Clamping Terminal Structure for Vibration-Resistant Stranded Conductors

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electrical contact elements for stranded conductors often damage the conductor ends during clamping, especially under high forces, and fail to securely maintain the connection against vibrations and pull-out forces.

Innovation Solution

An electrical contact element featuring a resilient clamping element with a clamping spring arm and holding arms that securely attach to a connection block, allowing for tool-free clamping of stranded conductors without damaging them, ensuring a secure and reliable electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a clamping sleeve is screwed to crimp the stranded conductor, then mechanical connection strength is improved, but the stranded conductor ends are damaged or severed

Engineering Contradiction:

Improvemechanical connection strengthVSAvoiddamage to stranded conductor ends

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The clamping element is divided into a clamping body and a separate clamping arm that can be independently actuated. The clamping arm applies force separately from the mounting screw, allowing the screw to secure the element to the terminal block while the spring-loaded clamping arm applies controlled clamping force to the conductor without excessive force that would damage it.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clamping force is made variable through the spring-loaded clamping arm mechanism. The spring constant and preload can be designed to provide sufficient clamping force for reliable electrical contact while remaining below the threshold that would damage the stranded conductor strands, thus optimizing the force parameter.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high forces are applied during crimping, then connection security is improved, but the stranded conductors are sheared off

Engineering Contradiction:

Improveconnection securityVSAvoidintegrity of stranded conductors

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The spring-loaded clamping arm acts as a cushioning element that limits the maximum clamping force. The spring compression provides a force buffer that prevents excessive force transmission to the conductor, ensuring reliable contact while protecting the conductor integrity beforehand.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Strength

If a screw connection is used to attach the contact element, then mechanical security is improved, but the complexity of assembly increases

Engineering Contradiction:

Improvemechanical security of attachmentVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The attachment function and clamping function are segmented into separate mechanisms: a screw connection for mounting the clamping element to the terminal block, and a separate spring-loaded clamping arm for clamping the conductor. This segmentation allows each function to be optimized independently while simplifying the overall assembly process.

Inventive Principle:

Principle #1Segmentation

4Stability of the object's composition

If the clamping element encompasses the contact element, then stability against vibrations is improved, but the device complexity increases

Engineering Contradiction:

Improvestability against vibrationsVSAvoidclamping element structure

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The clamping element combines multiple functions into a single integrated component: the clamping body provides structural support and vibration stability, while the integrated spring-loaded clamping arm provides automatic contact pressure. This merging reduces the number of separate parts needed compared to alternative designs.

Inventive Principle:

Principle #5Merging (Combining)

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 provides a secure, easy-to-produce connection that withstands vibrations and high pull-out forces, ensuring optimal electrical contact without damaging the stranded conductor ends, thus enhancing connection reliability and safety.

Implementation Method 1

a spring-loaded clamping element with a clamping spring arm (6) for clamping contact of a stranded conductor end (3)

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP3707780B1Contact element comprising a clamping terminal for a stranded conductor

Publication Date: 2023.09.27 AMPHENOL TUCHEL ELECTRONICS

Figure 1a~1d
Figure 2a~2d
Figure 3a~3d

AI summary

The invention relates to an electrical contact element (1) having a contact pin (2) and a resilient clamping element (5) which is secured to the contact element (1) and has a clamping spring arm (6) for contacting a stranded conductor end in a clamping manner between the clamping surface (40) of a contacting section (4) of a terminal block (9) of a contact element (1) and the clamping spring arm (6). The clamping element (5) has at least one retaining arm (50) having an end-face gripping section (51) to secure the resilient clamping element (5) to the terminal block (9) of the contact element (1) in a formfitting manner. The outer contour of the contact pin (2) is cylindrical with a round or polygonal cross-section in the securing region of the contacting section (4).