Tap Connector U-Shaped Leaf Spring Friction Reduction
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Solution Overview
Problem
Existing tap connectors for current-carrying profiles lack a compact design that ensures reliable and simple electrical connection to electrical conductors, often experiencing friction losses and inefficient force transfer due to integrated contact and spring elements.
Innovation Solution
A tap connector design featuring a U-shaped leaf spring with a spring leg, bow, and contact leg, where the contact element rests on the spring leg, allowing for decoupled movement and optimized material selection for spring elasticity and conductivity, with a conductor connection contact formed directly on the leaf spring for clamping electrical conductors using a spring arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the contact element is integrally connected to the spring element, then the structure is simpler, but friction losses increase and force transfer becomes inefficient
Solution Approach 1:
The contact element is separated from the spring element, with the spring element (U-shaped leaf spring) providing spring force independently while the contact element rests on the spring leg. This segmentation allows the spring force to be transferred to the contact element with minimal friction, as the contact element can move relative to the spring leg without being integrally connected.
2Ease of manufacture
If the contact element is integrally connected to the spring element, then manufacturing is easier, but contact force reliability decreases
Solution Approach 1:
The spring element and contact element are manufactured as separate components. The spring element (U-shaped leaf spring) is formed from sheet metal material with a spring leg, spring bow, and contact leg. The contact element rests on the spring leg and can move relative to it, allowing optimized material selection and independent manufacturing of each component for maximum reliability.
3Volume of moving object
If a compact design is implemented, then space is reduced, but contact reliability may be compromised
Solution Approach 1:
The conductor connection contact is formed in one piece with the leaf spring from the sheet metal material. The spring arm for clamping the electrical connection conductor is integrated into the leaf spring structure, creating a compact design that maintains sufficient contact force and reliability through the spring-elastic properties of the leaf spring.
4Adaptability or versatility
If the contact element is decoupled from the spring element, then material selection is optimized, but device complexity increases
Solution Approach 1:
The contact element and spring element are designed as separate components, allowing optimized material selection for each. The spring element can be made from sheet metal material with specific spring-elastic properties, while the contact element can be made from materials optimized for electrical conductivity and contact performance. This segmentation enables independent optimization of materials for each component's specific function.
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 provides a reliable, compact, and efficient electrical connection with minimal friction loss, allowing for optimized force transfer and reduced contact resistance, enabling reliable contact with current-carrying profiles while allowing for easy insertion and adjustment of contact elements.
Implementation Method 1
the spring element be a U-shaped leaf spring with a spring leg, a spring bow adjoining the spring leg, and a contact leg adjoining the spring bow. The contact element rests on the spring leg so that it can move relative to the spring leg.
Implementation Method 2
The conductor connection contact is formed in one piece with the leaf spring from the sheet metal material of the leaf spring and has a spring arm for clamping an electrical connection conductor.
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
A tap connector (1) with an insulating housing (2) and a contact element (7) movably mounted in the insulating housing (2) is described. The contact element (7) is designed for electrically conductive contact with electrical conductors (29) of a current-carrying profile. A spring element is arranged between a support (20, 35) of the insulating housing (2) and the contact element (7), and the contact element (7) can be subjected to a spring force by the spring element. The spring element is a U-shaped leaf spring (18) with a spring leg (22), a spring arc (21) adjoining the spring leg (22), and a contact leg (19) adjoining the spring arc (21). The contact element (7) rests on the spring leg (22) so as to be movably relative to the spring leg (22). The mounting leg (19) is supported on the bearing (20, 35) of the insulating housing (2) and has a conductor connection contact (25).