Tool-Free Connection Plug With Hard Metal Clamping Section
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Solution Overview
Problem
Existing connection plugs cannot be easily removed from direct plug-in connections with self-locking clamping springs, requiring tools and complicating the insertion and removal process.
Innovation Solution
A connection plug with a clamping section made of hard, low-roughness stainless steel that prevents self-locking, allowing for tool-free insertion and removal by counteracting spring force, and a sliding element with a pressure section interacting with the actuating device of the direct connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clamping spring is made self-locking to prevent conductor pull-out, then connection reliability is improved, but removal difficulty increases and tool requirement arises
Solution Approach 1:
The busbar element has different surface qualities in different areas: the clamping section has a smooth, hard metal surface (low roughness) that prevents self-locking and allows easy removal, while other areas may have different properties. This local differentiation resolves the contradiction by making the clamping area non-self-locking while maintaining connection reliability through proper mechanical engagement.
Solution Approach 2:
The surface roughness parameter of the clamping section is specifically controlled to be low, and the hardness is increased by using hard metal coating. These parameter changes prevent the clamping spring from digging into the busbar element, eliminating self-locking effects and enabling tool-free removal while maintaining adequate connection reliability.
2Ease of operation
If the busbar element surface is soft to allow easy insertion, then insertion ease is improved, but self-locking occurs and removal difficulty increases
Solution Approach 1:
The surface hardness and roughness parameters of the busbar element's clamping section are changed to be hard and smooth. This prevents the clamping spring from embedding into the surface, eliminating self-locking while maintaining easy insertion and tool-free removal capability.
Solution Approach 2:
The busbar element uses a composite structure with a conductive core coated with an electrically non-conductive sheath, and the clamping section is coated with hard metal. This composite material approach provides the necessary electrical properties, mechanical strength, and surface characteristics to prevent self-locking while enabling easy operation.
3Ease of operation
If hard metal coating is applied to the busbar element to prevent self-locking, then removal ease is improved, but manufacturing cost increases
Solution Approach 1:
The hard metal coating is applied only to the clamping section of the busbar element where it contacts the clamping spring, rather than the entire busbar element. This localized application reduces material costs and manufacturing complexity while still achieving the goal of preventing self-locking and enabling easy removal.
Solution Approach 2:
The additional connection plug appears to be designed as a disposable or temporary connection device. The busbar element with hard metal coating on the clamping section provides sufficient service life for this application at reduced cost compared to making the entire busbar element from expensive hard metal.
Data Source
Figure 1
Figure 2~2A
Figure 3
AI summary
Additional connection plug (10) for electrical conductors, for plugging into direct plugging connections (25) with clamping spring (7) and self-locking of connection devices (6) of connection terminals (2), with a housing (11) with a connection device (6') and an insertion opening (4') for inserting an electrical conductor into the connection device (6') of the additional connection plug (10); an actuating device (5') for releasing the connection device (6') of the additional connection plug (10) from a clamping position; a busbar device (14), which is fixed in the housing (11) and extends outside the housing (11) over a certain length, starting from a lower side (13) of the housing (11); a release device (34), which is guided movably in the housing (11), for releasing the connection device (6) of the connection terminal (2) to be assigned from a clamping position, wherein the release device (34) has a sliding element (37) with a pressure section (38), which, in the actuated position, interacts with an actuating device (5) of the clamping spring (7) of the direct connection (25) of the connection terminal (2) to be assigned.