Electrical Terminal Clamp Guide Arm Integration

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Solution Overview

Problem

Existing electrical terminal clamps require complex fabrication due to small dimensions and often rely on insulator housings for conductor guidance, making them difficult to manufacture and use effectively.

Innovation Solution

An electrical terminal clamp design where the guide arm forming the insertion bevel is integrated into the metal contact material, allowing conductor guidance independently of an insulator housing, with a clamping mechanism that includes preloaded clamping springs and a reaction bearing for easy conductor insertion and removal, and a rectangular cross-section conductor insertion channel for improved mechanical performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulator housing is used to form the insertion bevel for conductor guidance, then the conductor can be guided into the clamping device, but the fabrication becomes complex due to high precision requirements for small dimensions

Engineering Contradiction:

Improveconductor guidanceVSAvoidfabrication complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The guide arm is merged with the contact cage structure, forming an integral metal component rather than a separate insulator housing feature. This integration eliminates the need for separate insulator fabrication with precision bevels, while maintaining reliable conductor guidance through the metal contact material itself

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulator housing material system is replaced with a metal contact cage system for the guide function. The metal contact material provides the necessary mechanical properties and guidance functionality without requiring complex insulator fabrication processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Volume of moving object

If the terminal clamp dimensions are kept small (width 3-4 mm, height 3-4 mm, length 8 mm), then the terminal clamp remains compact, but the insulator housing fabrication precision requirements increase

Engineering Contradiction:

Improveterminal clamp sizeVSAvoidinsulator housing precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The guide arm functionality is combined with the metal contact cage structure, eliminating the need for separate precision-fabricated insulator housing features. This integration maintains compact dimensions while reducing manufacturing precision requirements by using the inherently precise metal contact material for guidance

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If the guide arm is formed by the contact cage metal material, then the conductor guidance becomes independent of insulator material, but the contact cage structure becomes more complex

Engineering Contradiction:

Improveguidance independenceVSAvoidcontact cage structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The contact cage is segmented into functional zones: the guide arm portion that slopes downward to guide conductors, the horizontal portion that forms the conductor insertion channel, and the clamping portion with clamping springs. This segmentation allows each zone to perform its specific function while maintaining overall structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal contact cage material serves multiple functions: electrical conduction, mechanical clamping through spring action, and conductor guidance through the sloped guide arm. This multi-functionality eliminates the need for separate insulator housing guidance features, achieving guidance independence without significant structural complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Facilitates simpler and more effective manufacturing and use of terminal clamps, enabling resistance-free conductor insertion and removal, and automated insertion with symmetrical spring deflection for reliable clamping and easy tool access.

Implementation Method 1

a conductor clamping device that includes at least one clamping spring that is preloaded against a reaction bearing

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11482797B2Electrical connection terminal

Publication Date: 2022.10.25 BJB GMBH & CO KG

AI summary

An electrical terminal clamp includes a contact cage including a contact floor, a contact ceiling, a first contact side wall and a second contact side wall that connect the contact floor and the contact ceiling. The contact floor, the contact ceiling, the first contact side wall and the second contact side wall jointly form a conductor insertion channel. A conductor clamping device that includes at least one clamping spring that is preloaded against a reaction bearing and an insertion bevel for a conductor configured in a portion of the contact ceiling, wherein the insertion bevel is formed by a guide arm that extends from the contact ceiling in the conductor insertion direction and that is configured sloped towards the contact floor.