Spring Clamp Terminal Rail Extension for Secure Conductor Clamping

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Solution Overview

Problem

Existing connecting terminals face issues with spring clamp damage to the plastic housing and the risk of the spring clamp being dislodged when maximum-sized conductors are inserted, leading to unreliable operation over time.

Innovation Solution

The current rail is modified with an extension that forms a second boundary of the conductor clamping region, guiding the spring clamp and preventing it from being dislodged, while also serving as a harder material to prevent damage to the plastic housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the spring clamp is fitted inside the plastic housing by compressing it and inserting it through an opening, then the assembly process is simplified, but the spring clamp may be dislodged when maximum-sized conductors are inserted

Engineering Contradiction:

Improveassembly processVSAvoidspring clamp retention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The current rail is segmented into multiple parts: the main rail body and separate extensions. These extensions are specifically designed to fit into the housing and provide retention features that prevent spring clamp dislodgement, while the main rail body remains accessible for assembly. This segmentation allows the retention function to be added without complicating the overall assembly process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The extensions are pre-formed as integral parts of the current rail before assembly. The retention features (such as ledges or blocking surfaces) are already in place on the extensions, so when the current rail is assembled into the housing, the spring clamp is automatically retained without requiring additional assembly steps or modifications to the housing.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the spring clamp exerts clamping force against the plastic housing extension, then the spring clamp is guided and retained, but the spring clamp may bite into and damage the plastic surface

Engineering Contradiction:

Improvespring clamp guidanceVSAvoiddamage to plastic housing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The extension acts as an intermediary element between the spring clamp and the plastic housing. It provides a dedicated metal surface for the spring clamp to contact and exert force against, preventing direct contact between the spring clamp and the plastic housing. This intermediary metal surface is harder and more resistant to damage from the spring clamp's clamping force.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The extension is strategically positioned to provide local reinforcement and guidance exactly where the spring clamp contacts the housing. The metal material of the extension provides locally increased hardness and durability at the contact point, while the rest of the plastic housing maintains its original properties. This localized quality change prevents damage without requiring the entire housing to be made of harder material.

Inventive Principle:

Principle #3Local quality

3Reliability

If the current rail is modified with an extension to guide the spring clamp, then the spring clamp is prevented from dislodgement, but the device complexity increases

Engineering Contradiction:

Improvespring clamp retentionVSAvoidcurrent rail structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The extension is merged with the current rail as an integral part, formed from the same material and assembled as a single component. This combining approach adds the guidance and retention functionality to the current rail without requiring separate parts or additional assembly steps. The extension becomes an inherent feature of the current rail structure, minimizing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 solution ensures secure fastening and guidance of the spring clamp, preventing damage to the housing and maintaining reliable operation even with maximum-sized conductors, while enhancing the electrical connection through additional metal contact.

Implementation Method 1

a spring clamp (4) disposed in the housing (1) and configured to exert a clamping force towards the first boundary of the conductor clamping region

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11837812B2Connecting terminal to produce an electric connection

Publication Date: 2023.12.05 CONNECTWELL IND PVT LTD

AI summary

A connecting terminal (A, B) comprising: a housing (1) comprising a conductor inlet opening (8) configured to receive a conductor (9) to be clamped, the housing (1) comprising a conductor clamping region extending from the conductor inlet opening (8) in an insertion direction of the conductor (9) to be clamped; a current rail (3) disposed in the housing (1) and forming at least a first boundary of the conductor clamping region; and a spring clamp (4) disposed in the housing (1) and configured to exert a clamping force towards the first boundary of the conductor clamping region shall provides a more reliable operation over an extended period of time, in particular with maximum size conductors. To that end, the current rail (3) comprises a first extension (27) forming a second boundary of the conductor clamping region.