Rail Terminal Wire Connector Segmentation for Rigidity and Heat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rail-type electrical terminals face challenges in manufacturing efficiency due to complex structures, high waste material yield, and the trade-off between electrical conductivity and rigidity, with inadequate heat dissipation and stability in the connection of conductive wires.
Innovation Solution
A conductive wire connection structure featuring a U-shaped support main body and C-shaped wire connector, assembled with a metal leaf spring, which simplifies manufacturing, enhances rigidity, and improves heat dissipation by allowing secure assembly and positioning of the metal leaf spring, ensuring stable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive support is made of copper material with good electrical conductivity, then electrical conductivity is improved, but rigidity or hardness becomes relatively low and cannot effectively restrict the motion of the metal leaf spring
Solution Approach 1:
The conductive support is divided into two separate components: a conductive support body made of copper or copper alloy for electrical conductivity, and a wire connector made of steel or iron for rigidity. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
The invention uses composite material construction by combining copper-based materials (for conductivity) with steel/iron materials (for rigidity) in the wire connector. This creates a system that achieves both good electrical conductivity and high rigidity through material composition rather than relying on a single material.
2Reliability
If the conductive support structure is complicated to ensure proper metal leaf spring restriction, then reliability is improved, but manufacturing becomes troublesome and time-consuming with high waste material yield
Solution Approach 1:
By separating the conductive support into a simple support body and a distinct wire connector component, the design achieves proper metal leaf spring restriction through the wire connector's specific structure rather than through overall complexity. This modular approach simplifies manufacturing while maintaining functional reliability.
Solution Approach 2:
The wire restriction function is extracted and concentrated into the dedicated wire connector component, which is specifically designed to hold and restrict the metal leaf spring. This extraction allows the support body to remain simple while the wire connector handles the complex restriction function efficiently.
3Stability of the object's composition
If the wire connector is designed to securely hold the metal leaf spring, then operational stability is improved, but device complexity increases
Solution Approach 1:
The wire holding and restriction functions are extracted and concentrated into the dedicated wire connector component. This allows the connector to be specifically optimized for securing the metal leaf spring through features like bending portions and positioning structures, achieving operational stability without requiring the entire device to be complex.
Solution Approach 2:
The wire connector incorporates dynamic elements such as bending portions that can flexibly adapt to the metal leaf spring while maintaining secure holding. This dynamic design allows the connector to provide stable connection through controlled flexibility rather than rigid complex structures.
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 reduces waste material in manufacturing, achieves better electrical conductivity and heat dissipation, and stabilizes the connection of conductive wires, addressing the limitations of conventional terminals by simplifying the structure and improving operational stability.
Implementation Method 1
the metal leaf spring serves to press and hold the conductive wire to electrically connect therewith... the head end serves to bite the conductive wire and prevent the conductive wire from easily detaching
Implementation Method 2
The conductive support is connected with multiple wire connectors... pivotally electrically contact or connect with the grounding wire... good electrical conductivity
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A conductive wire connection structure of rail-type electrical terminal is able to reduce the yield of waste material in manufacturing, enhance heat dissipation effect and increase operational and motional stability in condition of structural simplification. The conductive wire connection structure includes a conductive support (10) mounted in an insulation case (30). The conductive support (10) is divided into two parts of a U-shaped support main body (40) and a C-shaped wi re connector (50). The wire connector (50) is assembled with a metal leaf spring (20) and disposed on the support main body (40) together with the metal leaf spring (20) for pivotally connecting with the grounding conductive wire coming from a machine or an apparatus. The wire connector (50) and the metal leaf spring (20) are respectively formed with insertion sections (523, 534, 26) for assembling the wire connector (50) with the metal leaf spring (20) to help the support main body (40) to hold the metal leaf spring (20) and prevent the metal leaf spring (20) from deflecting.