Plug-in Connector Resilient Contact Clamping Surfaces
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Solution Overview
Problem
Existing plug-in connectors with resilient contact members are limited in accommodating conductors of varying diameters due to geometric constraints, restricting the maximum possible diameter of conductors that can be contacted.
Innovation Solution
The use of a resilient contact with at least two distinct clamping surfaces and additional bending areas forming an S-curve shape allows for selective engagement of conductors with different diameters, enabling contact with both smaller and larger diameter conductors by activating specific pressure areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single clamping leg design is used, then the structure is simple, but the diameter range of conductors that can be contacted is limited
Solution Approach 1:
The clamping leg is divided into multiple functional segments: a first clamping surface at the free end for smaller conductors, and a second clamping surface created by a bending area for larger conductors. This segmentation allows each segment to handle different conductor diameters, thereby expanding the overall adaptability without requiring multiple separate clamping mechanisms.
Solution Approach 2:
The clamping leg incorporates a bending area that can dynamically adjust its configuration. When a conductor is inserted, the bending area flexes to accommodate the conductor diameter, allowing the clamping leg to adapt its shape rather than requiring a fixed rigid structure. This dynamic behavior enables a single flexible structure to handle multiple conductor sizes.
2Reliability
If the clamping leg is bent around against the plug-in direction, then resistance against unintentional loosening is increased, but the maximum conductor diameter that can be contacted is reduced
Solution Approach 1:
The bending area is positioned specifically within the clamping leg at an optimal location that provides sufficient mechanical advantage for preventing loosening, while maintaining enough remaining leg length beyond the bend to accommodate larger conductor diameters. This local optimization of the bending area's position and geometry allows the structure to achieve both high reliability and expanded adaptability simultaneously.
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 effectively increases the diameter range of conductors that can be contacted, allowing for secure electrical engagement of conductors with varying diameters, including those with larger diameters that were previously uncontactable.
Implementation Method 1
a resilient contact having a clamping portion includes at least two distinct clamping surfaces for selectively engaging the outer circumferential surface of the conductor
Implementation Method 2
the conductor is biased by the clamping portion toward electrical engagement with the bus bar transverse wall
Data Source
AI summary
A plug-in connector arrangement includes a terminal block containing a chamber in which are mounted a horizontal bus bar having a transverse wall, and a resilient contact having a fixed horizontal leg portion, an intermediate portion bent upwardly from the first leg portion, and an outwardly biased second leg portion reversely bent back above the first leg portion. The second leg portion contains a clamping end portion that extends through a conductor opening contained in the first leg portion. The clamping portion includes at least two discrete clamping surfaces so arranged that when a bare conductor is inserted into the conductor opening, the conductor circumferential surface is selectively engaged by one or more of the clamping surfaces in accordance with the diametrical size of the conductor. The conductor is biased by the clamping portion toward electrical engagement with the bus bar transverse wall.