Self-Coupled Wire Connector With Bend Spring Sheet Clamping
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Solution Overview
Problem
Existing electrical connectors with shell or hardware restraint structures face issues such as high material requirements, increased costs, and reduced reliability due to the need for riveting or welding, which complicates manufacturing and can lead to deformation under high temperatures, affecting connection effectiveness.
Innovation Solution
A self-coupled wire connector design using a bend spring sheet and conductor sheet, where the spring sheet and conductor sheet are assembled in a coupling space within the main body, with deformable portions and a tooth-shaped structure to form a coupling gap for clamping the wire, eliminating the need for riveting or welding and enhancing the self-coupling effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the main body bears all forces generated by spring sheet deformation, then connection function is achieved, but material requirements and manufacturing cost increase
Solution Approach 1:
The spring sheet is segmented into multiple independent pressing units, each capable of deforming independently to press wires. This segmentation distributes the force-bearing function from the main body to the spring sheet itself, reducing the main body's structural complexity while maintaining connection reliability
Solution Approach 2:
The spring sheet performs self-service by generating and transmitting its own deformation forces to press wires, without requiring the main body to provide restraint structures. The spring sheet's own elasticity serves as the force source, eliminating the need for complex main body restraint mechanisms
2Strength
If riveting or welding is used to fix conductor sheet on spring sheet, then firm connection is achieved, but manufacturing process complexity and cost increase
Solution Approach 1:
The conductor sheet and spring sheet are merged into a single integrated component with unified material composition. This eliminates the need for separate riveting or welding processes to join different materials, simplifying manufacturing while maintaining joint strength through continuous material structure
Solution Approach 2:
Both the spring sheet and conductor sheet use the same or similar metal material with comparable mechanical properties, enabling direct forming and assembly without requiring specialized riveting or welding processes. The homogeneous material property allows simple stamping and bending operations instead of complex joining processes
3Ease of manufacture
If spring sheet has simple structure for riveting implementation, then manufacturing is easier, but pressure decomposition capability is reduced
Solution Approach 1:
The spring sheet is divided into multiple independent pressing units, each with its own deformable portion and wire pressing portion. This segmentation enables effective pressure decomposition as each unit independently deforms to press a specific wire, while maintaining simple manufacturing through standardized repeating structures
Solution Approach 2:
The spring sheet incorporates deformable portions that can dynamically adjust their shape and position during wire insertion. This dynamic capability allows effective pressure decomposition through elastic deformation, while the simple flat sheet structure remains easy to manufacture using standard stamping processes
4Ease of operation
If conductor sheet is fixed at specific position in advance, then assembly is simplified, but contact area flexibility is reduced
Solution Approach 1:
The conductor sheet and spring sheet are merged into a single integrated component where the conductor portion is formed as an integral part of the spring sheet. This merging simplifies assembly by eliminating separate positioning steps while maintaining contact area flexibility through the spring sheet's deformable structure that adapts to wire positions
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 ensures a firm and reliable connection while reducing manufacturing costs and complexity, improving the flexibility and durability of the connector by allowing reasonable force decomposition and avoiding stress concentrations that can lead to metal fatigue.
Implementation Method 1
each wire pressing unit includes a middle wire pressing portion and two deformable portions respectively located on two sides of the wire pressing portion... the deformable portions resist against the inside of the coupling space
Implementation Method 2
the tooth-shaped structure and the wire pressing portion cooperate with each other to form a coupling gap for clamping a wire end
Data Source
AI summary
The present disclosure relates to the technical field of electrical connection, in particular to a self-coupled wire connector using a bend spring sheet and conductor sheet, including a main body, a spring sheet and a conductor sheet; a coupling space for accommodating the spring sheet and the conductor sheet is formed inside the main body; a wire plugging hole passing through the coupling space is formed in the main body; the spring sheet and the conductor sheet are assembled in the coupling space, and are kept in a self-coupling state through the coupling space; a wire presses against the spring sheet and the conductor sheet to force the spring sheet and the conductor sheet to be self-coupled.