Segmented Flexible Conductor for Modular Terminal Connections
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Solution Overview
Problem
Existing methods for electrical connection of modular device terminals on a mounting support, such as those using flexible or rigid wires and combs, face inefficiencies due to alignment issues, mechanical stresses, and the need for tools to cut and align components, leading to a time-consuming and unreliable connection process.
Innovation Solution
A manufacturing process involving a flexible or semi-rigid conductor is used, where stripped parts are folded to form bridges, allowing for the creation of prefabricated connection elements that can be easily separated and connected to terminals without tools, enabling a fast and reliable electrical connection regardless of terminal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid combs are used for electrical connection, then the connection structure is stable, but mechanical stresses occur due to misalignment of terminals and tools are needed for cutting and installation
Solution Approach 1:
The conductor is divided into multiple bridges at regular intervals, with each bridge being a separate segment that can be independently inserted into terminals. This segmentation allows the connection device to adapt to misaligned terminals while maintaining structural stability, as each bridge can be positioned independently without requiring tools for installation.
Solution Approach 2:
The conductor is designed to be flexible rather than rigid, allowing it to bend and adapt to the actual positions of terminals. This dynamic flexibility eliminates mechanical stresses caused by misalignment while maintaining stable electrical connection, and the bridges can be formed without requiring cutting tools during installation.
2Ease of operation
If individual bridges are made by flexible wires with wiring tips, then the connection is flexible, but the connection time is particularly long due to multiple steps
Solution Approach 1:
Multiple bridges are combined into a single continuous conductor with bridges formed at regular intervals. This merging eliminates the need to handle and connect individual wires separately, significantly reducing connection time while maintaining the flexibility advantages of wire-based connections.
Solution Approach 2:
The bridges are pre-formed at regular intervals along the conductor during manufacturing, with stripped parts prepared in advance. This preliminary preparation eliminates the need for on-site cutting, stripping, and tip attachment operations, dramatically increasing connection speed while preserving flexibility.
3Device complexity
If rigid wire bridges are used without wiring tips, then the connection process is simpler, but the stripped rigid ends cannot accommodate misaligned terminals
Solution Approach 1:
The conductor is designed with flexibility to accommodate terminal misalignment, eliminating the need for complex alignment procedures while maintaining simple bridge structures. The flexible nature allows the bridges to adapt to varying terminal positions without requiring wiring tips or complex adjustment mechanisms.
4Adaptability or versatility
If combs are cut to adapt length to the number of devices, then the connection fits the specific application, but tools are required and alignment issues persist
Solution Approach 1:
The conductor is segmented into bridges at regular intervals with weakened zones between them, allowing easy manual separation into the required number of segments without tools. This maintains length adaptability for different applications while eliminating the need for cutting tools and complex alignment procedures.
Solution Approach 2:
The conductor is pre-manufactured with bridges at regular intervals and weakened zones at predetermined positions. This preliminary structuring allows the installer to simply break the conductor at the weakened zones to achieve the desired length, eliminating tool requirements and alignment issues while maintaining application-specific adaptability.
Data Source
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AI summary
The method involves taking a flexible or semi-rigid conductor e.g. single-strand copper wire, of a predetermined length, and creating stripped parts presenting a certain length at regular intervals along the conductor. A set of stripped portions (6, 7) located on both sides of each folding zone is superimposed so as to form a succession of bridges. The stripped portions are attached mechanically in a removable manner and are electrically connected so as form connection elements ready to be introduced into a terminal for electrical connection of a modular electric protection apparatus. An independent claim is also included for an assembly of modular electric protection apparatus.