Side-Loaded Spring Clamp Electrical Terminal Assembly
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Solution Overview
Problem
Copper electrical terminals in high-power applications face reduced spring force due to temperature increase, leading to decreased contact area and conductivity, and size limitations hinder further spring force enhancement.
Innovation Solution
An electrical terminal assembly with a base and a spring clamp, where the spring clamp is side-loaded onto the base, allowing for a compact design that maintains spring force over a wide temperature range, using materials like stainless steel for the clamp and copper alloys for the base, with a locking feature to secure the clamp in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper terminals are used for high power applications, then good electrical conductivity is achieved, but spring force is lost due to temperature increase
Solution Approach 1:
The terminal is divided into two separate components: a copper base providing electrical conductivity and a steel spring clamp providing spring force. This segmentation allows each component to be optimized for its specific function without the trade-offs of using a single material for both purposes.
Solution Approach 2:
The invention uses a composite structure combining copper (for electrical conductivity) and steel (for spring force retention at high temperatures). This composite approach allows the terminal to maintain both good electrical conductivity and stable spring force across a wide temperature range.
2Volume of moving object
If terminal size is reduced to meet size limitations, then compact design is achieved, but spring force cannot be further increased
Solution Approach 1:
By separating the conductive base from the spring clamp, the design allows the spring clamp to be optimized for force retention in a compact form, while the base provides the necessary electrical pathway. This segmentation enables achieving both compact size and adequate spring force.
3Strength
If spring clamp is mounted onto base during assembly, then secure connection is achieved, but undue stress or deformation is applied to base and spring clamp
Solution Approach 1:
Instead of mounting the spring clamp onto the base in the conventional direction, the spring clamp is inserted onto the base from the opposite direction. This inverted assembly approach reduces the risk of applying undue stress or causing deformation to either component during assembly.
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 assembly maintains strong clamping force and electrical conductivity across varying temperatures, reducing terminal size while ensuring high power handling capabilities, and the side-loaded assembly minimizes stress during assembly, preventing deformation.
Implementation Method 1
A spring clamp has a clamp base and first and second opposed spring beams extending from the clamp base in the first direction and disposed over the first and second base beams, biasing the first and second base beams toward one another.
Data Source
AI summary
An electrical terminal assembly includes a base having a body including a first end and a second end. First and second opposed base beams extend from the first end of the body in a first direction. A spring clamp has a clamp base and first and second opposed spring beams extending from the clamp base in the first direction and disposed over the first and second base beams biasing the first and second base beams toward one another. The body of the base is configured to permit the spring clamp to be inserted onto the base in a second direction normal the first direction.