Clamp Retainer Spring Layout for Vibration-Stable Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric connectors with clamp retainers face challenges in achieving reliable and cost-effective electrical connections with minimal effort, often requiring complex assembly and being susceptible to vibrations and unwanted movements.
Innovation Solution
A clamp retainer design featuring a clamping spring with a fixing portion directly held by an insulation housing, allowing for a cantilevered intermediate portion that compensates for vibrations, and a self-locking mechanism for easy insertion and secure clamping, eliminating the need for intermediate holding structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intermediate holding structures such as cages and frames are used to hold the clamping spring, then the clamping spring is supported and positioned, but material costs increase and assembly time is extended
Solution Approach 1:
The insulation housing is designed to directly hold the clamping spring without requiring separate intermediate holding structures. The clamping spring is inserted directly into the insulation housing, merging the support function into the housing itself, thereby reducing the number of parts and simplifying the overall structure while maintaining reliable clamping spring support.
2Stability of the object's composition
If the clamping spring rests against the housing in the insertion direction, then the clamping spring is stable, but the clamping spring becomes overly rigid and cannot compensate vibrations
Solution Approach 1:
The clamping spring is designed with differentiated local properties: the fixing portion is rigidly fixed to the insulation housing for stability, while the intermediate portion is made flexible and spaced apart from the housing to provide vibration compensation. This local quality differentiation allows the spring to maintain stability where needed while providing flexibility for vibration absorption in other areas.
3Reliability
If the intermediate portion of the clamping spring is spaced apart from the insulation housing, then vibration compensation is improved, but the clamping spring structure becomes more complex
Solution Approach 1:
The intermediate portion of the clamping spring is designed as a dynamic, flexible element that is spaced apart from the insulation housing, allowing it to move and deflect in response to vibrations. This dynamic design enables the spring to adapt to vibrational forces while maintaining a relatively simple overall structure, as the flexibility is inherent in the spring's geometry rather than requiring additional components.
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 design reduces material costs, shortens assembly time, enhances reliability by absorbing vibrations, and maintains consistent clamping force while allowing for easy and secure electrical connections.
Implementation Method 1
the clamping portion is deflectable towards the fixing portion... the intermediate portion can move without being obstructed by the insulation housing... better compensate vibrations
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a clamp retainer (1) for an electric connector (2), the clamp retainer (1) comprising an insulation housing (40) defining at least one receptacle (42) for inserting an electrical conductor (4) along an insertion direction (44), and at least one clamping spring (28) for clamping the electrical conductor (4) upon insertion into the at least one receptacle (42), wherein the at least one clamping spring (28) comprises a fixing portion (32), a clamping portion (34) and an intermediate portion (36), wherein the fixing portion (32) is held directly by the insulation housing (40), wherein the clamping portion (34) is deflectable towards the fixing portion (32), wherein the clamping portion (34) and the fixing portion (32) are jointed by the intermediate portion (36), and wherein the intermediate portion (36) is spaced apart from the insulation housing (40) in the insertion direction (44). The clamp retainer (1) exhibits an improved performance and reliability, while saving material costs and shortens assembly time due to a low number of parts. The invention further relates to an electric connector (2) with such a clamp retainer (1) as well as a manufacturing method for such a clamp retainer (1).