Shunt Connector Assembly with Integrated Bridging Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector assemblies for electrical systems are not compact enough and are difficult to handle and assemble, particularly in applications requiring high current ratings like commercial refrigerators and public buildings, where they need to be functional and easy to install.
Innovation Solution
A shunt connector assembly with a body comprising two casing portions connected by screws, featuring metal pins with socket and plug ends and collars for interference fit, and bridging elements acting as both electrical conductors and spring mechanisms to secure connections, ensuring compactness and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional connector assemblies are used, then electrical connection function is provided, but the assembly is not compact and is difficult to handle and assemble
Solution Approach 1:
The patent combines multiple functions into integrated components. The bridging elements serve dual purposes as both electrical conductors and spring mechanisms for securing connections. The metal pins integrally incorporate socket and plug ends with collars, eliminating the need for separate retaining components. This merging reduces the number of parts and overall assembly volume while maintaining ease of assembly through the integrated design.
Solution Approach 2:
The patent employs nesting by placing the bridging elements within seats formed in the casing portion, and the metal pins within cavities in the body. The collars on the metal pins provide interference fit within the body cavities, creating a nested structure that maximizes space utilization and achieves compactness without compromising assembly ease.
2Volume of moving object
If compact design is implemented, then volume is reduced, but manufacturing complexity increases
Solution Approach 1:
The connector assembly is segmented into distinct functional components: a body with cavities, a casing portion with seats, metal pins with integrated features, and bridging elements. This segmentation allows each component to be manufactured separately using optimized processes, then assembled through straightforward interference fits and seat placements, reducing overall manufacturing complexity despite the compact integrated design.
Solution Approach 2:
The bridging elements are designed with multi-functionality, serving as both electrical conductors and spring mechanisms for securing connections. This universal design reduces the total number of components needed, simplifying the assembly process while achieving compact volume, as fewer specialized parts are required.
3Device complexity
If integrated components with multiple functions are used, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by providing specific geometric features at critical locations: collars on metal pins for interference fit, seats in the casing portion for bridging elements, and cavities in the body for pin reception. These localized precision features are concentrated only where needed, allowing the majority of the component surfaces to be manufactured with standard tolerances, thus balancing reduced component complexity with manageable precision requirements.
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 compact, functional, and easy-to-handle connector assembly that can efficiently distribute high currents up to 16 amps and 240 AC volts, ensuring reliable electrical connections while simplifying the installation and production processes.
Implementation Method 1
Each of the aforementioned metal pins of circular section of the first and second groups integrally incorporates one end formed as a socket and an opposite end formed as a plug as well as, in its intermediate portion, a plurality of collars of enlarged diameter for insertion with an interference fit in respective cavities in the body of the assembly.
Implementation Method 2
the aforementioned bridging elements that connect, in pairs, the metal pins of the two groups have an active connection operating simultaneously as electrical conductors and spring mechanisms to secure the connection.
Implementation Method 3
the aforementioned bridging elements that connect, in pairs, the metal pins of the two groups have an active connection operating simultaneously as electrical conductors and spring mechanisms to secure the connection.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A shunt connector assembly for electrical systems comprises a body including a first, a second and a third coupling portion (6, 7, 8) for coupling to respective connectors. The contacts of the first and second coupling portions (6, 7) are defined by the opposite ends of a first group of metal pins of circular section (R1) received inside the body (2) of the connector assembly. The contacts of the third coupling portion (8) are defined by first ends of a second group of metal pins of circular section (R2) arranged parallel to and spaced from the pins of the first group. Each pin of the first group (R1) is electrically connected to a respective pin of the second group (R2) by a metal bridging element in the form of a planar lamina extending substantially in the plane containing the axes of the pins connected by said bridging element and integrally incorporating at each end a bent back-portion defining a resiliently deformable open bushing that surrounds and clasps a respective metal pin (R1, R2).