Poke-in Electrical Connector with Integrated Spring Beam
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Solution Overview
Problem
Pivot block style electrical connectors require multiple parts, high spring force, and often buckle smaller wires due to the need for a separate compliant spring to maintain contact with the wire.
Innovation Solution
A poke-in electrical connector with a housing featuring contact channels and pivot levers, where each electrical contact includes a poke-in spring beam that engages the wire upon insertion, allowing for a pinching action that holds the wire without the need for additional springs, and is movable between positions to facilitate easy wire removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate compliant spring is used to hold the electrical contact in physical contact with the wire, then the electrical connection reliability is improved, but the device complexity increases and the wire may be damaged due to high spring force
Solution Approach 1:
The patent combines the spring function and electrical contact function into a single integrated electrical contact component. The contact element itself is designed with elastic properties to provide the necessary spring force, eliminating the need for a separate compliant spring component while maintaining reliable electrical connection.
Solution Approach 2:
The patent removes the separate compliant spring from the connector assembly and extracts only the essential spring function, incorporating it directly into the electrical contact structure. This simplifies the overall device by eliminating unnecessary components while preserving the critical function of maintaining contact pressure.
2Reliability
If a separate compliant spring is used to hold the electrical contact in physical contact with the wire, then the electrical connection reliability is improved, but the spring force is excessively high causing wire buckling
Solution Approach 1:
The patent applies local quality by designing the electrical contact with varying elastic properties in different regions. The contact element has controlled flexibility that provides sufficient spring force for reliable electrical connection while limiting the maximum force to prevent wire damage. The local elastic characteristics are optimized to match the specific requirements of wire termination.
Solution Approach 2:
The patent changes the physical parameters of the electrical contact, specifically its elastic modulus and geometry, to achieve optimal spring force characteristics. By adjusting these parameters, the contact provides enough force for reliable electrical connection while staying below the threshold that would cause wire buckling or damage.
3Reliability
If multiple parts are used in the pivot block style connector, then the electrical connection reliability is improved, but the ease of manufacture decreases
Solution Approach 1:
The patent merges multiple components into fewer integrated parts. The electrical contact incorporates both the contact element and spring function in a single component that can be installed as one unit, simplifying the manufacturing and assembly process while maintaining reliable electrical connection through the integrated elastic contact 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
The solution provides a reliable, low-force termination method for a range of wire sizes, reducing the risk of wire damage and eliminating the need for additional springs, while maintaining a secure electrical connection.
Implementation Method 1
Each electrical contact includes a poke-in spring beam configured to engage the electrical wire when poked-in to the corresponding wire channel. The spring beam has a separable wire interface configured to engage in physical contact with the electrical wire.
Data Source
AI summary
An electrical connector includes a housing having contact channels with electrical contacts received therein each having a poke-in spring beam configured to engage an electrical wire when poked-in to the housing. The electrical contact is movable between a resting position when no wire is present in the wire channel and a clearance position where the electrical contact allows the electrical wire to be removed from the wire channel. Pivot levers are held by the housing and are coupled to corresponding electrical contacts with a pivot end pivotably coupled to the housing and a push button end having a push button pressed to move the corresponding electrical contact to the clearance position. When the electrical wire is loaded into the wire channel, the electrical contact is positioned in a pinching position in which the spring beam pinches against the electrical wire in physical contact with the electrical wire.