Spring Tongue Connecting Bus for Vibration-Resistant Power
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Solution Overview
Problem
Traditional electrical connections in vehicle power equipment are unreliable due to vibration and require precise implementation, especially in high current intensity applications, where screw-based systems are prone to unscrewing or drifting, necessitating a more reliable and simpler connection method.
Innovation Solution
A connecting bus with spring tongues provides a secure and easy-to-install electrical connection, replacing the screw/bolt system, ensuring continuous contact and reduced risk of disconnection, and featuring a rigid conductive bar with insulating layers for voltage isolation and mechanical fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a screw/bolt system is used for electrical connection, then the connection can be mechanically secured, but the reliability deteriorates under vibration conditions due to unscrewing or drifting
Solution Approach 1:
The patent replaces the screw/bolt mechanical fastening system with a spring-loaded contact system. The spring tongues provide continuous mechanical pressure to maintain electrical contact without requiring threaded fasteners, thereby eliminating unscrewing or drifting issues under vibration while maintaining strong mechanical connection.
Solution Approach 2:
The spring-loaded contact system introduces dynamic elements that can adapt to vibrations and movements. The springs continuously apply force and can absorb vibrations, maintaining reliable electrical contact under varying mechanical conditions, unlike static screw connections.
2Reliability
If a screw-based connection system is used, then electrical contact can be established, but the device complexity increases due to precise implementation requirements
Solution Approach 1:
The spring-loaded connector system is designed to self-align and self-adjust during installation. The spring tongues automatically engage with the contact surfaces and apply appropriate pressure without requiring precise pre-positioning or complex alignment procedures, thereby reducing implementation complexity while ensuring reliable contact.
3Power
If a rigid connecting bus is used with traditional connectors, then high current transmission is enabled, but the manufacturing precision requirements increase due to tight tolerance needs
Solution Approach 1:
The spring-loaded contact system changes the mechanical contact parameters by introducing elastic deformation capability. This allows the connector to accommodate larger dimensional variations in the rigid connecting bus while maintaining adequate contact pressure and electrical conductivity, thereby reducing manufacturing precision requirements.
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 enhances the reliability and simplicity of electrical connections in vehicle power equipment, maintaining contact integrity under vibration and allowing for higher current transmission with reduced dimensional tolerance requirements, ensuring stable power delivery in hybrid vehicles.
Implementation Method 1
The spring tongues of the connection means provide a safer connection than a screw/bolt system because there is no unscrew or drift risk. The electrical connection is prevented from being discontinued.
Data Source
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AI summary
Connecting bus (1) comprising an electrical conductive bar (2) including two electrical connection means. At least one of the two electrical connection means comprises a female connector (3) including one or several electrically conductive spring tongues (7).