Butterfly Spring Connector One-Piece Fabrication
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Solution Overview
Problem
Conventional butterfly spring connectors face challenges in providing a stable and adjustable clamping force while being easy to fabricate and cost-effective, with existing designs often resulting in complex structures, material wastage, and high assembly costs.
Innovation Solution
A butterfly spring connector formed from a one-piece blank with a frame comprising interconnected pieces that include a support and clip, allowing for adjustable clamping force and easy removal of wires or cables, fabricated using a conductive material like metal plates through pressing, which simplifies production and reduces material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional two-piece design is used for the butterfly spring connector, then the clamping force can be enhanced, but the production and assembly complexity increases
Solution Approach 1:
The patent combines the butterfly spring and housing into a single one-piece component formed from a single blank of electrically conductive material. This integration eliminates the need for separate parts and assembly steps, reducing manufacturing complexity while maintaining the clamping force through optimized spring geometry and material properties
2Strength
If the butterfly spring and housing are made as separate components, then the clamping force can be adjusted, but the manufacturing cost and material usage increase
Solution Approach 1:
The invention integrates the butterfly spring and housing into one monolithic component formed from a single blank, eliminating material waste from multiple parts and reducing manufacturing steps. The clamping force is maintained through careful design of the integrated spring geometry and material selection
Solution Approach 2:
The patent optimizes the physical parameters of the integrated component, including the spring thickness, wire diameter, and geometric dimensions, to achieve the desired clamping force while minimizing material usage and manufacturing complexity
3Stability of the object's composition
If a complex housing structure is used to support the butterfly spring, then the clamping stability is improved, but the fabrication difficulty increases
Solution Approach 1:
The patent creates a simplified housing structure that is integrated with the butterfly spring as a single component. The housing provides necessary support and stability through its geometric design rather than complex internal structures, making the entire assembly easier to fabricate while maintaining clamping stability
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 solution provides a stable and adjustable clamping force, reduces material and fabrication costs, and simplifies the assembly process, making it easier to produce and use the connector effectively.
Implementation Method 1
the wire or cable is firmly clamped by the upper piece and the opposite side wall of the frame body, due to the spring force of the butterfly spring
Implementation Method 2
The butterfly spring and the housing, or at least the opposite side wall of the housing, is made of electrically conductive material. Therefore, when inserted the wire or cable is in electrical contact with the butterfly springs and/or the opposite side wall of the housing
Data Source
AI summary
A butterfly spring connector made from a one-piece blank is disclosed. comprising a The butterfly spring connector includes:a frame, comprising a first, second and third frame pieces defining a bottom plane;a butterfly spring comprising the connection of an upper piece, a lower piece and a lateral piece, wherein the lateral piece extends from the first frame piece to a direction perpendicular to the bottom plane;a support formed at the third frame piece to support the lower piece; anda clip piece formed at the second frame piece, to clip a wire or a cable in association with the upper piece.The support and the clipping piece extend in the same direction of the lateral piece.