Spring-Clamp Contact Assembly With Integrated Insertion Channel
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Solution Overview
Problem
Existing contact assemblies for electrical conductor connections are not optimized for miniaturization and smooth outer contours, which is crucial for applications as contact inserts in conductor connection terminals.
Innovation Solution
The contact assembly design combines conductor rail and spring components to form the conductor insertion channel, allowing for a miniaturized and cost-effective solution with a smooth outer contour, where the conductor rail component and spring component are mechanically connected without additional fastening measures, and the spring component features a U-shaped curved section for efficient clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the contact assembly uses separate components for conductor rail and spring with traditional fastening methods, then the assembly is easier to manufacture, but the overall size increases and the outer contour becomes less smooth
Solution Approach 1:
The conductor rail component and spring component are merged into a single integrated structure where the spring component is formed as an integral part of the conductor rail component. This eliminates the need for separate fastening measures and reduces the overall number of parts, directly addressing the contradiction by minimizing assembly complexity while achieving compact dimensions.
Solution Approach 2:
The spring component is nested within or alongside the conductor rail component in such a way that one component is partially contained within or adjacent to the other, forming a compact arrangement. This nesting approach allows both components to occupy shared space, reducing the overall volume while maintaining manufacturability through integrated forming processes.
2Shape
If additional fastening measures are used to connect conductor rail and spring components, then the connection is more reliable, but the outer contour smoothness deteriorates and device complexity increases
Solution Approach 1:
By merging the conductor rail and spring components into a single integrated part, the patent eliminates fastening elements that would disrupt the outer contour. The integrated structure ensures a smooth surface suitable for recessed mounting while maintaining reliable mechanical connection through the inherent structural integration of the spring within the conductor rail body.
Solution Approach 2:
The spring component is positioned and formed such that it provides localized spring function without protruding or creating surface irregularities. The integration allows the spring to be embedded or closely coupled to the conductor rail in a way that maintains smooth external surfaces while ensuring reliable mechanical connection at the functional interface.
3Volume of moving object
If the contact assembly is miniaturized by integrating components, then the size is reduced, but the manual actuating force required increases
Solution Approach 1:
The nested arrangement of the spring component within or alongside the conductor rail component creates an efficient spatial configuration that maximizes spring leverage within a compact volume. This nesting allows the spring to act directly on the conductor insertion channel with minimal mechanical loss, reducing the actuating force required despite the miniaturized size.
Solution Approach 2:
The spring component is formed with a U-shaped curved section that provides optimal elastic deformation characteristics. The curved geometry allows the spring to store and release energy efficiently, providing sufficient clamping force with minimal actuating force in the compact integrated structure.
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 enables a miniaturized connector with reliable clamping and electrical contact, allowing for a compact and efficient connection terminal with reduced manual actuating force, suitable for use in conductor connection terminals without the need for additional tools.
Implementation Method 1
a spring component with a clamping spring, wherein the spring component is made of a spring material, is mechanically connected to the conductor rail component and is set up for clamping an electrical conductor via the clamping spring
Data Source
AI summary
A contact assembly for connecting an electrical conductor via a spring-loaded clamping. A conductor rail component is made of a conductor rail material and designed as a profile component angled parallel to the conductor insertion direction of an electrical conductor into the contact assembly, at least in sections. A spring component with a clamping spring is made of a spring material and is mechanically connected to the conductor rail component and is set up for clamping an electrical conductor via the clamping spring at a clamping point on the conductor rail component. A conductor insertion opening and a conductor insertion channel are connected to the conductor insertion opening, through which an electrical conductor inserted at the conductor insertion opening can be routed to the clamping point. The conductor insertion channel is formed from at least one first wall, a second wall, and a third wall.