Metal Leaf Spring Structure for Electrical Connection Terminal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional metal leaf spring structures in electrical connection terminals are prone to over-bending due to imprecise wire insertion angles, leading to elastic fatigue and reduced terminal lifetime, with complex designs and high manufacturing costs.
Innovation Solution
A redesigned metal leaf spring structure featuring a main body with a base section, a bent section, a locating section, and a reciprocally movable second section, where the locating section provides an elastic action force to prevent over-bending by forming a moving end point and incorporating a protrusion section fixed in a recess, simplifying the design and reducing the risk of over-bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protrusion section is added to the reception member to prevent over-bending of the clamping spring, then the clamping spring is protected from excessive deformation, but the structural complexity increases and manufacturing cost rises
Solution Approach 1:
The patent integrates the limiting function directly into the clamping spring structure by forming a bent section that contacts the wire, eliminating the need for a separate protrusion section on the reception member. The bent section serves both as a clamping element and as a mechanical stop, merging two functions into one component.
Solution Approach 2:
Instead of adding a protrusion to the stationary reception member to limit spring movement, the patent inverts the approach by creating a corresponding contact surface on the moving clamping spring itself. The bent section of the spring contacts the wire at a specific angle, and the spring's own geometry provides the limiting function rather than relying on an external structure.
2Ease of manufacture
If the clamping spring is designed with a simple structure, then manufacturing cost is reduced, but the spring is prone to over-bending when wires are inserted at imprecise angles
Solution Approach 1:
The patent applies local quality by creating a bent section with specific geometric properties at a critical location on the clamping spring. This bent section has enhanced structural characteristics (specific angle and contact surface) that provide over-bending protection precisely where needed, while the rest of the spring maintains a simple, easy-to-manufacture structure.
Solution Approach 2:
The bent section is designed with an asymmetric geometry that is optimized for its dual function of clamping and limiting. The specific angle and shape of the bent section are asymmetric relative to the spring's main body, allowing it to effectively contact wires at various insertion angles while maintaining structural integrity and preventing over-bending.
3Device complexity
If the metal leaf spring uses a conventional structure, then the design is simple, but elastic fatigue occurs after high-frequency assembling operations reducing terminal lifetime
Solution Approach 1:
The patent introduces dynamic characteristics to the clamping spring through the bent section design. The bent section allows the spring to adapt its contact angle and pressure dynamically based on wire insertion variations, distributing stress more evenly during high-frequency operations. This dynamic response reduces stress concentration and minimizes elastic fatigue accumulation.
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 stabilizes the metal leaf spring's movement, preventing over-bending and enhancing the secure pressing and restriction of conductive wires, thereby extending the terminal's lifespan and reducing manufacturing complexity.
Implementation Method 1
The locating section (40) is positioned in a reciprocally moving path of the second section (20) to set up a moving end point of the second section (20)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A metal leaf spring structure of electrical connection terminal includes a main body (100). The main body (100) has a base section (30) defined with a first end (31) and a second end (32). The first end (31) is connected with a first section (10) and a locating section (40). The second end (32) is connected with a bight section (50) and a reciprocally movable second section (20). The locating section (40) is positioned in the reciprocally moving path of the second section (20) to set up a moving end point of the second section (20). The metal leaf spring structure of electrical connection terminal improves the shortcomings of the conventional metal leaf spring that the conductive wire cannot be plugged into the terminal by a precise angle so that the metal leaf spring is over-bent to affect the pressing and securing effect.