Electrical Connector Limiter Structure for Leaf Spring Stability
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Solution Overview
Problem
Conventional wire connection terminals with metal leaf springs are prone to damage and instability due to human error during plug-in operations, leading to deflection and breakage, and have complex structures that are time-consuming to manufacture and occupy extra space, limiting their miniaturization potential.
Innovation Solution
The electrical connector limiter structure features a redesigned limiter with fully closed peripheries for the first and second spaces to securely receive and restrict the moving path of metal leaf springs, incorporating a window and protrusion ends to prevent deflection and enhance structural strength, allowing for easy assembly and operation of multiple conductive wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional wire connector limiter is assembled with the wire connector to restrict the moving path of the metal leaf spring, then the metal leaf spring is protected from deflection and breakage, but the structure becomes relatively complicated and time-consuming to process
Solution Approach 1:
The patent integrates the limiter function directly into the insulation case by forming a limiting groove within the case structure. This merging of functions eliminates the need for separate limiter components, reducing structural complexity while maintaining the protective function for the metal leaf spring.
Solution Approach 2:
The insulation case is designed to serve multiple functions: electrical insulation, mechanical support, and limitation of metal leaf spring movement. By making the insulation case multi-functional, the patent reduces the total number of components needed while maintaining reliability.
2Adaptability or versatility
If two or more connection terminals and wire connectors are arranged to connect multiple conductive wires, then each wire can be connected separately, but the total volume of the wiring device increases and occupies extra space
Solution Approach 1:
The insulation case is divided into multiple cavities, with each cavity capable of receiving and isolating individual metal leaf springs and conductive wires. This segmentation allows multiple connections within a compact structure, maintaining versatility while controlling overall volume.
Solution Approach 2:
The patent arranges multiple cavities and components in a nested or compact configuration within the insulation case. The limiting grooves and cavities are integrated in a space-efficient manner, allowing multiple wires to be connected without proportionally increasing the device volume.
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 redesigned limiter structure enhances the stability and operational ease of metal leaf springs, preventing deflection and deformation, facilitating the connection of multiple wires without increasing the terminal's volume, thus addressing the complexity and miniaturization limitations of conventional designs.
Implementation Method 1
the metal leaf spring applies an elastic force to the conductive wire to bite or hold the conductive wire together with the wire connector so as to electrically connect with the conductive wire
Data Source
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AI summary
An electrical connector limiter structure of wire connection terminal is easily operable to enhance the stability of the operation and motion of metal leaf springs. The wire connection terminal includes conductive components mounted in the insulation case and electrical connector assembled with the conductive components. The electrical connector has a limiter (10) for receiving the metal leaf springs and restricting moving path thereof. The limiter (10) is partitioned to define a first space (18) and a second space (19) with fully closed peripheries, in which the metal leaf springs are mounted. The wiring circuits or conductive wires coming from an apparatus can be easily directly plugged into the first and second spaces (18, 19) of the limiter (10) to insert with the metal leaf springs. The limiter (10) serves to prevent the metal leaf springs from deflecting in operation.