Spring-Loaded Terminal With Separate Retainer
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Solution Overview
Problem
Existing screwless electrical terminal assemblies are costly due to the expensive materials and complex manufacturing processes required for forming spring retainers as part of the current bars, and they are difficult to assemble.
Innovation Solution
A connector block design featuring a spring terminal with a separate, low-cost metal spring retainer that is not integral with the current bar, allowing for easier assembly and reduced material costs, where the spring is compressed between the current bar and the spring retainer, with abutment surfaces engaging to resist movement and distribute spring force effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spring retainer is formed as part of the current bar, then the electrical connection is maintained, but the material cost and manufacturing cost increase significantly
Solution Approach 1:
The spring retainer is separated from the current bar into a distinct component. The current bar remains as the electrical conductor while the spring retainer is a separate metal plate component that provides spring retention functionality. This segmentation allows each component to be optimized independently for its specific function, reducing overall manufacturing cost while maintaining electrical connection reliability.
Solution Approach 2:
The spring retention function is extracted from the current bar and implemented through a separate spring retainer component. This extraction eliminates the need to form expensive spring retainers from costly electrically conductive material, as the retainer can be made from lower-cost metal plate material while the current bar continues to provide the electrical conduction path.
2Stability of the object's composition
If the spring retainer is formed as part of the current bar, then the structure is integrated, but the assembly complexity and time increase
Solution Approach 1:
By segmenting the spring retainer from the current bar, the assembly process is simplified. The spring retainer can be pre-formed as a metal plate component and then easily attached to the current bar, reducing assembly complexity and time compared to forming an integrated structure through complex manufacturing processes.
3Reliability
If a U-shaped member is used to compress the spring, then the spring is retained, but the material cost increases due to the large component size
Solution Approach 1:
The spring retention function is extracted from a large U-shaped member and implemented through a compact spring retainer component. This extracted design achieves the same spring retention functionality using significantly less material, reducing material cost while maintaining reliable spring compression and retention.
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 reduces manufacturing costs, simplifies assembly, and allows for the use of low-cost materials like steel for the spring retainer, while maintaining effective electrical connections and reducing the load on housing components.
Implementation Method 1
The spring terminal utilizes a compressed spring that generates a spring force pressing the wire conductor against the current bar to form the electrical connection therebetween
Data Source
AI summary
An electrical terminal or spring terminal for forming an electrical connection between a wire conductor and a current bar includes a spring and a spring retainer, the spring retainer not integral with the spring and not integral with the current bar. Engageable abutment surfaces on the spring retainer and the current bar cooperate to transfer spring force to the current bar.