Clamping Spring Aperture Structure for Secure Stranded Conductor Terminals
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Solution Overview
Problem
Existing conductor connection terminals face issues with securing multiple-strand electrical conductors, preventing strand splaying and ensuring stable connection without damage during insertion and removal, while maintaining a compact design.
Innovation Solution
A clamping spring with lateral webs and a bus bar piece that forms a circumferentially closed aperture, allowing the bus bar piece to pass through twice, securing the conductor laterally and providing overload protection, with a transverse web limiting deflection and enhancing clamping force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional clamping spring without lateral webs is used, then the device complexity is low, but the conductor strands can splay during insertion and the connection stability is poor
Solution Approach 1:
The clamping spring is segmented by adding lateral webs that divide the spring structure into distinct sections. These lateral webs create a circumferentially closed aperture that acts as a guide for the conductor, preventing strand splaying while maintaining overall spring functionality.
Solution Approach 2:
Lateral webs are added to the clamping spring structure, extending the design from a simple planar spring into a three-dimensional configuration with circumferential apertures. This dimensional enhancement provides lateral guidance for conductor strands without significantly increasing overall complexity.
2Reliability
If the bus bar piece passes through the aperture only once, then the insertion is simple, but the conductor is not securely held and may be damaged during removal
Solution Approach 1:
The bus bar piece is designed to pass through the circumferentially closed aperture twice, creating a nested configuration where the conductor is guided through the aperture, makes contact with the clamping edge, and is secured by the second passage through the aperture structure.
3Strength
If the clamping spring has no transverse web, then the manufacturing is simpler, but the clamping leg deflection is unlimited and overload protection is absent
Solution Approach 1:
The transverse web is pre-formed as an integral part of the clamping spring structure, creating a built-in stop that limits clamping leg deflection before overload can occur. This preliminary structural feature prevents excessive deformation without requiring additional manufacturing steps.
4Reliability
If lateral webs are not provided, then the device is simpler, but multiple-strand conductors cannot be prevented from splaying and colliding with housing
Solution Approach 1:
Lateral webs are added only in the specific regions where conductor guidance is needed, creating local structural enhancements rather than a complete redesign of the entire clamping spring. The lateral webs are positioned to provide just enough containment for the conductor strands.
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 securely holds multiple-strand conductors, prevents splaying, and increases clamping force, ensuring stable connections and reduced malfunctions, while allowing easy insertion and removal without damage.
Implementation Method 1
The electrical conductor is held on the bus bar piece by the spring force of the clamping spring
Data Source
AI summary
A contact insert for a conductor connection terminal having a bus bar piece and a clamping spring having a clamping leg with a clamping edge for connecting an electrical conductor. The clamping edge of the clamping leg and the bus bar piece form a clamping point for the electrical conductor to be connected. At least two lateral webs are arranged on the clamping spring on mutually opposite sides of the clamping spring. The free ends of the lateral webs are connected to one another by a transverse web, and the lateral webs and the transverse web form a circumferentially closed aperture on the clamping spring. The bus bar piece extends between the lateral webs, at least when a clamping point is closed, and the bus bar piece passes through the circumferentially closed aperture at least twice.