Spring Force Terminal Block Contact Insert Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing spring-loaded connection terminals require complex assembly and high material costs when clamping large electrical conductors, as they need significant spring force, which complicates the manufacturing and assembly process.
Innovation Solution
A contact insert design where the insertion spring is integrated with the holding frame, allowing for a one-piece metal construction that simplifies assembly and reduces the number of components, using a clamping spring with an additional insertion spring to provide high clamping force without the need for additional mounting, and utilizing resilient flat material for efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the clamping spring is made from thicker strip material to provide sufficient clamping force for large conductors, then the clamping force is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The spring force system is divided into two independent springs: a clamping spring for gripping the conductor and an insertion spring for providing additional force. This segmentation allows each spring to be optimized separately, with thinner material that is easier to manufacture while collectively providing the required total clamping force for large conductors.
Solution Approach 2:
The insertion spring is integrated into the holding frame as a one-piece construction, merging the frame and spring into a single component. This reduces the number of parts, simplifies assembly, and lowers manufacturing complexity while maintaining the high clamping force capability through the combined action of both springs.
2Adaptability or versatility
If multiple separate components are used for the contact insert, then the functionality is improved, but the assembly complexity and production cost increase
Solution Approach 1:
The holding frame and insertion spring are merged into a single one-piece metal component, eliminating the need for separate assembly of these parts. This reduces the total number of components, simplifies the assembly process, and reduces production costs while maintaining all necessary functionalities through the integrated design.
Solution Approach 2:
The integrated holding frame with built-in insertion spring serves multiple functions: it provides structural support, delivers insertion force, and houses the clamping spring mechanism. This multi-functionality reduces the need for separate components, thereby reducing assembly complexity while maintaining comprehensive functionality.
3Reliability
If copper material is used extensively for high conductivity, then the electrical connection quality is improved, but the material cost increases
Solution Approach 1:
The spring material thickness is optimized to a range of 0.4-0.8mm, balancing mechanical performance and material usage. This parameter optimization allows the use of thinner, less expensive materials while maintaining sufficient spring force and electrical conductivity through the optimized spring geometry and contact area.
Solution Approach 2:
The contact insert uses a combination of different materials optimized for their respective functions: the holding frame and springs use resilient material with appropriate conductivity, while copper is used only where essential for electrical connection. This composite approach reduces overall copper consumption while maintaining reliable electrical connections through strategic material placement.
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 simplifies assembly, reduces production costs, and provides a high spring force for clamping large conductors with minimal material usage, ensuring reliable electrical connections with low voltage drop and quick wiring capabilities.
Implementation Method 1
at least one clamping spring (4) suspended in the holding frame (2), with an insertion spring (5) acting to increase the clamping force of the clamping spring (4)
Implementation Method 2
The clamping spring and/or the insert spring can be made of resilient flat material or strip material which has a relatively small thickness
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a contact insert of a spring-loaded terminal block with at least one retaining frame and at least one clamping spring suspended in the retaining frame, wherein at least within a region surrounded by a spring arc of the clamping spring, an insert spring acting to reinforce the clamping force of the clamping spring is arranged, the insert spring being formed integrally with the retaining frame. The invention further relates to a spring-loaded terminal block with at least one such contact insert.