Spring Terminal Insulating Apron for Safe Conductor Engagement
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Solution Overview
Problem
Existing electrical terminal designs for distribution cabinets face issues with maintaining reliable electrical contact and safety during conductor installation and removal, as they often require power cutoffs, use of non-conductive tools, and complex mechanisms, which can lead to accidents and increased manufacturing complexity.
Innovation Solution
A spring terminal with an insulating apron that covers the operating face of the spring, providing a simple and inexpensive solution by using a hinged or independently supported apron to protect the spring and facilitate tool operation without modifying the spring's structure, allowing for safe and efficient conductor engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating part is mounted on the case in front of the spring, then safety is improved by protecting the spring and preventing accidental contact, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The insulating apron is integrated directly into the insulating case as a single molded piece, eliminating the need for separate insulating components. This merging approach provides safety protection while avoiding additional assembly steps and reducing overall device complexity.
Solution Approach 2:
The insulating case serves multiple functions simultaneously: it provides mechanical housing for the spring mechanism, electrical insulation to prevent accidental contact, and structural support for the terminal. This multi-functionality reduces the need for separate protective components.
2Reliability
If push buttons or levers made of dielectric material are used to actuate the spring, then safety is improved by providing insulation during operation, but device complexity increases and the mechanism becomes cumbersome
Solution Approach 1:
The insulating protective function is extracted from the operational actuation mechanism. Instead of requiring insulated push buttons or levers, the spring is accessed through an opening in the insulating case, which provides insulation without interfering with the simple pressing operation.
Solution Approach 2:
The insulating case acts as an intermediary structure that provides safety protection while allowing direct access to the spring through an opening. This mediator approach maintains safety without requiring complex insulated actuation mechanisms.
3Reliability
If overmolding is used to provide insulation on the spring, then safety is improved by covering the conductive parts, but the spring's characteristics are modified due to temperature rise and mechanical stresses
Solution Approach 1:
The insulating protection is segmented into a separate insulating case and insulating apron components rather than being integrated through overmolding. This segmentation prevents thermal and mechanical interaction between the insulating material and the spring, preserving the spring's elastic characteristics while providing safety insulation.
4Stability of the object's composition
If a rigid pocket structure is used to receive and pivot the spring, then operational stability is improved, but manufacturing complexity increases and the pocket is prone to tearing during maneuvers
Solution Approach 1:
The insulating apron is designed as a thin, flexible component that covers the spring's operating face. This thin-film approach provides sufficient protection and guidance for spring operation without the manufacturing complexity and tearing risks associated with thick rigid pocket structures.
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 simplifies manufacturing, enhances safety by reducing the risk of accidents, and maintains the spring's characteristics while providing effective electrical insulation and easy operation, ensuring reliable contact without the need for complex mechanisms or power cutoffs.
Implementation Method 1
The spring exerts a constant application force as the screws loosen and require re-tightening periodically
Implementation Method 2
A spring terminal with an insulating apron that covers the operating face of the spring, providing a simple and inexpensive solution by using a hinged or independently supported apron to protect the spring and facilitate tool operation
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to an electrical terminal comprising a housing made of insulating material containing a flat metal spring (2) shaped into a loop having a contact face (2A) intended to bear against the bare end of an electrical conductor and an operating face (2B) accessible to a tool engaged through a window (4) of the housing to elastically deform the spring in order to move the contact face (2A) and engage the electrical conductor. This electrical terminal is characterized in that an apron (5) made of insulating material is, by means (6) of fastening, held on the spring to cover the operating face of said spring, said apron being independent of the housing and simply resting on it.