Electrical Connector with Belleville Spring and Screw Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connector technologies face issues with space occupation, slow wiring, low efficiency, and potential screw looseness or failure, while requiring special tools for wire disconnection.
Innovation Solution
A novel electrical connector design featuring a housing with integrated multi-socket wire connection, plug-in, and disconnection structures using a belleville spring mechanism, combined with screw mounting for reliability and ease of use, made from non-metallic and metal materials to meet IEC 60603-2 standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connection is used, then reliability is improved, but space occupation increases and wiring speed decreases
Solution Approach 1:
The connector is divided into modular components: a housing with multiple sockets, separate wire connection structures for each socket, and integrated screw mounting structures. This segmentation allows parallel assembly of multiple connections simultaneously, improving wiring efficiency while maintaining the reliability of screw-based mechanical and electrical connections.
Solution Approach 2:
The screw mounting structure serves multiple functions: it provides mechanical fastening, ensures electrical contact, and enables easy disconnection. The integrated design combines wire access, spring contact, and screw fixation into a single multi-functional assembly that improves both reliability and wiring productivity.
2Reliability
If screw connection is used, then connection reliability is improved, but wiring speed decreases
Solution Approach 1:
The wire connection structure is pre-configured with integrated screw mounting structures and belleville springs during manufacturing. Conductors can be pre-prepared and inserted into the housing before final screw fixation, allowing parallel preparation of multiple connections and reducing on-site wiring time while maintaining reliable screw-based connections.
3Productivity
If pull-back spring connection is used, then space occupation decreases and wiring speed increases, but special tools are required for wire disconnection
Solution Approach 1:
The design merges the advantages of both screw and spring connections by integrating a belleville spring contact mechanism with a screw mounting structure. The spring provides automatic contact pressure and shock resistance, while the screw provides reliable mechanical fastening and easy tool-based disconnection, eliminating the need for special disconnection tools.
4Area of stationary object
If pull-back spring connection is used, then space occupation decreases, but disconnection requires special tools
Solution Approach 1:
The belleville spring structure provides self-adjusting contact pressure that automatically maintains reliable electrical connection while accommodating conductor variations. The integrated screw mounting allows standard tools to service the connection for both tightening and disconnection, making the system self-sufficient without requiring proprietary or special tools.
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 provides high connection density, efficient wiring, shock resistance, and reliability, eliminating screw looseness while allowing flexible use and meeting industry standards.
Implementation Method 1
the wire connection structure has an opening for receiving an accessed conductor, which is jammed by spring force of the belleville spring; the wire disconnection structure is arranged as a button; the belleville spring is jacked by pressing the wire disconnection structure so as to release the conductor
Implementation Method 2
the plug-in connection structure consists of a spring clip, which forms an opening located behind the housing; the spring clip of the plug-in connection structure and the belleville spring at one side of the wire connection structure are integrated for a same socket
Data Source
AI summary
The present invention relates to an electrical connector, comprising a connector main body (1) and screws (2, 3). The connector main body (1) includes a housing (4), a multi-socket wire connection structure (5), a multi-socket plug-in connection structure (8), and a multi-socket wire disconnection structure (6). The screws (2, 3) are preferably set screws, which comprise a guide structure (9), a thread structure (10), a fall-off prevention structure (11), and a wrenching structure (12). The present invention has advantages of high connection density, ease of wiring connection, high efficiency, being shock-resistant, loosening-proof and reliable, while meeting the IEC 60603-2 standard.