Integrated Contact Spring for Modular Signal Connector Assembly
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Solution Overview
Problem
Existing signaling devices with interchangeable modules face challenges in ensuring a simple and reliable electrical connection to external electrical lines, often requiring multiple components and complex assembly processes.
Innovation Solution
A one-piece spring element serves as both a contact surface for functional modules and a cable clamping spring, allowing for a single-step connection to both the adjacent functional module and an external cable, eliminating the need for intermediate components and reducing assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (contact surface and cable clamping spring) are used for electrical connection, then the connection reliability is improved, but the device complexity and assembly process increase
Solution Approach 1:
The patent combines the contact surface and cable clamping spring into a single integrated spring element. This one-piece design performs both functions simultaneously: providing an electrical contact surface for the functional module and clamping the cable conductor. The merging eliminates the need for separate components and reduces assembly steps while maintaining connection reliability through the unified structure.
Solution Approach 2:
The spring element serves multiple functions within a single component: it acts as both the electrical contact surface and the cable clamping mechanism. This multi-functionality reduces the overall number of parts required in the connection system and simplifies the assembly process while ensuring reliable electrical connection between the signaling device and external cables.
2Stability of the object's composition
If multiple separate components are used for electrical connection, then the connection stability is improved, but the number of parts and assembly time increase
Solution Approach 1:
The contact surface and cable clamping spring are merged into a single spring element that can be installed in one piece. This eliminates the need to assemble multiple separate components, reducing assembly time while maintaining connection stability through the integrated design that ensures proper positioning and electrical contact.
Solution Approach 2:
The spring element is pre-formed with both the contact surface and clamping spring features integrated into a single component during manufacturing. This preliminary integration eliminates the need for on-site assembly of multiple parts, reducing assembly time while ensuring the connection stability is built into the component structure itself.
3Ease of operation
If a simple connection structure is used, then the ease of assembly is improved, but the connection reliability may deteriorate
Solution Approach 1:
The spring element integrates both contact and clamping functions in one component, simplifying the assembly process to a single installation step while maintaining reliable electrical connection. The unified structure ensures that both the contact surface and clamping force are provided by the same component, reducing the risk of assembly errors.
Solution Approach 2:
The spring element provides self-clamping functionality through its spring properties, automatically securing the cable conductor without requiring additional fastening operations. This self-service feature simplifies assembly while ensuring reliable electrical connection through the inherent clamping force of the spring mechanism.
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
This design simplifies the connection process, reduces the number of parts, and ensures a secure and reliable electrical connection by integrating the contact surface and cable clamping function into a single spring element, facilitating easy assembly and disassembly without tools.
Implementation Method 1
an electrical conductor (9) having a contact surface (10) for the connection of an adjacent functional module (29, 30, 31, 32, 33, 34)
Implementation Method 2
extends for the electrical connection of the contact surface (10) with a cable core (13) of an electrical cable up to a cable connection terminal (15) of the connection element (1)
Data Source
Figure 1~4
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Figure 6
AI summary
The invention relates to a connection element for the electrical connection of a signaling device with a functional module adjacent to the connection element, such as a light module for signaling one or more different operating states of a technical device such as a machine, a system, a vehicle, or the like, or a radio module for establishing a radio connection of the signaling device, wherein the connection element for the electrical connection of the functional module has at least one electrical contact surface of an electrical conductor. The connection element is characterized in that the electrical conductor having the contact surface extends to a cable terminal of the connection element for connection with at least one conductor of an electrical cable.