Clamping Body Structured Cavity Embossing
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Solution Overview
Problem
Existing screw terminal clamping bodies, especially those made from copper alloys, face issues with deformation under clamping forces, leading to unstable clamping conditions and reduced mechanical strength, which affects the reliability of electrical connections over time.
Innovation Solution
The production of clamping bodies with structured surfaces in the cavity, utilizing embossing techniques to create beads or microstructures on the surfaces, which enhances the clamping force and resistance to deformation, ensuring a secure and vibration-proof connection that meets and exceeds IEC 60947-1 standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a through hole is drilled in the cavity floor to structure the cavity and increase clamping effect, then the clamping effect between electrical conductor and clamping body is improved, but the mechanical strength of the clamping body is significantly weakened
Solution Approach 1:
The invention extracts the harmful through-hole from the clamping body design. Instead of drilling a hole through the entire cavity floor, the patent uses localized recesses or structuring only in the area where conductor contact is needed, thereby maintaining the integrity and mechanical strength of the side walls while still achieving enhanced clamping effect through localized surface structuring.
Solution Approach 2:
The invention applies local quality by structuring only specific areas of the cavity floor rather than creating a through-hole. The recesses or microstructures are localized to the contact zones where conductor clamping is required, leaving the surrounding areas intact to maintain structural strength. This selective structuring achieves the clamping enhancement without compromising overall mechanical integrity.
2Ease of manufacture
If the clamping body is made from stamped sheet metal or copper alloys using bending technology, then the manufacturing cost is reduced, but the deformation of sloping floor walls under clamping screw load increases
Solution Approach 1:
The invention applies preliminary action by pre-structuring the cavity floor with recesses or microstructures during the manufacturing process itself, rather than attempting to compensate for wall deformation after the fact. This pre-engineered structuring provides inherent resistance to deformation under clamping loads while maintaining the cost-effective stamped or bent manufacturing process.
Solution Approach 2:
The invention changes physical parameters by modifying the cavity floor geometry with recesses or microstructures that increase surface area and provide mechanical interlocking with the conductor. This geometric parameter change enhances deformation resistance and clamping stability without requiring material changes or more complex manufacturing processes.
3Reliability
If the cavity floor is structured with recesses to increase clamping effect, then the permissible clamping forces are reduced due to wall deformation, but reliable long-term clamping of conductors is required
Solution Approach 1:
The invention uses curvature by creating recesses with rounded bottoms and smooth transitions in the cavity floor. These curved geometries distribute clamping forces more evenly and prevent stress concentration that would lead to deformation. The rounded recesses maintain structural integrity while providing effective conductor clamping over long periods.
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 embossing process provides a cost-effective method to produce clamping bodies with uniform and reliable clamping forces, maintaining or increasing the strength of the clamping body, ensuring secure connections for electrical conductors and improving the clamping effect, especially for small terminal bodies in industrial applications.
Implementation Method 1
The production of clamping bodies with structured surfaces in the cavity, utilizing embossing techniques to create beads or microstructures on the surfaces
Data Source
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AI summary
The invention generally relates to electrical screw connectors in industrial applications. One use of the clamp body is to guarantee the fixing of the electrical conductor. In order to increase the clamping effect, the support and contact surfaces for the electrical conductor in the cavity of the clamping body are structured. According to the invention, the structuring of the support and contact surfaces for the electrical conductor is carried out by various production methods using embossing or stamping tools.