Conductor Connection Terminal With Busbar Contact Tabs
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Solution Overview
Problem
Conventional conductor connection terminals require additional clamping springs for secondary electrical conductors, leading to increased size and complexity, whereas the proposed solution integrates contact tabs on the busbar to facilitate electrical contact without additional springs, enabling a more compact and simplified design.
Innovation Solution
The insulating material housing features a base side with an opening and protruding contact tabs from the busbar, allowing a second electrical conductor to be contacted between these tabs, eliminating the need for an additional clamping spring and enabling a smaller, flatter terminal design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional clamping springs are used for secondary electrical conductors, then reliable electrical contact is achieved, but device size and complexity increase
Solution Approach 1:
The contact tabs are integrated directly into the busbar structure, merging the contact function with the existing busbar component. This eliminates the need for separate clamping springs for secondary conductors, reducing structural complexity while maintaining electrical contact reliability through the rigid busbar-integrated tabs
Solution Approach 2:
The busbar is designed to serve multiple functions: it acts as both the primary electrical conductor and the structural element that provides contact tabs for secondary conductors. This multi-functionality eliminates the need for additional dedicated clamping springs, simplifying the overall terminal structure
2Reliability
If additional clamping springs are used for secondary electrical conductors, then reliable electrical contact is achieved, but manufacturing complexity increases
Solution Approach 1:
The contact tabs are formed as an integral part of the busbar through a single stamping or forming process. This merging of components eliminates the need for separate manufacturing and assembly steps for additional clamping springs, significantly simplifying the manufacturing process while ensuring reliable electrical contact
3Adaptability or versatility
If the terminal design includes multiple clamping springs, then multiple conductors can be clamped, but the terminal size increases
Solution Approach 1:
The contact tabs are formed by bending or folding portions of the busbar itself, utilizing the existing busbar material and space. This merging approach allows multiple conductors to be connected without requiring additional clamping springs that would increase the terminal's overall footprint, maintaining compact dimensions while preserving conductor connection versatility
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 configuration allows for efficient electrical contact of a second conductor without additional springs, resulting in a more compact and user-friendly conductor connection terminal that can be easily integrated into socket inserts and other electrical devices.
Implementation Method 1
the clamping spring (3) has a clamping leg (3a) and wherein the clamping leg (3a) and the busbar (2) form a clamping point (4) for the electrical conductor to be clamped
Implementation Method 2
the contact tabs (2b) are designed in such a way as to contact a second electrical conductor (5) between the contact tabs (2b)
Data Source
AI summary
A conductor connection terminal with an insulating material housing having a conductor insertion opening for inserting an electrical conductor in a conductor insertion direction, with a busbar and a clamping spring, wherein the clamping spring has a clamping leg and wherein the clamping leg and the busbar form a clamping point for the electrical conductor to be clamped. The insulating material housing has a base side, wherein the base side is arranged adjacent to the side of the busbar facing away from the clamping point and wherein the base side has an opening, wherein on the side of the busbar facing away from the clamping point, two contact tabs protrude from the busbar, wherein the contact tabs are designed to contact a second electrical conductor between the contact tabs, wherein the second electrical conductor can be led through the opening of the base side between the contact tabs.