Stacked Conductor Assembly With Rail-Guided Terminal Alignment
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Solution Overview
Problem
Existing busbar clamp-type connectors for electronic devices like servers and power storing cabinets have complex assembly processes due to compactly arranged terminals that require intricate spacing and alignment, making production and assembly difficult.
Innovation Solution
The introduction of rail structures on conductive pieces that facilitate easy assembly by guiding them into predetermined relative positions, allowing terminals to be alternatively arranged and enabling simple alignment and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If terminals are compactly arranged in related-art connectors, then space utilization is improved, but assembly complexity increases and production becomes difficult
Solution Approach 1:
The connector is divided into an upper connector and a lower connector that can be assembled separately. The upper connector includes upper terminals and the lower connector includes lower terminals, allowing independent preparation and assembly of each segment, thereby reducing overall assembly complexity while maintaining compact terminal arrangement
Solution Approach 2:
The patent transitions from a single-plane terminal arrangement to a three-dimensional stacked configuration. Terminals are arranged in multiple layers (upper and lower connectors stacked vertically), enabling compact space utilization while simplifying assembly through sequential stacking rather than complex in-plane alignment
2Ease of manufacture
If terminals are spaced with greater interval using separate conductive plates, then manufacturing becomes easier, but the structure requires complicated assembling steps
Solution Approach 1:
The upper connector and lower connector are merged into a single integrated assembly through vertical stacking. The engagement structure combines the two connectors with complementary engagement protrusions and recesses, creating a unified component that maintains easy manufacturability while eliminating complicated multi-step assembly procedures
Solution Approach 2:
The engagement structure features self-aligning protrusions and recesses that automatically guide the upper and lower connectors into correct relative positions during assembly. This self-service mechanism eliminates the need for complex external alignment tools or multiple assembly steps, allowing the components to self-assemble into the correct configuration
Data Source
AI summary
A conductor assembly includes: a first conductive piece having a plurality of first terminals and a first rail structure, and the first terminals are parallelly arranged; and a second conductive piece having a plurality of second terminals and a second rail structure, and the second terminals are parallelly arranged. The first conductive piece and the second conductive piece are mutually stacked. The first rail structure and the second rail structure are mutually engaged to guide the first conductive piece and the second constructive piece to relatively move to a predetermined relative position. When the first conductive piece and the second conductive piece are at the predetermined relative position, the first terminals and the second terminals are alternatively arranged. The first and the second conductive pieces are easily assembled through the first and the second rail structures being mutually engaged.