Spring Clip for Vibration-Resistant Electrical Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connections using screw constructions for highly conductive materials are prone to loosening due to vibrations and handling errors, leading to instability and safety concerns.
Innovation Solution
A spring clip with a socket section, snap-fit section, and bending section that forms a mechanical and electrical connection between contact partners, reducing clamping force and enhancing elasticity to prevent loosening, while allowing for secure and easy assembly without the need for torque or angular positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw constructions are used to connect highly conductive materials, then electrical connection is achieved, but the connection is prone to loosening due to vibrations and handling errors
Solution Approach 1:
The patent transitions from static screw connections to dynamic spring clip connections that automatically adapt to load conditions. The spring element provides continuous contact pressure that self-adjusts during assembly and operation, eliminating the need for precise torque control while maintaining reliable electrical connection under vibration and handling conditions.
Solution Approach 2:
The patent changes the connection mechanism from friction-based screw fastening to elastic deformation-based spring clipping. By utilizing the elastic properties of the spring element and its ability to undergo reversible deformation, the connection achieves both ease of assembly (no torque required) and high reliability (maintained contact pressure under vibration).
2Reliability
If tensioning force is increased to prevent loosening, then connection stability improves, but material setting occurs which reduces tension and allows loosening under extreme loads
Solution Approach 1:
The spring element is pre-loaded during assembly to apply immediate contact pressure that prevents loosening from the start. This beforehand cushioning through elastic pre-tensioning compensates for potential loosening forces before they can cause damage, while the elastic material prevents permanent deformation even under extreme loads.
Solution Approach 2:
The patent utilizes the elastic properties of the spring element to dynamically adjust the tensioning force. The spring can undergo large elastic deformations that absorb extreme loads without causing material setting, while maintaining sufficient contact pressure for reliable electrical connection under normal operating conditions including vibration and handling.
3Ease of operation
If spring clip with reduced clamping load is used, then connection of soft highly conductive materials is achieved, but connection strength may be reduced
Solution Approach 1:
The patent optimizes the spring element parameters (wire diameter, coil diameter, number of active coils, material properties) to achieve the right balance between contact pressure and connection strength. The elastic modulus and geometric parameters are selected to provide sufficient clamping force for soft highly conductive materials while maintaining adequate connection strength for the application.
Solution Approach 2:
The spring clip provides dynamic contact pressure that adapts to the softness of the conductive materials. The elastic deformation of the spring allows it to conform to material variations while maintaining consistent electrical contact, achieving both ease of assembly and adequate connection strength for soft materials.
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 spring clip provides a reliable, secure, and compact electrical connection that resists vibration-induced loosening and handling errors, enhancing safety and simplifying assembly processes compared to traditional screw contacts.
Implementation Method 1
a bending section between the socket section and the snap-fit section, wherein the bending section can be bent between a relaxed state and a tensioned state
Data Source
AI summary
A spring clip for securing contact partners is presented, wherein the contact partners can be connected electrically and in a form fitting manner. The spring clip has a socket section with at least one guide lug for a form fitting connection to a first contact partner, a snap-fit section with at least one snap-fit hook that snaps into a second contact partner, and a bending section between the socket section and the snap-fit section. The bending section can be bent thereby, between a relaxed state and a tensioned state.