Spring-Loaded Bus Connector for Misalignment and Gap Variation
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Solution Overview
Problem
Existing electrical connectors in power supply panels face challenges in maintaining consistent contact force across varying gap distances and misalignment issues, leading to increased electrical resistance and installation difficulties due to high contact force requirements and temperature rise limitations.
Innovation Solution
The electrical connector features spring-loaded arms that apply equal pressure against the contact plates of the power supply bus, independent of the connector's cross-section, allowing for optimized current flow and accommodating misalignment through rounded contact surfaces and pivoting capability, with adjustable bias force via tension springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid contact portions are used to ensure stable electrical connection, then connection reliability is improved, but contact force becomes excessive causing installation difficulty and misalignment issues
Solution Approach 1:
The contact portions are designed as spring-loaded elements that can dynamically adjust their position and applied force. The springs allow the contact portions to pivot and accommodate misalignment while maintaining consistent contact force, resolving the contradiction between stable connection and easy installation.
Solution Approach 2:
The contact force parameter is made variable through the spring mechanism rather than fixed as in rigid connectors. The spring constant and pre-load can be designed to provide optimal contact force that is sufficient for reliable electrical connection but not excessive to cause installation difficulty.
2Reliability
If higher contact force is applied to reduce electrical resistance, then electrical conductivity is improved, but temperature rise increases due to excessive current density
Solution Approach 1:
The contact force is optimized to a specific range that provides sufficient electrical conductivity without creating excessive current density. The spring mechanism allows precise control of the contact force parameter to balance conductivity requirements with thermal management.
3Manufacturing precision
If fixed geometry contact portions are used, then manufacturing precision is improved, but adaptability to varying gap distances is reduced
Solution Approach 1:
The contact portions are designed with pivoting capability through spring mounting, allowing them to adapt to varying gap distances and misalignments. This dynamic adjustment maintains reliable electrical connection across different installation conditions while the contact portions themselves can be manufactured with standard precision.
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 reduces current density and temperature rise, maintains consistent contact force across varying gap sizes, and ensures reliable electrical connections even with manufacturing tolerances, improving thermal performance and ease of installation.
Implementation Method 1
A spring applies a bias force to the contact portions to apply equal pressure by the contact portions against the sides of the opening
Data Source
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AI summary
An electrical connector is provided for electrically coupling two electrical components. Opposing ends of the connector are coupled to each of the electrical components. At the first end, the connector is disposed in an opening of the first electrical component to establish electrical connection. The first end includes multiple contact portions that are equally biased against the sides of the opening.