Spring-Loaded Contact Clip for Low Resistance Electrical Connection
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Solution Overview
Problem
Existing contacting devices for electrical conductors and conductor tracks in electrical components often result in high contact resistance and complex fixation processes, particularly due to the presence of steel frames or cages that introduce additional resistance and complexity.
Innovation Solution
A contacting device with a modular terminal connection featuring a spring-loaded contact clip that directly presses the electrical conductor against the conductor track, eliminating the need for a steel frame and allowing for easy attachment to the electrical component body, thereby reducing contact resistance and simplifying the fixation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a steel frame or steel cage is used to hold the contact bracket in position, then the contact bracket is securely positioned and functions properly, but additional contact resistance is introduced between the electrical conductor, steel frame, and electrical conductor track
Solution Approach 1:
The patent removes the steel frame or steel cage from the contacting device, eliminating the intermediate contact path that caused additional contact resistance. The contact bracket is held in position and function through alternative means (housing structure and contact clip design) without requiring a steel frame, thus directly resolving the contradiction by extracting the harmful element while maintaining functionality.
Solution Approach 2:
The patent integrates the contact bracket directly with the housing structure, eliminating the need for a separate steel frame. The housing body itself provides the structural support and positioning for the contact bracket, merging the framing function into the housing design. This reduces the number of components and eliminates the additional contact resistance path.
2Device complexity
If a modular terminal connection with integrated contact bracket is used, then the device complexity is reduced and fixation is simplified, but the contact bracket must simultaneously serve as both contacting element and connecting element
Solution Approach 1:
The contact bracket is designed to perform multiple functions: it serves as the contacting element that presses the electrical conductor against the conductor track, and simultaneously as the connecting element that attaches the contacting device to the housing structure. This multi-functional design reduces device complexity by eliminating separate components while maintaining all necessary functions through the integrated contact bracket structure.
Solution Approach 2:
The contact bracket is divided into two functional sections: a first section arranged in the cavity for pressing the electrical conductor against the conductor track, and a second section for fixing the contacting device to the housing structure. This segmentation allows each section to be optimized for its specific function while maintaining the overall integrated design, resolving the contradiction between simplicity and functional versatility.
3Reliability
If the contact clip is designed as a spring element, then low contact resistance is achieved through direct press fit, but the spring element must generate sufficient pressing force without additional mechanical structures
Solution Approach 1:
The contact clip is designed as a spring element that generates pressing force through its elastic properties. By changing the physical state of the contact clip from a rigid element to a spring element, the system achieves both low contact resistance through direct press fit and sufficient pressing force through the spring's elastic recovery. The spring constant and geometry are optimized to provide the required force without additional mechanical structures.
Solution Approach 2:
The spring element contact clip generates its own pressing force through its elastic properties without requiring external actuation or additional mechanical structures. When the electrical conductor is inserted, the spring element automatically exerts pressing force to create the press fit between the conductor and conductor track, and simultaneously provides the force needed to attach the contacting device to the housing structure.
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 achieves low contact resistance and easy fixation to the electrical component body, providing a cost-neutral, space-efficient, and quality-neutral contacting method for electrical conductors and conductor tracks, eliminating the need for additional connecting elements and reducing complexity.
Implementation Method 1
The contact clip is designed as a spring element
Implementation Method 2
One leg of the contact clip clamps the electrical conductor to be connected to the conductor or current path
Implementation Method 3
the electrical conductor, after the electrical conductor and the electrical conductor track have been inserted into the cavity of the housing, is pressed against the electrical conductor track by means of the first section of the contact clip
Data Source
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AI summary
The invention relates to a contacting device (1) for contacting an electrical conductor (10) to an electrical conductor path (20), comprising a housing (100) having a hollow chamber (104), into which the electrical conductor (10) and the electrical conductor path (20) can be inserted. The contacting device (1) furthermore comprises a contact bridge (200) having a first section (210), which is arranged in the hollow chamber (104) of the housing, and a second section (220). The electrical conductor (10) can be clamped directly to the electrical conductor path (20) by means of the first section (210) of the contact bridge (200). Furthermore, the contacting device (1) can be fastened to an element of the electrical component (2) by means of the second section (220) of the contact bridge (200) to provide the electrical conductor path (20).