Compact Wiring Terminal Frame for High Current in Limited Space
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Solution Overview
Problem
Conventional front screw wiring terminals face limitations in miniaturization, resulting in reduced conductive cross-sectional area, leading to insufficient wiring capacity and current flowing capacity, especially in applications with limited space.
Innovation Solution
A compact wiring terminal design that integrates a wiring frame with a current-guiding structure, where multiple sides of the frame participate in the current conduction path, increasing the effective cross-sectional area by using conductive materials for the guiding frame and high-strength materials for the clamping frame, forming a closed frame with internal spaces for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the wiring terminal is miniaturized to reduce overall dimension, then the size of the terminal is reduced, but the conductive cross-sectional area is reduced, leading to insufficient wiring capacity and current flowing capacity
Solution Approach 1:
The patent transitions from a conventional single-strip current-guiding structure to a three-dimensional cage-like structure formed by multiple conductive bars arranged in a spatial framework. This dimensional transformation allows the conductive path to extend in multiple directions (length, width, and depth), effectively increasing the conductive cross-sectional area without proportionally increasing the overall terminal volume. The cage structure creates multiple parallel current paths through its longitudinal and transverse bars, solving the contradiction between miniaturization and maintaining adequate current carrying capacity.
Solution Approach 2:
The patent employs a composite structure combining conductive materials (for the cage-like current-guiding bars) and insulating materials (for the housing and structural support). This composite approach allows the conductive framework to be optimized for electrical performance while the insulating components provide mechanical support and electrical isolation, enabling the terminal to achieve both small size and high current capacity through material optimization rather than simply scaling up all dimensions.
2Volume of moving object
If the wiring terminal is miniaturized, then the terminal size is reduced, but the wiring capacity becomes insufficient
Solution Approach 1:
The cage-like structure introduces a third dimension to the current conduction path, arranging conductive bars in a spatial framework that provides multiple parallel pathways for current flow. This three-dimensional arrangement increases the effective wiring capacity by creating numerous concurrent current channels within a compact volume, allowing the terminal to handle higher current loads without increasing its footprint proportionally.
Solution Approach 2:
The current-guiding function is segmented into multiple discrete conductive bars arranged in a cage structure, rather than relying on a single continuous strip. Each bar acts as an independent current-carrying element, and their collective arrangement creates a network of parallel conduction paths. This segmentation allows the wiring capacity to be distributed across multiple elements, enhancing overall capacity while maintaining a compact form factor.
3Ease of operation
If conventional front screw wiring technology is used, then the terminal can be operated from the front side, but the enclosed wire clamping frame plus current-guiding strip structure limits the conductive cross-sectional area
Solution Approach 1:
The patent replaces the planar current-guiding strip with a three-dimensional cage-like framework of conductive bars. This spatial structure allows current to flow through multiple dimensions simultaneously, creating a much larger effective conductive cross-sectional area within the same footprint. The cage structure's longitudinal and transverse bars work together to provide numerous parallel current paths, dramatically increasing the conductive area available for current flow while maintaining the front-wiring operational convenience.
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
The invention discloses a compact wiring terminal comprising a housing; and a wiring assembly located within the housing, the wiring assembly comprising a wiring frame, the wiring frame comprising a wire inlet for a wire in and out, and the wiring frame comprising conductive front and back side walls substantively parallel to a wire inletting direction, the wiring frame further comprising a current-guiding outlet part located on a side opposite to the wire inlet for forming an electrical contact, the current-guiding outlet part extending out from the front and back side walls and being integrated with the front and back side walls.