Wire Terminal Limiter Structure Preventing Leaf Spring Over-Bending
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Solution Overview
Problem
Conventional wire connection terminals with metal leaf springs face issues of material fatigue and instability due to over-bending caused by excessive operational forces, leading to poor holding of conductive wires and potential damage to the terminal case.
Innovation Solution
The electrical contact limiter structure features a redesigned limiter with a limitation mechanism that includes assembling sections with perforation structures and a stopper body, preventing over-bending of metal leaf springs by restricting their moving range and bending angle, thereby enhancing stability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metal leaf spring is designed without a limitation mechanism, then the structure is simple and easy to manufacture, but the metal leaf spring can be over-bent during operation causing material fatigue and reduced reliability
Solution Approach 1:
The limitation mechanism is integrated into the limiter body structure, where the stopper sections are formed as integral parts of the limiter rather than separate components. This merging approach provides over-bend protection for the metal leaf spring while maintaining manufacturing simplicity and avoiding additional assembly steps.
Solution Approach 2:
The stopper sections act as intermediary elements between the limiter body and the metal leaf spring. These stopper sections physically intervene to prevent the metal leaf spring from being over-bent during operation, thereby protecting the spring's durability without requiring complex external mechanisms.
2Object-affected harmful factors
If a conventional limiter structure is used without a limitation mechanism, then the device is easy to operate, but the metal bare end of the conductive wire can deflect the metal leaf spring and scrape or break the case
Solution Approach 1:
The protective function against case damage is merged into the limiter's structure through the stopper sections. These stopper sections are formed as integral parts of the limiter that extend to restrict the moving path of the metal leaf spring, preventing it from scraping or breaking the case during operation.
Solution Approach 2:
The stopper sections are pre-positioned within the limiter structure to establish a restricted moving path for the metal leaf spring before operation begins. This preliminary configuration prevents the spring from deflecting excessively and causing case damage during wire insertion or removal operations.
3Reliability
If the metal leaf spring is allowed to move freely without restriction, then the ease of operation is high, but material fatigue occurs due to excessive bending forces applied during frequent plug-in operations
Solution Approach 1:
The stopper sections serve as intermediary elements that mediate between the operator's insertion force and the metal leaf spring. They provide a physical barrier that prevents excessive bending while still allowing sufficient movement for wire insertion, thus protecting the spring from material fatigue without significantly impeding ease of operation.
Solution Approach 2:
The stopper sections are strategically positioned at specific locations within the limiter to provide localized restriction only where needed to prevent over-bending. This localized quality approach maintains ease of operation in other areas while providing targeted protection against material fatigue at critical points.
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 solution effectively minimizes material fatigue and breakage of metal leaf springs, ensuring stable operation and secure holding of conductive wires without increasing the terminal device's volume, facilitating easier manufacturing and operation.
Implementation Method 1
a stopper body (22) disposed on the assembling sections (21)... for restricting moving path and range of metal leaf spring
Implementation Method 2
the metal leaf spring applies an elastic force to the conductive wire to bite or hold the conductive wire together with the wire connector
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An electrical contact limiter structure of wire connection terminal has a simplified structure and is easy to operate to enhance the stability of the operation and motion of a metal leaf spring. The wire connection terminal includes conductive components mounted in the insulation case and electrical contact assembled with the conductive components. The electrical contact has a limiter (10) for receiving the metal leaf spring and restricting moving path thereof. The limiter (10) is partitioned into at least one space. A limitation mechanism (20) is assembled with the limiter (10). The metal leaf spring is mounted in the space. The wiring circuits or conductive wires coming from an apparatus can be easily directly plugged into the space of the limiter (10) to insert with the metal leaf spring. The limiter (10) and the limitation mechanism (20) cooperatively prevent the metal leaf spring from being deflected and over-bent and damaged in operation.