Sheet Metal Conductor Clamp With Integrated Overload Stop
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Solution Overview
Problem
Conductor connection terminals lack a compact and material-saving design that provides independent overload protection without relying on insulating material housings, leading to inefficiencies in current conduction and potential plastic deformation.
Innovation Solution
A conductor connection terminal with a clamping element formed from a single sheet metal part, featuring a base section, spring bow, clamping leg, and an overload stop formed from the same material, where the overload stop prevents excessive displacement of the clamping leg and is designed to be elastically flexible, and the connection contact is bent out of the plane to minimize current transfer resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the conductor clamping element is formed in one piece from a sheet metal part including base section, spring bow, and clamping leg, then the device complexity is reduced and manufacturing is simplified, but the structural design becomes more challenging to achieve both clamping function and overload protection
Solution Approach 1:
The patent combines multiple functions (clamping, spring action, and overload protection) into a single integrated sheet metal component. The base section, spring bow, clamping leg, and overload stop are formed as one piece through stamping or bending operations, eliminating the need for separate parts and reducing assembly steps while maintaining all necessary functions.
Solution Approach 2:
The single sheet metal part performs multiple functions: the spring bow provides elastic clamping force, the clamping leg secures the conductor, and the overload stop prevents excessive compression. This multi-functional design reduces the total number of components needed in the connector assembly.
2Reliability
If the connection contact is bent out of the plane of the base section, then the current transfer resistance is minimized and electrical conduction is optimized, but the structural stability during assembly may be compromised
Solution Approach 1:
The connection contact is pre-bent out of the plane during the stamping process to establish optimal electrical contact geometry before assembly. This preliminary shaping ensures minimum current transfer resistance is achieved while the remaining flat portions of the base section provide sufficient structural stability during handling and assembly.
Solution Approach 2:
The sheet metal part has different geometries in different regions: the connection contact area is bent out of plane for optimal electrical contact, while the base section maintains sufficient planar area for structural stability. This local differentiation of geometry optimizes each region for its specific function.
3Loss of substance
If the overload stop is formed from the same sheet metal part and bent out of plane, then material usage is reduced and the design is more compact, but the overload protection mechanism becomes more complex to implement
Solution Approach 1:
The overload stop is integrated into the same sheet metal component as the clamping element, eliminating the need for separate overload protection parts. The single stamping operation produces both the clamping structure and the overload stop, reducing material usage and simplifying manufacturing.
Solution Approach 2:
The overload stop is formed from the excess material of the base section itself, using material that would otherwise be waste. This self-service approach converts potential waste material into a functional overload protection element, minimizing additional material requirements.
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 results in a compact, material-saving design that optimizes current conduction, reduces stress on the clamping leg, and prevents plastic deformation, while maintaining effective overload protection and secure electrical connections.
Implementation Method 1
a spring bow 11 which merges into a clamping leg 12
Implementation Method 2
establishing an electrically conductive connection between the electrical conductor and a device
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a conductor connection clamp (1) comprising at least one conductor clamp element (3) which is formed integrally from one sheet metal section and has a base section (10), a spring bow (11) connected to said base section (10), and a clamping limb (12) that is connected to said spring bow (11) and lies opposite the base section (10). The free clamping end (13) of the clamping limb (12) forms a clamping edge for clamping to an electrical conductor (4). An end section (14) of the base section (10), lying opposite said spring bow (11), extends towards the clamping limb (12) from the plane spanned by the base section (10) and forms an overload stop for said clamping limb (12).