Adjustable Terminal Assembly for Multiple Electrical Conductors
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Solution Overview
Problem
Conventional multiple connection terminal architectures for electrical conductors in circuit breakers are inflexible, prone to connection loosening, and inefficient in accommodating varying conductor sizes, leading to unreliable electrical contact and increased voltage drops, while also being space-consuming and costly to manufacture.
Innovation Solution
A terminal assembly featuring a protection plate with resilient portions and a metallic part, which provides adjustable housing for multiple conductors, ensuring uniform gripping and reliable contact through a fastening mechanism that transfers tightening load directly to the metallic part, and includes ingress protection features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional single tunnel terminal architecture is used with fixed screw position, then the connection structure is simple, but connection loosening occurs and the quality of electrical contact deteriorates
Solution Approach 1:
The patent applies the dynamics principle by making the screw position adjustable rather than fixed. The screw can move vertically along the clamp to adapt to different conductor combinations (cable above busbar or busbar above cable), ensuring optimal contact pressure and preventing connection loosening while maintaining electrical contact quality.
Solution Approach 2:
The patent changes the positional parameter of the screw along the clamp's vertical axis. By allowing the screw to occupy different positions (upper, middle, or lower) based on the conductor arrangement, the system adapts to various connection scenarios without compromising electrical contact quality or requiring complex additional structures.
2Adaptability or versatility
If conventional double tunnel terminal architecture is used with movable screw, then flexibility for different conductor combinations is improved, but the screw may fall out during fully disengage condition
Solution Approach 1:
The patent introduces a retention mechanism as an intermediary element between the screw and the clamp. This mechanism includes a retention member with a retention cavity that receives and holds the screw when in the fully disengaged position, preventing the screw from falling out while still allowing the screw to move freely for different conductor combinations.
Solution Approach 2:
The patent segments the clamp into multiple functional zones: an upper lodging for conductors, a lower lodging for conductors, and a retention mechanism zone. The retention mechanism is separated as a distinct functional element that can independently hold the screw without interfering with the conductor clamping function, thus maintaining both flexibility and reliability.
3Reliability
If conventional connecter clip is used to hold screw, then screw retention is improved, but the assembly becomes space-consuming and insertion space for conductors is minimized
Solution Approach 1:
The patent applies the nesting principle by integrating the retention mechanism within the clamp's internal structure. The retention cavity is formed inside the clamp body, and the retention member is nested within this cavity. This nested arrangement allows the screw to be retained without requiring external space-consuming clips, thus preserving maximum insertion space for conductors while ensuring reliable screw retention.
Solution Approach 2:
The patent merges the retention function with the clamp structure itself. Instead of using a separate external clip, the retention mechanism is combined with the clamp's body, creating a unified structure that performs both clamping and retention functions. This integration eliminates additional space requirements and maintains conductor insertion space.
4Ease of manufacture
If conventional terminal assembly is designed for specific conductor combination, then manufacturing is simplified, but adaptability to different conductor sizes and combinations is reduced
Solution Approach 1:
The patent applies the universality principle by designing the clamp and screw mechanism to perform multiple functions: accommodating different conductor types (cables and busbars), different conductor sizes, and different arrangement configurations (cable above busbar or busbar above cable). The adjustable screw position and retention mechanism enable a single terminal assembly design to serve multiple application scenarios without requiring different specialized components.
Solution Approach 2:
The patent uses dynamics to enable the screw to adapt its position vertically along the clamp based on the specific conductor combination being installed. This dynamic adjustment capability allows the same clamp structure to accommodate varying conductor heights and configurations, providing versatility while maintaining a standardized manufacturing design for the clamp itself.
5Ease of manufacture
If conventional architecture uses constant height connecter clip, then manufacturing is simplified, but proper engagement cannot be achieved for varying conductor sizes
Solution Approach 1:
The patent replaces the constant-height rigid clip with a dynamic retention mechanism where the retention member can move vertically within the retention cavity. This dynamic capability allows the mechanism to accommodate varying conductor heights and sizes while maintaining proper engagement, eliminating the need for precision-matched constant-height clips for each conductor size variation.
Solution Approach 2:
The patent changes the vertical position parameter of the retention member along the clamp's axis. By allowing this parameter to vary based on conductor size and configuration, the system achieves proper engagement accuracy for different conductor dimensions without requiring multiple specialized clip designs, thus maintaining manufacturing simplicity while improving engagement precision.
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 enhances flexibility and reliability in accommodating various conductor sizes, ensuring uniform gripping and effective electrical contact without additional accessories, while being cost-effective and space-efficient, thus improving the modularity and safety of electrical apparatuses.
Implementation Method 1
a protection plate arranged with a resilient portion at its both ends
Implementation Method 2
the metallic part is insert-molded or pressfitted with the protection plate
Implementation Method 3
the metallic part is insert-molded or pressfitted with the protection plate
Implementation Method 4
a fastening means is secured against the through hole in the clamp and has a cylindrical or non-threaded tip to contact the metallic part through the opening in the protection plate. The fastening means is fastened on the clamp to press down the protection plate with the metallic part in relation to movement of the fastening means
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B~3C
AI summary
A terminal assembly (100) for multiple connection in an electrical apparatus comprises a protection plate (10) arranged with a resilient portion (12) and a base part provided with with a gripping profile on its surface. A clamp (103) is formed with a passage (104) for receiving and securing multiple electrical conductors. A fixed connector (6) is placed inside the clamp (103) in such a way that the passage of the clamp (103) is divided into an upper and lower housing portions to provide separate lodging for clamping the electrical conductors. A fastening means (105) is secured within the clamp (103) with its cylindrical or non-threaded tip contacting the base part of the protecting plate (10) and the fastening means (105) passing through a hole of a cooperating plate of said protecting plate (10), which is introduced into the passage of the clamp (103) in such a way that the resilient portion (12) of the protection plate (10) faces away from the clamp (103). The fastening means (105) is fastened on the clamp to press down the protection plate (10) such that the passage of the clamp (103) is adjusted in accordance with dimensional variations of the electrical conductors. Such assembly provides highest reliability and flexibility to achieve uniform and larger space for insertion of multiple electrical conductors.