Contact Clip Segmentation for Tool-Free Plug Removal
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Solution Overview
Problem
Conventional contacting devices for electrical conductors and plugs to conductor tracks require cumbersome mechanisms or tools to secure and release connections, especially when dealing with multiple plug pins, leading to inefficiencies in securing and removing electrical connectors.
Innovation Solution
A contacting device with a clamping spring having a sharp-edged first section for securing conductors and a flat second section for holding plugs, allowing secure attachment and easy removal of plugs by overcoming static friction without the need for additional mechanisms or tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sharp-edged contact clip is used to secure electrical conductors by notching, then the conductor is securely fixed against slipping out, but the release mechanism becomes complex requiring actuating mechanisms or tools to further deflect the leaf spring
Solution Approach 1:
The contact clip is divided into two distinct sections: a first section with a sharp-edged end for securing electrical conductors through notching, and a second section with a bearing area for holding electrical plugs through friction. This segmentation allows each section to have optimized geometry for its specific function, resolving the contradiction between secure conductor fixation and simple release mechanism.
Solution Approach 2:
Different sections of the contact clip have different geometric properties: the first section has a sharp edge for penetrating and notching conductor material, while the second section has a flat bearing area for generating static friction with plug surfaces. This local differentiation enables the contact clip to perform both securing functions with appropriate local characteristics.
2Reliability
If an actuating mechanism or tool is required to release plugs from the contacting device, then secure contact is maintained, but the ease of operation deteriorates especially when dealing with multiple plug pins
Solution Approach 1:
The contact clip is segmented into a first section for conductor contact and a second section for plug contact. The second section is specifically designed with a bearing area that generates static friction to hold plugs securely during operation, but allows easy removal by simple pulling without requiring actuating mechanisms or tools, even when multiple plug pins are present.
Solution Approach 2:
Instead of requiring active action to release plugs (as with conventional actuating mechanisms), the design allows passive release through simple pulling motion. The static friction in the second section maintains secure contact during normal use, but is easily overcome by pulling force in the opposite direction, inverting the conventional approach where release requires additional mechanical action.
3Device complexity
If a single contact clip design is used for both conductors and plugs, then device complexity is reduced, but the ability to differentiate between secure conductor fixation and easy plug removal is compromised
Solution Approach 1:
The contact clip is divided into a first section with sharp-edged end for conductor notching and a second section with bearing area for plug friction contact. This segmentation within a single component enables differential holding capabilities: conductors are secured through material notching while plugs are held through static friction, allowing easy differentiation in release mechanisms without requiring separate components.
Solution Approach 2:
The contact clip exhibits local quality differentiation where the first section has sharp geometric features for conductor engagement and the second section has flat bearing surfaces for plug engagement. This local differentiation enables the single contact clip to provide adaptability for both conductor security and plug ease-of-removal functions.
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
Enables secure attachment and easy release of electrical conductors and plugs, reducing the complexity of releasing multiple plug pins by utilizing the static friction generated by the contact clip's design, allowing for efficient and tool-free removal.
Implementation Method 1
The electrical plug is held by the static friction generated by the pressing force of the deflected second section of the contact clip
Implementation Method 2
the contact clip (200) is designed as a clamping spring
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
A contacting device (1) comprises a housing (100) with a first opening (101) for inserting the electrical conductor (10) and the electrical connector (20) into a cavity (103) of the housing (100) and with a second opening (102) for inserting the electrical conductor (30) into the cavity (103) of the housing. The contacting device (1) further comprises a contact bracket (200) arranged in the cavity (103) of the housing, with a first section (210) for securing the electrical conductor (10) in a clamping fit on the electrical conductor (30) and with a second section (220) for holding and pressing the electrical connector (20) against the electrical conductor (30).