Terminal Contact Assembly with Direct Leaf Spring Locking
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Solution Overview
Problem
Conventional electrical connection terminals face issues with the metal leaf spring and conductive support detaching due to deformation of the plastic housing, leading to security problems and inconvenient assembly.
Innovation Solution
The electrical contact assembly structure features a conductive support with a connected section and a metal leaf spring with a connection section that can be directly assembled, using a plug plate with shoulder and stop sections to securely attach to the conductive support without external housing, ensuring stable connection through a socket and plug mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the metal leaf spring is simply located by the internal structure of the plastic housing, then the device complexity is reduced, but the reliability deteriorates due to detachment from conductive support
Solution Approach 1:
The patent merges the metal leaf spring and conductive support into an integrated assembly where the connection section of the metal leaf spring is directly connected to the conductive support. This integration ensures that when the plastic housing deforms, both components move together as a unit, preventing relative displacement and detachment, thereby maintaining reliable electrical connection while keeping the overall structure relatively simple.
Solution Approach 2:
The patent implements preliminary action by providing pre-formed connection sections on the metal leaf spring and corresponding connected sections on the conductive support before assembly. These connection structures are designed in advance to ensure proper alignment and secure attachment, preventing future detachment issues without requiring complex additional structures during operation.
2Ease of manufacture
If the conductive leaf spring and current bar are connected without a connection structure, then the ease of manufacture is improved, but the reliability deteriorates due to relative displacement and detachment
Solution Approach 1:
The patent applies segmentation by dividing the connection system into distinct functional sections: the connection section of the metal leaf spring, the connected section of the conductive support, and the abutment section for wire contact. This segmentation allows each part to be manufactured independently with optimized structures while ensuring they assemble together reliably, maintaining both ease of manufacture and connection stability.
3Reliability
If the metal leaf spring is compressed and rotated to fasten into the conductive support, then the connection reliability is improved, but the ease of operation deteriorates due to troublesome assembly process
Solution Approach 1:
The patent implements self-service through the elastic properties of the metal leaf spring. The spring's natural elasticity allows it to self-align and self-secure into the conductive support without requiring external compression or rotation operations. The elastic deformation during assembly automatically creates a secure fit, improving ease of operation while maintaining connection reliability.
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 solution simplifies the manufacturing and assembly process while maintaining a secure connection between the metal leaf spring and conductive support, preventing detachment and enhancing operational reliability.
Implementation Method 1
The abutment section serves to elastically abut against a conductive wire
Implementation Method 2
the metal leaf spring can be connected with the conductive support... the conductive wire is electrically connected with the conductive support
Data Source
Figure 1
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AI summary
An electrical contact assembly structure of terminal device includes a conductive support and a metal leaf spring. A connected section is disposed on the conductive support. A curved section is formed at a middle portion of the metal leaf spring. A connection section and an abutment section are respectively disposed at two ends of the metal leaf spring. The connection section can be directly assembled with the connected section. The abutment section serves to elastically abut against a conductive wire, which extends into the conductive support from outer side, whereby the conductive wire is electrically connected with the conductive support. The manufacturing and assembling processes of the electrical contact assembly structure are facilitated. In addition, the metal leaf spring can keep securely connected with the conductive support without the location of an external plastic housing.