Spring-cage terminal with separate current bar
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Solution Overview
Problem
Existing spring-loaded connection terminals face challenges in optimizing the balance between clamping force and conductor guidance, often requiring thicker conductive materials for both the busbar and the current bar, which can increase volume resistance and complexity.
Innovation Solution
A separate current bar is introduced into the receiving space of the busbar piece, allowing the busbar to be made from thin, easily shaped material optimized for guiding, while the current bar is optimized for current conduction, with protruding clamping edges to concentrate the clamping force and enhance surface pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar piece is made from thicker conductive material to optimize both guiding and current conduction, then current conduction is improved, but volume resistance increases and complexity increases
Solution Approach 1:
The invention divides the busbar system into two separate components: a thin-walled busbar piece for guiding and a separate current bar for current conduction. This segmentation allows each component to be optimized for its specific function without compromise, resolving the contradiction between reliable current conduction and reduced device complexity.
Solution Approach 2:
The invention applies local quality by making different parts of the system have different properties - the busbar piece has thin walls optimized for guiding, while the current bar has sufficient cross-section optimized for current conduction. This resolves the contradiction by allowing each component to have the appropriate thickness for its specific function.
2Force
If the busbar piece is made from thicker material to provide both guiding and clamping functions, then clamping force is improved, but manufacturing complexity increases
Solution Approach 1:
The invention segments the clamping function from the busbar piece and assigns it to a separate clamping bracket. This allows the busbar piece to be manufactured from thin, easily shaped material, while the clamping bracket provides the necessary clamping force, resolving the contradiction between improved clamping force and ease of manufacture.
3Reliability
If a separate current bar is introduced into the receiving space, then current conduction is optimized, but device complexity increases
Solution Approach 1:
The invention merges the current bar with the clamping bracket structure, where the clamping bracket serves dual purposes: providing clamping force and supporting the current bar. This integration reduces the number of separate components while maintaining optimized current conduction, resolving the contradiction between improved current conduction and reduced device complexity.
4Ease of manufacture
If the busbar piece is made thinner for easier shaping, then ease of manufacture is improved, but structural strength decreases
Solution Approach 1:
The invention segments the structural support function from the thin-walled busbar piece and assigns it to the clamping bracket. This allows the busbar piece to be made thin for easy shaping while the clamping bracket provides the necessary structural strength, resolving the contradiction between ease of manufacture and structural strength.
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 achieves secure conductor guidance and optimal current transmission with reduced volume resistance, enabling a compact and efficient spring-loaded connection terminal.
Implementation Method 1
A clamping spring (8) is in operative connection with the busbar section (5) and the associated tension bracket (10) in order to exert a spring force on the tension bracket (10)
Implementation Method 2
the current bar is optimized for current conduction
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
What is described is: a spring-loaded connection terminal (3) comprising a busbar piece (5) which has a base surface (6) and side walls (7) emerging laterally from the base surface (6). Mutually opposite side walls (7) delimit a receiving area (35) on both sides. The spring-loaded connection terminal (3) has a terminal arrangement for the terminal connection of an electrical conductor at an associated clamping point with at least one clamping spring (8), which is operatively connected to the busbar piece (5). At least one current bar (25, 25a, 25b) which is separate from the busbar piece (5) is introduced into the receiving area (35) of the busbar piece (5) and arranged in the receiving area (35) so as to form a clamping surface for the terminal connection of an electrical conductor.