Electric Connector Leaf Spring Clamp Design
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Solution Overview
Problem
Existing electrical connectors are costly and bulky, making them unsuitable for use as both single-pole and multi-pole connectors in space-constrained applications, and they require significant material for spring steel sheets to ensure conductivity.
Innovation Solution
A compact electrical connector design featuring a U-shaped, two-legged leaf spring clamp connection supported by the insulating housing, with a contact wall guiding the conductor and pin to maximize overlap and reduce material usage, allowing for efficient production and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a piece of spring steel sheet is used for both pin clamp contact and conductor clamp connection, then electrical conductivity is maintained, but material costs increase and device size increases
Solution Approach 1:
The connector is divided into separate functional components: a pin clamp contact made of spring steel sheet for electrical connection, and a conductor clamp connection made of insulating material for mechanical clamping. This segmentation allows each component to be optimized for its specific function, reducing overall material usage while maintaining conductivity where needed.
Solution Approach 2:
The electrical conductivity function is extracted from the insulating material and assigned to a dedicated spring steel sheet component (pin clamp contact). This extraction allows the insulating material to be reduced or eliminated in areas where conductivity is not needed, reducing total material quantity.
2Reliability
If pin clamp contact and conductor clamp connection are arranged far apart, then interference is avoided, but connector size increases
Solution Approach 1:
The pin clamp contact and conductor clamp connection are merged into a closely integrated structure where the spring steel sheet forms both the pin clamp contact and extends to form the conductor clamp connection. This merging reduces the distance between components and minimizes connector size while maintaining functional independence through the spring steel sheet's flexibility.
Solution Approach 2:
The components are arranged in a compact three-dimensional configuration where the spring steel sheet folds and bends to provide both clamping functions in close proximity. By utilizing vertical and lateral spacing rather than only horizontal distance, interference is avoided without increasing overall connector footprint.
3Strength
If insulating material is dimensioned large, then structural integrity is maintained, but connector size increases
Solution Approach 1:
The insulating material is applied selectively only where structural integrity and electrical insulation are required, rather than uniformly throughout the connector. The spring steel sheet components provide structural support in areas where insulating material would be unnecessary, allowing the insulating material dimensions to be reduced.
Solution Approach 2:
The connector uses a composite structure combining spring steel sheet (for conductivity and clamping force) with insulating material (for electrical insulation and structural support). This composite approach allows each material to be used in optimal quantities, reducing overall connector size while maintaining structural integrity.
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 new connector is inexpensive to manufacture, reduces material usage, and maintains effective electrical contact with improved positional accuracy, enabling its use in both single-pole and multi-pole configurations in limited spaces.
Implementation Method 1
a leaf spring clamp connection with a leaf spring, which in the direction of conductor insertion and at an angle against the electr. Conductor extends and clamps the insulation-free end of the inserted conductor with its leaf spring end
Data Source
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AI summary
The invention relates to an electrical connector for connecting a contact pin to an electrical conductor. It is proposed that the insulating housing of the connector provides a connection space into which the contact pin and the electrical conductor can be inserted in opposite directions with an approximately parallel orientation and overlap with their axial lengths, wherein the conductor has a structurally permissible displacement range transverse to its longitudinal axis and the leaf spring of the conductor clamping connection presses the conductor towards the contact pin.