Electrical Lug Protruding Elements Terminal Connection
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Solution Overview
Problem
Existing electrical connection lugs face challenges in maintaining optimal electrical contact quality with connection terminals, especially when connecting electric cables and power conductors, leading to potential disconnections and suboptimal contact.
Innovation Solution
The electrical connection lug features protruding elements that are inserted into the connection terminal walls, allowing for an irremovable connection, ensuring improved contact quality and preventing unwanted disconnections by deforming to fit securely within the terminal's side walls during a screwing operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional lug with orifice and slot is used for connection to terminal, then the connection can be made with standard screw and clamp, but the electrical contact quality is limited and disconnection may occur
Solution Approach 1:
The lug base is segmented into multiple protruding elements (at least two) that can be inserted into the terminal walls. This segmentation allows the connection function to be distributed across multiple contact points, improving electrical contact quality and reliability while maintaining a relatively simple overall structure.
Solution Approach 2:
The connection mechanism transitions from a single-plane slot insertion to a three-dimensional structure where protruding elements extend into the terminal walls. This dimensional change enables the lug to be held in position by multiple walls of the terminal, significantly improving contact quality and preventing disconnection.
2Reliability
If the lug is connected removably to the terminal, then the connection can be made and removed easily, but unwanted disconnection may occur and electrical contact quality deteriorates
Solution Approach 1:
The protruding elements are pre-formed on the lug base before installation. During the connection process, these elements are inserted into the terminal walls and then deformed by the screwing operation to create an irremovable connection. This preliminary preparation ensures that once connected, the lug cannot disconnect unintentionally, while the installation process remains straightforward.
Solution Approach 2:
The screwing operation, which could potentially damage the lug, is converted into a beneficial force that deforms the protruding elements to create a secure, irremovable connection. The mechanical stress applied during tightening transforms the protruding elements into locked positions within the terminal walls, converting a potential harm into a connection-strengthening mechanism.
3Ease of manufacture
If the lug structure is simplified for easy manufacturing, then production cost decreases, but the ability to maintain optimal electrical contact is compromised
Solution Approach 1:
The lug design changes the geometric parameters of the base by adding protruding elements with specific dimensions. These elements have controlled width, length, and deformation characteristics that enable them to be inserted into terminal walls and deformed during screwing. This parameter optimization allows the lug to maintain precise electrical contact while remaining manufacturable using standard 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
This solution enhances the quality of electrical contact between the lug and the terminal, facilitating the connection of both electric cables and power conductors, while ensuring the lug remains securely attached, thus preventing disconnections and optimizing the connection process.
Implementation Method 1
the lug being deformed in a screwing operation, in order to be connected in an irremovable manner to the connection terminal
Data Source
Figure 1
Figure 2
Figure 3~7
AI summary
This electrical connection lug (47) for an electrical connection terminal comprises a connection area (64) for an electrical wire and a base (66). The base (66) includes an opening (72) for the passage of a connection means and two lateral sides (74, 76) extending overall along a longitudinal axis (X47) of the lug. According to the invention, the base (66) comprises, on at least one of its lateral sides, at least one element projecting (86) beyond the corresponding lateral side and the rest of the base (66).