W-Shaped Contact Element for Busbar and Plug Connector Interfaces

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Solution Overview

Problem

Existing contact elements for bus systems are not versatile enough for connecting electrical devices to external bus systems, particularly for handling power currents, and do not provide sufficient contact points or surface area for reliable connections.

Innovation Solution

A W-shaped contact element with multiple receiving tulips, made of highly conductive material, designed to accommodate multiple busbars and plug connectors, featuring a clamping mechanism with spring properties and optional overspring for enhanced clamping force, allowing for efficient electrical connection and improved current-carrying capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a traditional contact element structure is used, then the device complexity is low, but the contact surface area and number of contact points are insufficient for power currents

Engineering Contradiction:

Improvecontact surface areaVSAvoidcontact element structure

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The contact element is divided into multiple receiving tulips (at least three), each capable of receiving electrical connection elements independently. This segmentation allows the contact surface area to be increased across multiple contact points while maintaining a relatively simple overall structure that is easy to manufacture.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If more receiving tulips are added to increase connection capacity, then the versatility for connecting busbars and plug connectors improves, but the device complexity increases

Engineering Contradiction:

Improveconnection capacityVSAvoidcontact element structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The contact element is designed with at least three receiving tulips that can universally accommodate different types of electrical connection elements, including both busbars and plug connectors. This multi-functional design increases versatility without requiring multiple different contact element types, thereby limiting the increase in device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the contact element is made of highly conductive material, then the current-carrying capacity improves, but the manufacturing cost increases

Engineering Contradiction:

Improvecurrent-carrying capacityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The contact element is made from highly conductive sheet metal material (such as copper) with optimized thickness and geometric dimensions. By adjusting these parameters, the current-carrying capacity is enhanced while controlling material usage and manufacturing cost, achieving a balance between reliability and ease of manufacture.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If the contact element is designed as a one-piece stamped and bent part, then the ease of manufacture improves, but the clamping force may be insufficient without additional springs

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidclamping force

Core Design Contradiction:

Ease of manufactureVSForce

Solution Approach 1:

The contact element is designed with inherent spring properties through its geometric configuration, allowing it to dynamically adapt and exert clamping force on inserted electrical connection elements. This dynamic design provides sufficient clamping force while maintaining the simplicity of a one-piece stamped and bent structure, eliminating the need for additional springs in many cases.

Inventive Principle:

Principle #15Dynamics

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 W-shaped contact element enables reliable and efficient electrical connections for power currents by providing multiple contact points and a large contact surface, supporting both busbars and plug connectors, while being easy to manufacture and assemble, thus enhancing the versatility and performance of electrical connections in bus systems.

Implementation Method 1

The contact element according to claim 1 is also made of an electrically highly conductive material, so that it conducts electricity well

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

The contact element particularly preferably has good spring properties, so that when electrical connection elements are inserted it bends against a restoring force and acts like a clamping spring

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP3028345B1Contact element for a plug arrangement in a bus system, more particularly an externally routed bus system

Publication Date: 2019.01.30 WEIDMULLER INTERFACE GMBH & CO

Figure 1a~1c
Figure 1d~1e
Figure 2a~2b

AI summary

The present invention relates to a contact element for electrically connecting electrical connection elements in an externally routed bus system, more particularly comprising busbars and/or plug connectors, and having at least three receptacle elements for receiving the electrical connection elements. The present invention also relates to a plug arrangement comprising a contact element of the type described, and to an electrical device, more particularly a series module, comprising an electrical sub-assembly and a plug arrangement of the type described.