Reinforced Metal Spring Plate for Fatigue-Resistant Conductor Crimping
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Solution Overview
Problem
Conventional metal spring plates in conductor connection devices suffer from deformation, material fatigue, and breaking due to frequent use, leading to unstable conductor crimping and reduced electrical conductivity and safety.
Innovation Solution
A redesigned metal spring plate structure with an elongated elevated structure extending from the base part to the crimp part, featuring hollow-out areas or connection walls, which enhances structural strength and stability without increasing material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional metal spring plates are added to increase holding force, then conductor crimping stability is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The metal spring plate is segmented into multiple functional regions: a base part, a curved section, a crimp part with teeth, and an elongated elevated structure. This segmentation allows each region to perform its specific function optimally while maintaining overall structural integrity, eliminating the need for multiple separate spring plates
Solution Approach 2:
The elongated elevated structure extends in the longitudinal direction, creating a three-dimensional reinforcement that distributes stress along the length of the spring plate. This dimensional addition provides enhanced structural strength without requiring multiple layered plates, simplifying the overall structure
2Duration of action of moving object
If metal spring plate is used frequently over long time, then conductor connection function is maintained, but material fatigue and breaking occur at bent locations
Solution Approach 1:
The elongated elevated structure acts as a pre-designed stress distribution element that cushions and disperses mechanical loads before they can concentrate at critical bent locations. This preventive structural feature reduces fatigue accumulation during frequent operation, extending service life
Solution Approach 2:
The curved section between the base part and crimp part provides a smooth transition that distributes bending stresses more evenly. The curvature radius is specifically designed to avoid stress concentration points, reducing the risk of fatigue cracking during repeated flexing operations
3Ease of manufacture
If metal spring plate structure is simplified, then assembly is easier, but structural strength and holding-down force are reduced
Solution Approach 1:
The elongated elevated structure provides localized reinforcement at critical stress zones along the longitudinal axis. This local quality enhancement concentrates material where needed for maximum structural strength while keeping other areas minimal, maintaining ease of manufacture and assembly
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 structure provides improved structural strength and stable conductor crimping force, preventing deformation and fatigue, ensuring reliable electrical connection over time.
Implementation Method 1
a curved section (13) formed between the first section and the crimp part (20)
Implementation Method 2
at least one elongated elevated structure (40) is provided on the main body (100). The elongated elevated structure (40) overlaps at least a part of the crimp part (20) and passes at least a part of the curved section (13) to extend toward the first section (11)
Data Source
AI summary
A metal spring plate structure for conductor connecting device includes a main body having a base part, a crimp part connected to a first section of the base part for crimping an external conductor, and a locating part connected to a second section of the base part for removably engaging with a conducting component, such that the conducting component and the conductor are electrically connected. A curved section is formed between the first section and the crimp part, and an elongated elevated structure is protruded from an upper or a lower side of the main body. The elongated elevated structure overlaps the crimp part and passes the curved section to extend toward the first section. The metal spring plate provides good structural strength and stable conductor crimping force without becoming deformed or unstable in contact after operating over a long time to ensure good conducting efficiency and safety in use.