Screwless Terminal Clamping Spring Extension
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Solution Overview
Problem
Conventional screwless connection terminals experience high electrical contact resistance and heat generation when handling high currents, leading to inefficiencies and safety risks due to limited current-carrying capacity and inadequate heat dissipation.
Innovation Solution
The introduction of a screwless connection terminal with a clamping spring featuring a conductor clamping extension that increases the clamping surface area, combined with a contact element equipped with cooling surfaces and a clamping spring ring for enhanced heat transfer and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional clamping springs with limited clamping surface area are used, then the device complexity remains low and ease of manufacture is good, but electrical contact resistance increases and heat generation worsens when handling high currents
Solution Approach 1:
The clamping spring is segmented into multiple functional regions: the original clamping leg for mechanical attachment, the conductor clamping extension for electrical contact, and the cooling surface elements for thermal management. This segmentation allows each region to be optimized for its specific function while working together as an integrated component.
Solution Approach 2:
The clamping spring is extended from a two-dimensional flat structure into a three-dimensional configuration with the conductor clamping extension protruding perpendicular to the clamping leg. This dimensional change creates additional contact surface area without significantly increasing the overall footprint of the component.
2Temperature
If the clamping surface area is increased to reduce electrical contact resistance, then heat dissipation improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The cooling surface elements are merged directly into the clamping spring structure rather than being separate components. The extension itself serves dual purposes: providing electrical contact surface area and providing thermal conduction path to the clamping leg, eliminating the need for separate cooling components.
Solution Approach 2:
The material properties of the clamping spring are optimized for thermal conduction, and the geometry of the cooling surfaces is parameterized to maximize heat dissipation efficiency. The extension thickness and surface area are carefully controlled to balance electrical contact resistance reduction with manufacturing feasibility.
3Reliability
If conventional clamping springs are used without additional extensions, then ease of operation is good and device complexity is low, but current-carrying capacity is limited due to high contact resistance
Solution Approach 1:
The conductor clamping extension acts as an intermediary element between the conductor and the contact element. It provides a dedicated electrical contact path that improves current flow while the cooling surfaces facilitate heat removal from this critical interface, thereby enhancing overall reliability for high current applications.
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 electrical contact resistance, improves heat dissipation, and increases the current-carrying capacity while ensuring a secure and efficient mechanical connection, minimizing the risk of overheating and damage.
Implementation Method 1
The clamping spring (5) has a clamping opening (6) which is to be brought into a prestressed release position and into which the conductor (2) to be connected is pushed
Implementation Method 2
the contact element (1) with a connection section (3) having a contact surface (4) for making contact with the conductor (2)
Implementation Method 3
the contact element (1) with at least one cooling surface element to improve the heat transfer to the environment
Implementation Method 4
a clamping spring ring (25) which serves to increase the clamping connection force
Data Source
Figure 1A~1D
Figure 2A~2E
Figure 3A~3E
AI summary
The invention relates to a screwless terminal block with a contact element (1) to which a conductor (2) is to be electrically connected, with a connection section (3) and a contact surface (4), with a clamping spring (5) by means of which the conductor (2) is to be clamped to the contact surface (4) of the contact element (1), wherein the clamping spring (5) has a clamping leg (7), a contact leg (8) and a clamping leg (9), wherein a clamping opening (6) is formed in the clamping leg (7) through which the conductor (2) is to be guided, the contact leg (8) of the clamping spring (5) rests against the contact element (1), the clamping leg (9) of the clamping spring (5) connects the contact leg (8) to the clamping leg (7), wherein the clamping leg (7) further comprises a conductor clamping extension (10) with a clamping surface (11) which is oriented substantially parallel to the contact surface (4) of the contact element (1).wherein the conductor (2) to be connected is to be clamped between a surface section of the clamping surface (11) of the conductor clamping extension (10) and the contact surface (4) of the contact element (1).