Multi-Direction Bushing Contact Insert for Flexible Pin Insertion

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Solution Overview

Problem

Existing contact inserts with bushing contacts allow contact pin insertion only from one side, limiting flexibility in plug-in direction, which is not suitable for various application conditions.

Innovation Solution

Designing the bushing contact with a longitudinal extension direction perpendicular to the conductor insertion direction, enabling contact pin insertion from both vertical and horizontal directions, and incorporating a switch spring with a connecting web for flexible electrical connection between contact inserts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the bushing contact is designed with contact arms for single-direction insertion, then the structure is simple and manufacturing is easy, but the plug-in direction is limited and adaptability to different application conditions is reduced

Engineering Contradiction:

Improveplug-in direction flexibilityVSAvoidbushing contact structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The bushing contact is designed with two contact arms that can receive contact pins from multiple directions (perpendicular to the longitudinal extension direction and in the longitudinal extension direction). This multi-functional design allows the same bushing contact structure to accommodate different plug-in directions, eliminating the need for separate single-direction contact inserts and improving adaptability to various application conditions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If the contact arms are arranged to receive contact pins from multiple directions, then the adaptability to different application conditions is improved, but the device complexity increases

Engineering Contradiction:

Improveinsertion direction flexibilityVSAvoidcontact insert manufacturing

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Multiple functional capabilities (receiving contact pins from different directions) are merged into a single bushing contact structure. The two contact arms are integrated into one piece with the busbar piece, forming a unified contact insert that combines multiple insertion direction capabilities. This merging approach achieves multi-directional adaptability while maintaining manufacturing efficiency through integrated construction.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If the bushing contact longitudinal extension direction is perpendicular to conductor insertion direction, then multi-directional contact pin insertion is enabled, but the conductor clamping alignment may be affected

Engineering Contradiction:

Improvecontact pin insertion directionVSAvoidconductor alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The contact insert exhibits different functional characteristics in different spatial directions. The bushing contact portion is optimized for receiving contact pins from multiple directions with its longitudinal extension direction perpendicular to conductor insertion, while the busbar piece and clamping spring maintain their conductor clamping function. This local differentiation allows each region to be optimized for its specific function without compromising overall performance.

Inventive Principle:

Principle #3Local quality

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 contact insert allows for flexible insertion of contact pins from multiple directions and enables reliable clamping and electrical connection, improving usability across different application conditions while ensuring efficient current flow and secure conductor alignment.

Implementation Method 1

a clamping spring (3) for clamping an electrical conductor (20) in a conductor insertion direction (L)

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11387582B2Contact insert and switch spring

Publication Date: 2022.07.12 WAGO VERW GMBH

AI summary

A contact insert for a connecting terminal, wherein the contact insert has a busbar piece and a clamping spring for clamping an electrical conductor in a conductor insertion direction, wherein the busbar piece and the clamping spring form a clamping point for the electrical conductor to be clamped, and wherein the contact insert has a bushing contact for receiving a contact pin. The longitudinal extension direction of the bushing contact runs essentially perpendicular to the conductor insertion direction from the busbar piece. The bushing contact is designed to receive the contact pin perpendicular to the longitudinal extension direction of the bushing contact and to receive the contact pin in the longitudinal extension direction of the bushing contact.