Metal Part for Electric Connecting Device with Inverted Bending
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Solution Overview
Problem
Existing metal parts for electrical connection devices require excessive material usage due to their design, which is not solely determined by current-carrying capacity.
Innovation Solution
The metal part design involves bending the contact leg directly from the base leg, with side walls bent from both the contact and base legs in a way that reduces material usage by aligning bending edges parallel to the transport direction, creating a stable and efficient clamping mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the contact leg is bent from the side wall and the side wall is bent from the base leg, then the metal part provides sufficient structural support and stability, but the material usage becomes excessive
Solution Approach 1:
The patent inverts the conventional bending sequence by bending the contact leg directly from the base leg, rather than bending it from the side wall. This reversal of the manufacturing process eliminates the need for the side wall to serve as an intermediate bending element, thereby reducing material consumption while maintaining the structural integrity and support functions of the metal part
2Loss of substance
If the side wall is made relatively large to prevent lateral displacement of the conductor, then the conductor is securely held in position, but the material consumption increases
Solution Approach 1:
The patent extracts the essential function of lateral conductor guidance from the side wall by bending the contact leg directly from the base leg. This creates a more efficient structural configuration where the contact leg itself provides the necessary lateral positioning guidance, allowing the side wall to be minimized or eliminated, thus reducing material consumption while maintaining reliable conductor positioning
3Ease of manufacture
If the contact leg is bent from the side wall, then the clamping mechanism is formed, but the bending edge is not aligned with the transport direction causing excessive material usage
Solution Approach 1:
The patent changes the geometric parameters of the metal part by aligning the bending edge between the contact leg and base leg parallel to the transport direction. This parameter change optimizes the manufacturing process for production efficiency while simultaneously reducing material consumption, as the bending operation becomes more material-efficient when aligned with the standard transport and processing direction
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 significantly reduces material consumption while maintaining functionality, preventing conductor displacement and providing stability to the contact leg, allowing for efficient production and use in electrical connection terminals.
Implementation Method 1
with a clamping spring acting as a compression spring on the conductor end
Implementation Method 2
The metal part is initially used to transmit a current between the contact point with the electrical conductor and a second contact point
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
The invention relates to a metal part for an electric connecting device for connecting at least one stripped conductor end, comprising a base limb (2), a contact limb (3) that is substantially perpendicular relative to said base limb, and at least one lateral wall (4). The contact limb (3) together with a clamping limb (6) of a clamping spring (5) forms a spring clamp terminal for an electric conductor to be connected. The metal part according to the invention requires only a small amount of material in that the contact limb (3) is bent away from the base limb (2), and the lateral wall (4) is bent away from the contact limb (6), wherein the bending edge (8) between the contact limb (3) and the base limb (2) runs perpendicular relative to the longitudinal extension of the contact limb (3) and the base limb (2), while the bending edge (9) between the contact limb (3) and the lateral wall (4) runs parallel relative to the longitudinal extension of the contact limb (3).