Spring-Loaded Clamping Connection with Separate Frame Element
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Solution Overview
Problem
Existing spring clamp connections for electrical conductors lack a self-supporting design that optimizes material selection for efficient current transmission and cost-effectiveness, as they often integrate materials with conflicting requirements for conductivity and resilience.
Innovation Solution
A spring clamp connection with a separate frame element that extends along the contact leg, forming a conductor receiving space behind the clamping point, allowing for the use of copper for the busbar and spring steel for the clamping spring, and inexpensive sheet steel for the frame, which is stiff and non-resilient, optimizing material usage and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single integrated structure is used for the clamping connection, then manufacturing is simpler, but material selection is limited and cannot optimize both conductivity and resilience
Solution Approach 1:
The clamping connection is divided into three separate components: a clamping spring made of spring steel for resilience, a busbar made of copper for conductivity, and a frame element made of inexpensive sheet steel for structural support. This segmentation allows each component to be optimized with the most suitable material for its specific function, resolving the contradiction between manufacturing simplicity and material selection flexibility.
2Reliability
If copper is used for the busbar to optimize current transmission, then conductivity is improved, but cost increases due to copper's high price
Solution Approach 1:
Copper is used specifically for the busbar where high electrical conductivity is required for current transmission, while the frame element and clamping spring use less expensive materials (sheet steel and spring steel respectively) where electrical conductivity is not the primary requirement. This local application of expensive material only where necessary optimizes the balance between reliability and cost.
3Strength
If spring steel is used for the clamping spring to provide resilience, then clamping force is improved, but electrical conductivity deteriorates compared to copper
Solution Approach 1:
The clamping spring is made of spring steel optimized for mechanical resilience and clamping force, while the busbar made of copper handles the electrical conductivity requirement. This functional separation allows each component to excel at its primary function without compromising the other, as the spring steel spring and copper busbar work together in the same assembly.
4Quantity of substance
If the frame element is made from inexpensive sheet steel to reduce cost, then material cost is reduced, but structural strength may be insufficient
Solution Approach 1:
The frame element, clamping spring, and busbar are merged into a coordinated assembly where the frame element provides structural support and positioning, the clamping spring provides resilient clamping force, and the busbar provides conductive path. This merging allows inexpensive sheet steel to suffice for the frame element, as its structural role is complemented by the stronger spring steel and copper components in the 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 solution provides a self-supporting structure with improved current transmission and reduced material costs by using copper for conductivity and spring steel for resilience, while the frame element's stiffness and lower strength requirements allow for cost-effective production and enhanced conductor guidance.
Implementation Method 1
The clamping spring has a contact leg, a spring arc adjoining the contact leg, and a clamping leg adjoining the spring arc. The clamping leg has a clamping edge for forming a clamping point with the adjacent busbar for clamping an electrical conductor.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A spring-loaded clamping connection (1) for clamping electrical conductors is described, said spring-loaded clamping connection having a clamping spring (2) and a bus bar (6). The clamping spring (2) has a contact limb (3), a spring arc (4) adjoining said contact limb (3) and a clamping limb (5) adjoining said spring arc (4). The clamping limb (5) has a clamping edge (12) for forming a clamping point with the adjacent bus bar (6) for a conductor to be clamped. The spring-loaded clamping connection (1) also has a frame element (7) which is a part separate from the clamping spring (2) with the bus bar (6) and which has a base portion (10), a curved portion (9) adjoining said base portion (10) and a retaining portion (8) adjoining said curved portion (9) and spaced from the base portion (10). The contact limb (3) of the clamping spring (2) is secured to the retaining portion (8). The retaining portion (8) extends in the extension of the direction of extension of the contact limb (3). The curved portion (9) limits, in the insertion direction (L) for a conductor to be clamped behind the clamping point, a conductor-accommodating chamber (14) for accommodating a free end of an electrical conductor. The base portion (10) extends from the curved portion (9) toward the free end of the base portion (10) counter to the insertion direction (L) for an electrical conductor to be clamped.