Clamping Spring Contact Insert With Integrated Overstretch Stop
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Solution Overview
Problem
Existing clamping spring contact devices in the prior art require significant manufacturing effort and subject the clamping spring to unnecessary stress during actuation, leading to potential long-term functional impairment.
Innovation Solution
A clamping spring contact device with an integrated overstretch protection mechanism, where the actuator's movement is limited by a stop on the busbar, preventing overextension of the clamping spring and eliminating the need for a separate stop, thereby reducing manufacturing complexity and stress on the spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate stop body or punched tab is used to prevent overextension of the clamping spring, then the clamping spring is protected from overstretching, but the manufacturing effort and device complexity increase
Solution Approach 1:
The stop function is merged with the actuator by forming a stop projection directly on the actuator body. This eliminates the need for separate stop components (such as punched tabs on the busbar or inserted stop bodies) and integrates the overextension protection function into the actuator itself, thereby reducing manufacturing effort and device complexity while maintaining protection of the clamping spring
Solution Approach 2:
The actuator is given multiple functions: it not only actuates the clamping spring to release the electrical conductor but also provides overextension protection through its integrated stop projection. This multi-functionality eliminates the need for dedicated stop components and reduces the overall device complexity
2Reliability
If a separate stop component is used to limit actuator movement, then the clamping spring is protected from overextension, but the clamping spring is subjected to unnecessary stress during actuation
Solution Approach 1:
The stop function is merged with the actuator structure itself through the stop projection. This eliminates the need for the clamping spring to interact with separate stop components during actuation, thereby preventing unnecessary stress and potential irreversible deformation of the clamping spring while still providing effective overextension protection
3Reliability
If additional stop components are added to the device, then the clamping spring is protected from overstretching, but the manufacturing costs and device complexity increase
Solution Approach 1:
The stop function is merged with the actuator by forming a stop projection directly on the actuator body. This eliminates the need for separate stop components that would require additional manufacturing steps (such as punching tabs in the busbar or inserting separate stop bodies), thereby reducing manufacturing costs and production complexity while maintaining reliable overextension protection
Solution Approach 2:
The actuator is designed to perform multiple functions including actuation of the clamping spring and provision of overextension protection through its integrated stop projection. This multi-functionality reduces the total number of components and simplifies manufacturing processes, lowering production costs while ensuring reliable protection of the clamping spring
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 ensures the clamping spring is not irreversibly deformed, maintains functionality, and reduces manufacturing costs by eliminating the need for additional components, while ensuring reversible elastic deformation during actuation.
Implementation Method 1
the clamping spring can have a boss that comes into contact with the actuator in its actuated position to amplify the restoring force
Data Source
Figure 1a~1d
Figure 2a~2b
AI summary
Disclosed is an overstretch prevention mechanism for a clamping spring (3) of a clamping spring-type contact device, the overstretch prevention mechanism consisting of a stop (21, 11) of an actuator (2) on a bus bar (1).