Clamping Spring Bead Embossing for Conductor Holding Force
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Solution Overview
Problem
Conductor connection terminals with clamping springs face challenges in achieving high conductor holding force without increasing production costs or material usage, as they are not designed for frequent mating and detaching like electrical connectors.
Innovation Solution
Incorporating a bead embossed into the clamping leg's material, particularly in the bending area, to increase spring stiffness and enhance the conductor holding force, while maintaining a compact design and reducing material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the clamping spring is designed with conventional smooth clamping legs, then the production cost and material usage are kept low, but the conductor holding force is insufficient
Solution Approach 1:
The patent applies local quality by introducing beads at specific locations (bending areas and free ends) of the clamping leg rather than uniformly thickening the entire structure. These localized beads increase spring stiffness and conductor holding force only where mechanically critical, while keeping the rest of the clamping leg material-efficient. This resolves the contradiction by providing enhanced force output without proportional increase in material consumption.
2Force
If the clamping spring is designed with increased spring stiffness through thicker material, then the conductor holding force increases, but the overall size and weight increase
Solution Approach 1:
The beads are strategically positioned at bending areas and free ends where structural reinforcement is most needed for maximizing spring stiffness and force output. This localized reinforcement achieves the desired conductor holding force without requiring uniform thickening of the entire clamping spring, thereby avoiding unnecessary weight and size increases.
Solution Approach 2:
Instead of increasing spring stiffness by adding material in the traditional dimensional sense (thicker legs), the patent introduces three-dimensional beads that protrude from the clamping leg surface. This dimensional approach creates localized stiffness enhancement without proportionally increasing the overall envelope or weight of the clamping spring.
3Strength
If the bead extends to the free end of the clamping leg, then the spring stiffness is maximized, but the manufacturing complexity increases
Solution Approach 1:
The beads are designed to extend partially along the clamping leg rather than covering the entire length. This partial action provides sufficient spring stiffness enhancement at the critical bending and free end areas without requiring complex manufacturing processes that would be needed for full-length beads. The partial extension achieves the necessary mechanical performance while maintaining manufacturing simplicity.
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 effectively increases the conductor holding force of the clamping spring and terminal without increasing size or weight, improving mechanical and electrical fixing of the conductor, and is cost-effective to produce.
Implementation Method 1
The spring stiffness of the clamping leg is increased by the bead, in particular in a bending area of the clamping leg
Data Source
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AI summary
The invention relates to a clamping spring (4) of a conductor terminal (1) for connecting an electrical conductor by means of spring clamping, wherein the clamping spring (4) has a contact leg (40) for fixing the clamping spring (4) in the conductor terminal (1), a spring arc (42) adjoining the contact leg (40), and a clamping leg (43) adjoining the spring arc (42), wherein the clamping leg (43) is configured for clamping the electrical conductor by means of its free end, and wherein the clamping leg (43) has at least one groove (7) embossed in the material of the clamping leg (43). The invention also relates to a conductor terminal with such a clamping spring.