Clamping Spring Terminal Structure for Robust Conductor Connection
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Solution Overview
Problem
Existing connection terminals for electrical conductors lack a compact and robust design that is cost-effective and resilient, often leading to bending or deformation due to improper use and inadequate positioning within the housing.
Innovation Solution
The connection terminal features a clamping spring with a tab formed in one piece and punched out of the contact leg, providing a compact and robust design. The tab is integrated as an integral part of the clamping spring, and a support section with a curvature or rounding in the housing ensures proper positioning and reduces wear and friction, allowing for smooth operation and efficient clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the tab is formed as a separate component and attached to the contact leg, then the clamping spring can be assembled in a flexible manner, but the structure becomes more complex and less robust
Solution Approach 1:
The tab is merged with the contact leg to form an integrated clamping spring structure. The tab and contact leg are produced as a single piece through punching operations, eliminating the need for separate components and attachment processes. This integration reduces structural complexity while simultaneously improving robustness by eliminating potential failure points at attachment interfaces.
Solution Approach 2:
The contact leg is designed with a through-opening that corresponds to the punched-out tab, creating a segmented structure that allows the tab to be formed and removed. This segmentation enables the tab to be integrated with the contact leg while maintaining functional independence, resolving the contradiction between structural simplicity and functional robustness.
2Ease of manufacture
If the tab is punched out of the contact leg, then the clamping spring becomes more compact and cost-effective, but the contact leg structure becomes more complex
Solution Approach 1:
The through-opening is pre-formed in the contact leg before the tab is punched out. This preliminary action simplifies the punching process and enables the tab to be cleanly removed, reducing manufacturing complexity and cost while achieving the desired compact clamping spring structure.
Solution Approach 2:
The tab is extracted from the contact leg through the punching process. This extraction creates a compact clamping spring structure that is cost-effective to manufacture, while the through-opening in the contact leg provides the necessary structural accommodation without significant added complexity.
3Manufacturing precision
If the support section has a sharp edge, then the positioning is precise, but the clamping spring experiences increased wear and friction
Solution Approach 1:
The support section is designed with a curved surface instead of a sharp edge. This curvature reduces friction and wear on the clamping spring during operation while maintaining sufficient positioning precision through the geometric constraints of the housing and clamping spring interaction.
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
This design achieves a compact, robust, and cost-effective connection terminal that prevents bending or deformation, ensuring reliable and efficient clamping of electrical conductors while maintaining spring force for secure contact with the current bar.
Implementation Method 1
The clamping spring (120) has a contact leg (121) for resiliently clamping an electrical conductor to be connected against the current bar (160)
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2~3
AI summary
The invention relates to an electric connection terminal (100) for connecting an electric conductor, comprising a housing (110), a clamping spring (120) which is arranged in the housing (110), a current bar (160), and a clamping lever (140), wherein the clamping spring (120) has a contact limb (121) in order to clamp an electric conductor to be connected against the current bar (160) in a spring-elastic manner, wherein the clamping lever (140) is secured to the housing (110) and can be pivoted about a pivot axis (141) between an open position and a closed position, and the clamping lever (140) has a driver (142) which is paired with a tab (122) of the clamping spring (120), said tab being provided on the contact limb (121) of the clamping spring (120).