Adapter Housing Structure for Modular Top-Hat Rail Mounting
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Solution Overview
Problem
Existing terminal blocks for electrical systems are limited in their application due to high production costs and inefficient use of installation space, as they are designed to be functionally different but have identical housing shapes for mounting on top-hat rails, leading to unused depth in installation spaces.
Innovation Solution
An adapter housing system with complementary connecting means for reversible connection of adapter housings and a top-hat rail fixing element, allowing multiple adapter housings with contact carriers to be connected and aligned on top-hat rails, expanding the application of existing contact carriers and utilizing previously unused space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If terminal blocks are designed with identical housing shapes for mounting on top-hat rails, then mounting compatibility is improved, but production costs increase due to small quantities of individual terminal blocks
Solution Approach 1:
The terminal block system is divided into two independent parts: a standardized adapter housing for mounting and individual contact carriers for specific functions. This segmentation allows the adapter housing to be produced in large quantities for cost efficiency while contact carriers can be customized for different applications.
Solution Approach 2:
The adapter housing serves as a universal mounting component that can accommodate multiple different contact carriers with various functions. This multi-functionality allows a single standardized housing design to support diverse terminal block applications, reducing the need to manufacture different housing shapes for each function.
2Area of stationary object
If terminal blocks are lined up next to each other on top-hat rails, then width space is optimized, but depth space is wasted
Solution Approach 1:
The adapter housing extends in the depth direction beyond the top-hat rail, creating additional usable space in the previously underutilized depth dimension. This allows contact carriers to be positioned optimally while utilizing both width and depth spaces effectively.
3Reliability
If adapter housings are connected with locking mechanisms, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is integrated directly into the adapter housing structure itself, merging the housing and locking components into a single unified part. This integration reduces the number of separate components and assembly steps while maintaining reliable locking functionality.
Solution Approach 2:
The locking mechanism is designed to automatically engage when adapter housings are connected, eliminating the need for separate manual locking operations. The complementary connecting means with locking elements perform the locking function automatically during the connection process.
Data Source
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Figure 8~9
AI summary
The invention relates to an adapter housing (1, 1', 1'', 1''') for receiving a contact insert (2, 2'), wherein the adapter housing (1, 1', 1'', 1''') has on its outer wall two connecting means, moulded on opposite one another and complementing one another, for reversibly connecting to an adapter housing (1, 1', 1'', 1''') of the same type and/or to a top-hat rail fixing element (4) and wherein the adapter housing (1, 1', 1'', 1''') has on the inserting side at least one locking means for reversibly locking the adapter housing (1, 1', 1'', 1''') to a further adapter housing (1, 1', 1'', 1'''). The invention likewise relates to a system consisting of a first adapter housing (1, 1''), with a first contact carrier (2, 9) received therein, a second adapter housing (1', 1'''), with a second contact carrier (2', 9') received therein, and a top-hat rail (11).