Spring Clamp Terminal Support Plate for Busbar Stability

Solution Overview

Problem

Conductor connection terminals face challenges in optimizing production costs and size while ensuring mechanical stability and efficient electrical connection, particularly under high spring forces and thermal loads.

Innovation Solution

Incorporating a support plate that provides mechanical stability to the busbar, allowing for compact design and efficient heat dissipation, and using a self-supporting contact system with spring-loaded clamps to secure electrical conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the busbar is made mechanically robust to support high spring forces, then mechanical stability is improved, but device size and manufacturing cost increase

Engineering Contradiction:

Improvemechanical stabilityVSAvoiddevice size

Core Design Contradiction:

Stability of the object's compositionVSVolume of stationary object

Solution Approach 1:

The support function is segmented from the busbar by introducing a separate support plate. The busbar focuses on electrical conduction while the support plate handles mechanical support, allowing each component to be optimized independently for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support plate acts as an intermediary element between the clamping spring and the busbar. It transfers and distributes the high spring forces away from the busbar, preventing the busbar from needing to be excessively robust while maintaining mechanical stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the busbar is made mechanically robust to support high spring forces, then mechanical stability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvemechanical stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The support function is segmented from the busbar by introducing a separate support plate. The busbar focuses on electrical conduction while the support plate handles mechanical support, allowing each component to be optimized independently for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support plate acts as an intermediary element between the clamping spring and the busbar. It transfers and distributes the high spring forces away from the busbar, preventing the busbar from needing to be excessively robust while maintaining mechanical stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If the busbar is made mechanically robust to support high spring forces, then mechanical stability is improved, but electrical and thermal performance deteriorates

Engineering Contradiction:

Improvemechanical stabilityVSAvoidelectrical connection reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The support function is segmented from the busbar by introducing a separate support plate. The busbar focuses on electrical conduction while the support plate handles mechanical support, allowing each component to be optimized independently for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support plate acts as an intermediary element between the clamping spring and the busbar. It transfers and distributes the high spring forces away from the busbar, preventing the busbar from needing to be excessively robust while maintaining mechanical stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 results in a cost-effective, compact conductor connection terminal that maintains mechanical stability and enhances electrical connection reliability under high loads, with improved heat dissipation and automated assembly capabilities.

Implementation Method 1

a clamping leg of the clamping spring is pre-tensioned relative to the busbar, so that an electrical conductor can be clamped under spring force between the clamping leg and a conductor connection side of the busbar

Methodology Applied

Scientific EffectSpring force: Spring

Implementation Method 2

The support plate also facilitates heat dissipation

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Implementation Method 3

Another advantage is that the support plate provides additional electrical and thermal support to the busbar under increased stress, such as during a prolonged short circuit

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3454422B2Cable connection terminal

Publication Date: 2024.04.17 WAGO VERW GMBH

Figure 1
Figure 2~3
Figure 4~5

AI summary

The invention relates to a conductor terminal (9) with at least one spring-loaded clamping connection (1, 2) which has at least one clamping spring (11, 21) and at least one busbar (3), wherein a clamping leg (12, 22) of the clamping spring (11, 21) is biased against the busbar (3), so that an electrical conductor can be clamped under spring force between the clamping leg (12, 22) and a conductor connection side (39) of the busbar (3), characterized in that the conductor terminal (9) has as a further component at least one support plate (8) by which the busbar (3) is supported against a deformation of the busbar (3) caused by the clamping spring (11, 21).