Spring-Clamped Busbar Terminal for Low-Height Conductor Connection
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Solution Overview
Problem
Existing electrical connection terminals are not compact enough, and there is a need for a more efficient and space-saving design that can securely clamp electrical conductors while maintaining electrical conductivity.
Innovation Solution
A compact electrical connection terminal design featuring a U-shaped busbar with specific dimensions and a clamping spring having a contact leg and clamping leg connected via a spring bend, where the clamping spring is partially accommodated in the busbar's conductor connection channel, with a form-fit connection and actuation mechanism for easy conductor insertion and secure clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the busbar dimensions and clamping spring design are optimized for compactness, then the installation height is minimized and space for conductors is increased, but the clamping force and electrical contact reliability may be compromised
Solution Approach 1:
The clamping spring is designed with dynamic characteristics that allow it to adapt to different conductor sizes and shapes. The spring's elastic properties enable it to maintain reliable clamping force within the compact busbar structure, resolving the contradiction between compact dimensions and contact reliability.
Solution Approach 2:
The patent optimizes specific geometric parameters of the busbar and clamping spring, such as the width ratio between contact wall and abutment wall (50-80%), and the side wall height relative to contact wall width (less than 2.5 times). These parameter changes achieve compactness while maintaining sufficient clamping force and electrical contact reliability.
2Volume of moving object
If the busbar width is reduced to achieve compactness, then the available space for conductors is increased, but the structural strength and current carrying capacity may be reduced
Solution Approach 1:
The busbar is designed as a composite structure combining different wall sections (side wall, contact wall, abutment wall) with optimized thicknesses and materials. This allows the busbar to maintain high structural strength and current carrying capacity even with reduced overall width, while providing sufficient space for conductor insertion.
3Reliability
If the contact wall width is increased to improve electrical contact area, then the clamping effectiveness is enhanced, but the overall compactness and space efficiency are reduced
Solution Approach 1:
The contact wall is designed with locally optimized properties, including specific width ratios (50-80% of abutment wall width) and surface characteristics, to maximize electrical contact area precisely where needed. This localized quality enhancement achieves reliable electrical contact without increasing the overall busbar dimensions, maintaining compactness while improving contact effectiveness.
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 design achieves a compact and efficient clamping of electrical conductors with minimal installation height, allowing for larger space within the conductor connection channel for stranded conductors and providing reliable electrical contact with reduced material usage.
Implementation Method 1
a clamping spring accommodated at least in part in sections in the conductor connection channel of the busbar, in particular braced in the busbar between the abutment wall and the contact wall
Data Source
AI summary
An electrical connection terminal for the clamping contact of an electrical conductor, comprising a busbar with a side wall on which an abutment wall and a contact wall spaced apart therefrom are integrally formed with formation of a conductor connection channel that is accessible via an insertion opening. A clamping spring is provided with a contact leg that is contacted at the abutment wall of the busbar, and with a clamping leg that is connected to the contact leg. A clamping edge is guided against the contact wall of the busbar with formation of a clamping point.