Electrical Terminal Wire Trap Retention Mechanism
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Solution Overview
Problem
Non-crimped electrical connections in electrical terminals often result in inadequate retention forces, leading to inadvertent withdrawal of wires and discontinuity in the electrical circuit, particularly in situations where crimping tools are not available, such as in the lighting industry.
Innovation Solution
An electrical terminal design featuring a body with a channel and a contact gripping element that extends at an angle, exerting a contact gripping force on the conductor, along with a locking portion to secure the terminal in a connector housing, allowing for reliable crimpless connections without the need for special tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If non-crimped connections are used in electrical terminals, then ease of operation is improved (no crimping tools needed), but retention force is insufficient leading to wire withdrawal
Solution Approach 1:
The contact gripping element is designed as a resilient, movable component that dynamically adjusts to apply retention force on the conductor. The element can move between engaged and disengaged positions, providing automatic retention without requiring crimping tools while maintaining sufficient holding force through its elastic properties
Solution Approach 2:
The contact gripping element utilizes changes in physical parameters (elastic deformation, resilient force) to provide retention. By incorporating a resilient material or structure, the element can deform and rebound to exert continuous retention force on the conductor, resolving the contradiction between ease of operation and sufficient retention force
2Force
If a contact gripping element extends into the channel at an angle, then contact gripping force is improved, but device complexity increases
Solution Approach 1:
The contact gripping element is segmented from the terminal body as a separate, movable component. This segmentation allows the gripping element to be independently designed with optimal angular geometry for force application while keeping the overall terminal structure simple and modular
Solution Approach 2:
The angular extension of the contact gripping element into the channel is achieved through a dynamic, resilient structure that naturally positions itself at the optimal angle during engagement. This eliminates the need for complex fixed angular mechanisms, reducing overall device complexity while maintaining effective contact gripping force
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
The design provides secure retention of electrical conductors, preventing withdrawal and ensuring reliable connections, while allowing for blind assembly and installation in either direction, reducing the risk of external features capturing elements and improving installation ease.
Implementation Method 1
The contact gripping element is resiliently moveable in a radial direction and where the insertion of the electrical conductor exerts a radial force upon the contact gripping element
Data Source
AI summary
An electrical terminal includes a body having a first end, a second end, and a channel having an axis. The channel extends at least through the first end toward the second end, the channel configured and disposed to receive an electrical conductor. A contact gripping element intermediate the first and second ends extends into the channel at an angle from the axis. The contact gripping element is associated with the body. The contact gripping element terminates at an end having a reduced thickness. The contact gripping element is configured to exert a contact gripping contact force on the electrical conductor.