Contact Insert Structure for Secure Conductor Clamping
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Solution Overview
Problem
Existing contact inserts for electrical conductors face issues with secure clamping and prevention of strand splicing, especially when multiple strands are involved, and lack effective overload protection and compact design.
Innovation Solution
A contact insert design featuring side webs and a cross web on the clamping spring, forming a closed cutout through which the busbar section passes twice, providing secure clamping and lateral protection, with optional features like a crossbar for overload protection and additional clamping edges for enhanced holding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple clamping spring with busbar piece is used, then the device complexity is low, but the reliability of clamping and prevention of strand splicing is insufficient
Solution Approach 1:
The clamping spring is segmented into multiple functional components: side webs forming a cutout structure, a cross web connecting the side webs, and a clamping leg with clamping edge. The busbar piece is also segmented with specific geometric features. This segmentation allows each component to perform its specific function while working together to achieve secure clamping and prevent strand splicing.
Solution Approach 2:
The busbar piece is designed to pass through the cutout formed by the side webs and cross web at least twice, creating a nested configuration where the busbar is embedded within the cutout structure. This nesting provides mechanical interlocking that secures the electrical conductor against lateral breakout and prevents strand splicing.
2Reliability
If the busbar piece passes through the cutout multiple times, then the clamping security is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The cutout structure with side webs and cross web is pre-formed on the clamping spring before assembly, and the busbar piece is designed with predetermined path geometry. This preliminary configuration guides the busbar piece through the correct insertion path, reducing the need for high alignment precision during assembly while ensuring the busbar passes through the cutout the required number of times.
3Reliability
If additional components like crossbar and multiple clamping edges are added, then the overload protection and holding capability are improved, but the device complexity increases
Solution Approach 1:
The crossbar function for overload protection and the additional clamping edges are integrated into the existing clamping spring structure. The side webs and cross web that form the cutout also serve as additional clamping points. This merging allows multiple functions (clamping, overload protection, strand splicing prevention) to be achieved without adding separate independent components, thus limiting the increase in device complexity.
Solution Approach 2:
The side webs and cross web structure serves multiple functions simultaneously: it forms the cutout through which the busbar passes, provides additional clamping edges for enhanced holding, and creates lateral barriers to prevent strand splicing. This multi-functionality reduces the need for separate dedicated components for each function.
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 design ensures secure clamping of electrical conductors, prevents strand splicing, and offers overload protection, while maintaining a compact form factor, enhancing reliability and ease of insertion.
Implementation Method 1
a clamping spring (3), wherein the clamping spring (3) has a clamping leg (3c) with a clamping edge (4) for clamping an electrical conductor (13)
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to a contact insert (1) for a conductor connection terminal, comprising a busbar piece (2) and a clamping spring (3), said clamping spring (3) having a clamping limb (3c) with a clamping edge (4) for clamping an electric conductor (13). The clamping edge (4) of the clamping limb (3c) and the busbar piece (2) form a clamping point for the electric conductor (13) to be clamped, wherein - at least two lateral webs (5) are arranged on opposing sides of the clamping spring (3), - the free ends of the lateral webs (5) are connected together via a transverse web (6), - the lateral webs (5) and the transverse web (6) form a recess (7), which is closed on all sides, on the clamping spring (3), - the busbar piece (2) extends between the lateral webs (5) at least when the clamping point is closed, and - the busbar piece (2) passes through the recess (7) closed on all sides at least twice.