Integrated Contact Element for Connection Clamp
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Solution Overview
Problem
Existing connection terminals face challenges in reliably connecting multiple clamping elements due to diameter mismatches between U-shaped wires/stamped parts and connecting wires, leading to inconsistent contact quality, and existing solutions either require pre-installed separate contacts or increase assembly costs.
Innovation Solution
A contact element designed as a stamped and bent part with integrated clamping means for both jumpers and pins, featuring a cage-like structure with mechanical prestress, allowing flexible and cost-effective connection of terminal poles, including a test contact area for signal verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate electrical contacts are installed in advance to bridge clamping elements, then reliable electrical connection is achieved, but assembly costs increase and the connection cannot be detached
Solution Approach 1:
The patent combines the jumper connection function and the connecting pin function into a single integrated contact element. This stamped and bent part simultaneously provides electrical bridging between clamping elements and mechanical attachment, eliminating the need for separate pre-installed electrical contacts and reducing assembly complexity while maintaining reliable electrical connection.
2Adaptability or versatility
If a U-shaped piece of wire or stamped part is used to connect clamping elements, then electrical connection is established, but contact reliability deteriorates due to diameter mismatch with connecting wires
Solution Approach 1:
The contact element features locally optimized clamping surfaces with specific geometric shapes (undercuts, bulges, recesses) that are tailored to match the dimensions of connecting wires and pins. This local quality adaptation ensures reliable contact regardless of the diameter or type of connector being joined, resolving the diameter mismatch problem.
3Ease of manufacture
If the contact element is designed as a stamped and bent part with integrated clamping means, then manufacturing simplicity and cost-effectiveness are achieved, but structural complexity must be optimized
Solution Approach 1:
The contact element is designed as a stamped and bent part with distinct functional segments: a first clamping means for jumpers and a second clamping means for connecting pins. This segmentation allows each region to be optimized for its specific function while maintaining overall structural integrity and enabling single-step manufacturing processes.
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
Ensures reliable and secure clamping of both jumpers and pins, facilitating flexible and cost-effective connections while maintaining optimal contact quality, and allowing for easy production in a single process step.
Implementation Method 1
the corresponding sections of the stamped and bent part are optionally provided with a suitable mechanical prestress
Data Source
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AI summary
The contact element (8) has a press bent part, in which a clamping unit (13) for fixing a link plug and another clamping unit (15) for fixing a connector pin (21) are integrated. The contact element has a cage-like structure. Independent claims are included for the following: (1) a connecting terminal, particularly printed circuit board connecting terminal, with two clamping elements; and (2) a link plug for a contact element.