Push-in Electrical Connector for Fine-Wire Conductors
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Solution Overview
Problem
Existing connecting devices with direct plug-in technology struggle to easily and efficiently connect and disconnect fine-wire conductors, as the trigger bar cannot be released when inserting very fine-wire conductors, and often require tools for operation.
Innovation Solution
A connecting device with a manually operated locking and release element, featuring a clamping spring and a latching and triggering mechanism that can be moved into a cocked and open position without tools, allowing for easy connection and disconnection of conductors using a push-in technique, and is designed to handle fine-stranded conductors with a defined, precisely noticeable open position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a trigger bar mechanism is used in direct plug-in connection devices, then connection speed is improved, but the mechanism cannot be released when inserting very fine-wire conductors
Solution Approach 1:
The patent changes the operational parameter from a trigger bar requiring lateral movement to a push-button requiring axial force application. This parameter change enables the release mechanism to work effectively with fine-wire conductors that cannot actuate the traditional trigger bar, while maintaining fast connection speeds through the spring-loaded clamping mechanism.
Solution Approach 2:
Instead of using a trigger bar that must be pulled or pushed laterally to release the clamping spring, the patent inverts the mechanism to use a push-button that applies axial force in the same direction as conductor insertion. This inverted approach allows the button to directly actuate the release lever, enabling reliable operation with fine-wire conductors.
2Reliability
If a locking arm with release bar is used, then connection stability is improved, but tool operation is required for release
Solution Approach 1:
The patent implements a self-service mechanism where the conductor itself, upon insertion, actsuates the push-button through its own movement. The conductor's insertion motion automatically triggers the release lever, which then releases the clamping spring to secure the conductor. This eliminates the need for external tools while maintaining reliable locking through the spring mechanism.
Solution Approach 2:
The clamping spring is pre-loaded in a tensioned state before conductor insertion. The push-button and release lever are pre-positioned so that conductor insertion automatically actuates the release mechanism. This preliminary preparation allows the connection to be secured reliably without requiring subsequent tool operation.
3Ease of operation
If the clamping point is kept open for easy insertion, then ease of operation is improved, but connection stability is reduced
Solution Approach 1:
The patent employs a dynamic clamping mechanism where the clamping spring transitions from a tensioned ready-state to an engaged clamping-state upon conductor insertion. The push-button mechanism dynamically controls the spring's engagement, keeping the clamping point accessible for insertion while automatically securing stable connection when the conductor is present. This dynamic behavior resolves the contradiction between open accessibility and stable connection.
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
Enables quick and easy connection and disconnection of conductors, particularly suitable for fine-stranded wires, without the need for tools, reducing handling time and improving operational efficiency in various applications, including terminal blocks and PCB areas.
Implementation Method 1
a clamping spring (4), having a base leg (6), which is supported and held on an abutment (7), and a free clamping leg (8), which is connected to the base leg (6) via a bend (9)
Data Source
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AI summary
An electrical connector comprises housing (1), bus bar (3), spring (4), retaining mechanism (14), and release mechanism (5). The housing is formed from an electrically insulating synthetic plastic material. The housing contains a chamber (1a), and a conductor opening (13) communicating with chamber. The conductor opening is operable to receive a bare end portion (11) of insulated conductor. The bus bar is mounted in chamber. The bus bar has a first portion (3a) arranged adjacent the conductor opening. The spring is arranged in the chamber for biasing the conductor bare end portion into engagement with the bus bar first portion. The spring includes stationary base portion (4a) fixed within the housing chamber, and a movable first leg portion (4b) connected with one end of the base portion for movement between extended and retracted positions adjacent and spaced from the bus bar first portion, respectively. The first leg portion is normally biased towards the extended position. The retaining mechanism retains the spring movable portion in the retracted position to permit the insertion of the bare cable end into the housing chamber. The release mechanism operates the retaining mechanism to release the spring movable portion. The bare conductor end is biased by the spring first leg portion toward electrical engagement with the bus bar first portion. The spring includes connecting portion. The bus bar includes second portion orthogonally relative to the bus bar first portion. The connector includes cage, reset mechanism, and return mechanism. The retaining mechanism comprises ledge portion integral with release mechanism.