Tapered Receiving Area for Secure Conductor Clamping
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Solution Overview
Problem
Existing contacting devices struggle to reliably and easily connect electrical conductors with larger cross sections to coil bodies, as the conductor's size often exceeds the outer dimensions of the contact pins, making secure and efficient connection challenging.
Innovation Solution
A contacting device with a holder featuring a tapered receiving area that deforms the electrical conductor upon insertion, providing a clamped fit without bending the holder, and includes projections to prevent slippage, allowing for secure connection in both x and z directions, enabling connection of conductors with cross sections up to 1.6 mm^2.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the electrical conductor has a larger cross section than the contact pins, then the conductor can carry higher current, but it becomes difficult to connect securely to the contacting device
Solution Approach 1:
The receiving area is designed with a tapered geometry where the opening dimensions are larger than the bottom dimensions, allowing the conductor to be inserted easily and then deformed to create a clamped fit. This parameter change in the receiving area geometry enables secure connection of large cross-section conductors without bending the holder.
Solution Approach 2:
The receiving area is divided into distinct functional zones: an opening for insertion, tapered side walls for deformation, and a bottom surface for clamping. This segmentation allows each zone to perform its specific function in securing the conductor, enabling reliable connection of thick conductors.
2Reliability
If the holder is designed to clamp the electrical conductor securely, then connection reliability improves, but the holder may require bending which complicates the structure
Solution Approach 1:
Instead of bending the holder to clamp the conductor, the conductor is deformed by the rigid tapered receiving area. The inversion is in which component undergoes deformation - the conductor rather than the holder - simplifying the holder structure while maintaining secure clamping.
Solution Approach 2:
The tapered geometry of the receiving area creates increasing clamping force as the conductor is inserted, with the side walls angled at 5° to 15° to the perpendicular. This parameter design provides secure clamping without requiring the holder to be bent or deformed.
3Reliability
If the receiving area is designed to deform the conductor cross section for clamping, then connection reliability improves, but the insertion process becomes more difficult
Solution Approach 1:
The receiving area is segmented with a larger opening dimension that facilitates easy insertion, followed by tapered side walls that gradually deform the conductor. This segmentation allows the insertion and deformation processes to occur in sequence, maintaining ease of operation while achieving reliable clamping.
Solution Approach 2:
The opening of the receiving area is designed with dimensions larger than the conductor cross-section, allowing easy insertion. As the conductor is pushed in, the tapered side walls (angled 5° to 15°) gradually deform the conductor material, creating a clamped fit without making insertion difficult.
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
Enables reliable and easy handling of electrical conductor connections, allowing for secure attachment of stranded or enameled wires to contact pins, even when the conductor's cross section exceeds the pin size, facilitating efficient assembly of inductive components like coils or transformers.
Implementation Method 1
The receiving area tapers between the entry opening and the bottom surface in such a way that when the electrical conductor is inserted into the receiving area, a cross section of the electrical conductor is deformed, as a result of which the electrical conductor is held in a clamped fit on the connection contact
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
The invention relates to a contacting device (100) for connecting an electrical conductor (11), which comprises a connection contact (101) for fastening the electrical conductor (11) to the contacting device (100), wherein the connection contact (101) has a retainer (110). The retainer (110) has an accommodating region (112) for accommodating the electrical conductor (11). The accommodating region (112) is tapered between an inlet opening (E112) and a bottom surface (B112) of the accommodating region (112) in such a way that a cross-section (A11) of the electrical conductor (11) is deformed when the electrical conductor (11) is inserted into the accommodating region (112), whereby the electrical conductor is retained on the connection contact (101) in a clamping seat. Thus, the electrical conductor (11) can be fastened to the connection contact (101) without bending of the retainer (110).