Push-In Spring-Terminal Wire Retention Design
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Solution Overview
Problem
Existing electrical connectors often damage wires during removal, leading to increased material and labor costs due to the separation of wires from contact terminals, and they are not easily reusable.
Innovation Solution
A one-piece push-in electrical spring contact terminal with a main contact body and sidewalls forming a central cavity, featuring multiple spring contacts that engage and retain wires without damaging them, allowing for multiple insertions and removals without compromising the wire or contact integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wire is soldered or crimped to the contact terminal, then connection strength is improved, but manufacturing complexity and labor cost increase
Solution Approach 1:
The terminal body and contact are merged into a single integrated component, eliminating the need for separate crimping or soldering operations. The contact is formed as an integral part of the terminal body, providing both mechanical support and electrical connection in one piece.
Solution Approach 2:
The terminal structure provides self-retaining capability through its geometric design. The contact geometry and terminal body configuration automatically secure the wire through friction and mechanical interlocking, without requiring external fastening operations.
2Ease of operation
If wire is inserted into insulation displacement contact, then ease of operation is improved, but connection reliability deteriorates due to wire damage during removal
Solution Approach 1:
The contact incorporates spring elements that provide dynamic, resilient pressure against the wire. This elastic force maintains continuous electrical contact while allowing the wire to be inserted and removed without permanent deformation or damage to the wire insulation.
Solution Approach 2:
The spring contact acts as a flexible element that deforms elastically during wire insertion and removal. This flexibility allows the contact to accommodate wire variations while maintaining sufficient gripping force, preventing wire damage during connector operations.
3Strength
If connector is designed for permanent installation, then connection strength is improved, but adaptability deteriorates as connector becomes unusable after single use
Solution Approach 1:
The terminal design allows for recovery and reuse of the connector body after wire removal. The spring contacts are designed to return to their original position, and the terminal structure maintains its integrity, enabling the same connector to be used multiple times with different wires.
Solution Approach 2:
The spring-based contact system provides dynamic retention that allows wires to be inserted and removed repeatedly. The elastic deformation of the spring contacts during each insertion/removal cycle does not compromise the structural integrity of the terminal, enabling multiple reuse cycles.
4Reliability
If spring pressure is increased to improve wire retention, then connection reliability is improved, but wire damage risk increases
Solution Approach 1:
The spring contact provides flexible, elastic pressure that adapts to the wire diameter and material properties. This flexible contact approach distributes the retaining force over a larger area and allows for dynamic adjustment, reducing the risk of localized stress concentration and wire damage while maintaining reliable retention.
Solution Approach 2:
The spring contact system allows for parameter adjustment in terms of pressure magnitude and contact geometry. By optimizing the spring constant, contact surface area, and engagement geometry, the design achieves reliable wire retention while keeping the contact pressure within safe limits that prevent wire damage.
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 enables secure and repeatable connections for a range of wire sizes, reducing material waste and labor costs by allowing wires to be easily inserted and removed without damaging the wire or the contact terminal, thus enhancing the usability and efficiency of electrical connectors.
Implementation Method 1
a first spring contact extending from the base into the central cavity, and a second spring contact extending from one of the set of sidewalls into the central cavity
Data Source
AI summary
Embodiments herein are directed to a wire spring terminal including a main contact body having a base and a set of sidewalls defining a central cavity, a first spring contact extending from the base into the central cavity, and a second spring contact extending from one of the sidewalls into the central cavity, wherein the first and second spring contacts are configured to engage a wire inserted into the main contact body. In some embodiments, the wire spring terminal includes a third spring contact extending from the base into the central cavity, and a fourth spring contact extending from another one of the set of sidewalls into the central cavity, the third and fourth spring contacts configured to engage a wire. The first and third spring contacts may be arranged side-by-side, separated by a slot. The second and fourth spring contacts are also arranged side-by-side, separated by another slot.