Electrical Terminal With Funnel Insertion And Leaf Spring Clamping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connection terminals face issues with secure clamping of electrical conductors due to inadequate conductor guidance, leading to insecure connections and complex designs with high metal content.
Innovation Solution
A compact and material-saving electrical connection terminal design featuring a channel-shaped contact frame with funnel-like conductor insertion region formed by both the contact frame and insulating material housing, along with leaf springs that form a clamping edge for secure conductor guidance and easy insertion/removal, and an integrated push element for opening the clamping point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional design with separate conductor guidance and clamping structures is used, then the conductor clamping function is achieved, but the device complexity increases and material consumption rises
Solution Approach 1:
The patent merges the conductor guidance function and clamping function into a single integrated contact frame structure. The channel-shaped contact frame with its side walls provides both guidance for the conductor and, through the integrally formed leaf springs, the clamping action. This eliminates the need for separate guidance components and reduces overall device complexity while maintaining reliable clamping.
Solution Approach 2:
The contact frame is segmented into functional zones: the channel-shaped body with side walls for guidance, the leaf springs for clamping, and the connection regions for electrical contact. This segmentation allows each part to perform its specific function efficiently within the unified structure, optimizing both guidance and clamping without requiring additional separate components.
2Strength
If a conventional design with high metal content contact frame is used, then the structural strength is sufficient, but the manufacturing cost increases and material efficiency decreases
Solution Approach 1:
The contact frame utilizes thin metal sheets stamped into complex three-dimensional shapes, including the channel-shaped body and leaf springs. This approach replaces traditional heavy-gauge metal construction with thin-walled formed sections that provide sufficient strength through geometric design rather than material quantity, significantly reducing metal consumption while maintaining structural integrity.
Solution Approach 2:
The patent changes the geometric parameters of the contact frame, creating a channel-shaped cross-section with optimized wall thicknesses and integrated leaf spring dimensions. These parameter optimizations allow the structure to achieve required strength with minimal material, improving manufacturing efficiency and reducing metal content compared to conventional solid bar or tube constructions.
3Device complexity
If inadequate conductor guidance is provided, then the device structure remains simple, but the conductor clamping security deteriorates
Solution Approach 1:
The contact frame merges guidance and clamping functions into a single integrated structure. The channel-shaped body with side walls provides conductor guidance, while the integrally formed leaf springs provide clamping force. This unified design achieves reliable conductor securing without requiring separate guidance components, maintaining structural simplicity while improving clamping security.
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
Ensures secure clamping of electrical conductors with a simple and compact design, allowing for easy conductor guidance and rapid adaptation to various requirements, while providing overload protection and cost-effective operation.
Implementation Method 1
a leaf spring in the form of a tongue, which is formed from the flat metal part and which is bent out of the plane of the flat metal part in such a way that the free end of the leaf spring forms a clamping edge
Data Source
AI summary
An electrical connection terminal provides secure clamping of an electrical conductor and at the same time has a simple structure. Simple and effective conductor guidance is achieved on account of a funnel-like conductor insertion region being composed of an insulating material housing and a contact frame. The contact frame can be of very simple, compact and material-saving design.