Compression Spring Terminal with Dual Contact Zones
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Solution Overview
Problem
Existing direct plug-in compression spring terminals struggle to securely hold and contact both rigid solid conductors and flexible, fine-wire stranded conductors, particularly during insertion and under vibration.
Innovation Solution
The design incorporates a second contact zone on the busbar, spaced from the first contact zone, with a cutout or recess to guide and center the conductor strands, and a clamping spring mechanism with multiple contact zones arranged in a triangular configuration to ensure secure clamping and contact across various conductor types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single contact zone is used on the busbar, then the structure is simple, but both rigid solid conductors and flexible stranded conductors cannot be securely held and contacted
Solution Approach 1:
The busbar is divided into multiple contact zones (first contact zone and second contact zone) spaced at specific distances. The first contact zone contacts the conductor end, while the second contact zone contacts the conductor middle section, allowing secure holding of both rigid solid conductors and flexible stranded conductors through distributed contact points
Solution Approach 2:
The patent introduces a spatial dimension by spacing contact zones at specific distances along the busbar length. This dimensional arrangement allows the conductor to be engaged at multiple positions, providing mechanical fixation and electrical contact for various conductor types without increasing structural complexity
2Reliability
If the busbar is designed for secure clamping, then conductor holding is reliable, but insertion ease is reduced
Solution Approach 1:
The busbar is designed with a ramp at the insertion end that preliminarily guides and centers the conductor before it reaches the contact zones. This preliminary action facilitates easy insertion while ensuring the conductor is properly positioned for secure clamping at the contact zones
Solution Approach 2:
Different regions of the busbar are given different local qualities: the insertion end has a ramp for guiding, the contact zones have specific geometries for secure clamping, and the spaces between provide appropriate clearance. This localized design ensures both easy insertion and reliable holding
3Length of stationary object
If contact zones are spaced closer together, then the terminal size is reduced, but conductor centering and bundling effectiveness is compromised
Solution Approach 1:
The patent specifies optimal spacing parameters between contact zones (at least 2-5 mm distance) that balance terminal size reduction with conductor centering effectiveness. This parameter optimization ensures strands are properly bundled and centered while maintaining a compact terminal design
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 solution allows for easy and secure insertion of both rigid and flexible conductors, maintaining contact and mechanical fixation even under vibration, ensuring reliable electrical and mechanical connection.
Implementation Method 1
a clamping spring (3), which is intended for clamping the electrical conductor end (5) inserted into the direct plug-in compression spring terminal (1)
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a~2b
AI summary
The present invention relates to a direct plug-in compression spring terminal, in particular for connecting a braided conductor end, which direct plug-in compression spring terminal comprises a clamping cage with a busbar, and also a clamping spring for clamping an electrical conductor end which is inserted into the direct plug-in compression spring terminal, wherein at least a first contact zone for making electrical contact and a second contact zone for making contact with and guiding the electrical conductor end are provided on the busbar, wherein the second contact zone is at a distance from the first contact zone and is arranged behind the first contact zone in a conductor insertion direction of the electrical conductor end.