 1
conductive contacts with spring elements
Data Source
Figure 1A~1B
Figure 2~4
Figure 5~9
AI summary
An electrical disconnect includes a male housing having an enclosed contact and a female housing similarly having an enclosed contact. The contact in at least one of the housings includes a busbar to electrically couple a plurality of wires. Upon joining the disconnect, the contacts in the two housing engage to form as releasable connection. By including a busbar, multiple conductors in one of the housings may be coupled to a single conductor in the second housing. Additionally, by disconnecting the housing, each load in the circuit may be simultaneously interrupted as desired.