Spring-Force Terminal Sleeve Assembly for Simpler Busbar Joining
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Solution Overview
Problem
Existing spring-loaded terminal connections for electrical conductors are technologically demanding and complex to manufacture, requiring intricate tools and processes, and often limit the use of different materials and geometries for busbars and sleeves.
Innovation Solution
A separate sleeve is inserted into the through opening of a busbar, allowing for independent manufacturing and use of different materials, with joining methods such as force-fitting, material bonding, or form-fitting to ensure a reliable and compact connection with low contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a material passage is integrally formed from the busbar using a forming process, then the connection structure is achieved, but the manufacturing process becomes technologically demanding and complex
Solution Approach 1:
The busbar is divided into two separate components: the busbar itself and a sleeve. The sleeve is inserted into a through-hole of the busbar and connected via joining methods such as force-fitting, material bonding, or form-fitting. This segmentation eliminates the need for complex integral forming processes while achieving the same functional result.
Solution Approach 2:
A separate sleeve acts as an intermediary component between the busbar and the conductor. The sleeve is inserted into the through-hole and connected to the busbar, providing the necessary clamping function without requiring complex forming processes on the busbar itself.
2Adaptability or versatility
If a separate sleeve is inserted into the through-hole, then different materials and geometries can be used, but additional joining steps are required
Solution Approach 1:
The connection structure is segmented into a busbar and a separate sleeve component. This allows each component to be manufactured independently with optimal materials and geometries for their specific functions, then joined together through standardized joining methods.
Solution Approach 2:
The separate sleeve design serves multiple functions: it provides electrical connection, mechanical support, and allows for different materials and geometries. The same sleeve design can be adapted for various applications by changing materials or dimensions without redesigning the entire connection system.
3Productivity
If the busbar and sleeve are manufactured independently, then production efficiency is improved, but connection reliability must be ensured through proper joining
Solution Approach 1:
Independent manufacturing of busbar and sleeve components enables parallel production processes, improving overall manufacturing efficiency. The components are then joined using reliable methods such as force-fitting, material bonding, or form-fitting to ensure connection reliability.
Solution Approach 2:
The busbar is prepared in advance with a through-hole of specific dimensions and geometry. The sleeve is also pre-manufactured with matching dimensions. This preliminary preparation ensures that when the components are joined, proper fit and connection reliability are achieved without requiring complex on-site adjustments.
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 approach simplifies the manufacturing process, enables complex geometries, and allows for optimal current distribution with reduced contact resistance, facilitating efficient production of spring-loaded clamp connections adaptable to various conductor types.
Implementation Method 1
a clamping spring (15) designed to clamp an electrical conductor (not shown) to the busbar (2)
Implementation Method 2
The sleeve wall (41) can have an outer circumferential contour that, when the sleeve (4) is inserted into the through-hole, rests against an inner circumferential contour of the through-hole
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention discloses a spring-loaded clamping connection (1) with a busbar (2) which spans a busbar plane and has a through-opening (3), and with a clamping spring (15), wherein a separate sleeve (4) with a sleeve wall (5, 6, 7) is provided, which extends from an inlet (E) to an outlet (A) of the sleeve (4) in a longitudinal direction, wherein the separate sleeve (4) is inserted into the through-opening (3) transversely to the busbar plane in the longitudinal direction, wherein the sleeve wall (5, 6, 7) has an outer circumferential contour which, in the inserted state of the sleeve (4) in the through-opening (3), abuts an inner circumferential contour of the through-opening (3), and wherein the sleeve (4) is connected to the busbar (2).