Clamping Spring Contact with Integrated Overstretch Stop

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Solution Overview

Problem

Existing clamping spring-type contact devices require complex manufacturing processes and are prone to irreversible deformation due to unnecessary loading of the clamping spring when actuated.

Innovation Solution

The clamping spring-type contact device incorporates an overstretch prevention mechanism where the actuator strikes against the busbar, limiting its movement and preventing overstretching, eliminating the need for a separate stop and reducing manufacturing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate stop body or stamped-out tab is used to prevent clamping spring overstretching, then the clamping spring is protected from overstretching, but the manufacturing complexity and effort increase

Engineering Contradiction:

Improveclamping spring protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stop function is merged with the actuator body itself. The actuator includes an integrated stop element that directly limits the clamping spring's extension without requiring a separate stop body or stamped-out tab, thereby simplifying manufacturing while maintaining protection functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stop function is extracted from separate components (stop body or stamped-out tab) and integrated into the actuator structure, eliminating the need for additional parts and reducing manufacturing steps

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If a separate stop body or stamped-out tab is used to prevent clamping spring overstretching, then the clamping spring is protected from overstretching, but the number of components and manufacturing steps increase

Engineering Contradiction:

Improveclamping spring protectionVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The actuator is designed to be self-sufficient by incorporating the stop function directly into its structure, eliminating the need for external stop components and reducing assembly steps

Inventive Principle:

Principle #25Self-service

3Reliability

If a stop is used to limit clamping spring movement, then overstretching is prevented, but the clamping spring is unnecessarily subjected to load during actuation

Engineering Contradiction:

Improveoverstretch preventionVSAvoidclamping spring durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The stop function is replicated within the actuator structure itself rather than using a separate stop component, allowing the stop mechanism to be integrated into the actuation path and avoid unnecessary loading of the clamping spring

Inventive Principle:

Principle #26Copying

Solution Approach 2:

Instead of using a separate stop component that pushes against the clamping spring, the actuator itself is designed with an integrated stop that limits spring extension through the actuation mechanism, inverting the traditional approach and eliminating harmful loads

Inventive Principle:

Principle #13The other way round (Inversion)

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 allows for simple manufacturing and prevents irreversible deformation of the clamping spring, reducing costs and ensuring reliable electrical contact without compromising the spring's functionality.

Implementation Method 1

a clamping spring held on the busbar for clamping and electrically connecting the electrical conductor to a contact region of the busbar

Methodology Applied

Scientific EffectSpring force: Spring

Implementation Method 2

an actuator held indirectly or directly on the busbar for transferring the clamping spring from the unactuated state into an actuated state for releasing the electrical conductor

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

the overstretch prevention mechanism consists of the actuator striking against the busbar

Methodology Applied

Scientific EffectImpact force: Impact Force

Data Source

PatentUS12573773B2Clamping spring-type contact device having an overstretch prevention mechanism, and plug connector insert having at least one such clamping spring-type contact device

Publication Date: 2026.03.10 HARTING ELECTRIC STIFTUNG & CO KG

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).