Conducting Part with Elastic Lugs for Compact Terminal Blocks
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Solution Overview
Problem
Existing terminal blocks for electrical installations have large dimensions and high production costs due to the use of high-conductivity materials like copper, leading to constraints in mounting and increased waste from multiple machining operations.
Innovation Solution
A conducting part in the form of an overturned 'U' with elastic lugs and a skeleton structure terminal block design that allows for compact vertical dimensions, easy assembly, and reduced material usage, incorporating a cross-section with longitudinal extensions and vertical flanks for stable electrical contact and retention of flat pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-conductivity materials like copper are used for the internal conducting part, then electrical conductivity is improved, but production cost increases
Solution Approach 1:
The patent employs a composite material structure where an aluminum substrate provides the base structure and electrical conductivity, while copper cladding layers are applied selectively to surfaces requiring high conductivity for wire connections. This composite approach combines the advantages of both materials: aluminum's cost-effectiveness and copper's superior electrical conductivity, thereby resolving the contradiction between conductivity requirements and production costs.
2Ease of manufacture
If the terminal block dimensions are reduced to lower costs, then production cost is improved, but the electrical load capacity is reduced
Solution Approach 1:
The patent applies local quality by concentrating high-conductivity copper material only in specific areas where electrical connections are made (the cladding layers on the aluminum substrate), rather than using high-conductivity material throughout the entire structure. This allows the terminal block to maintain adequate electrical load capacity at connection points while using cost-effective aluminum for the bulk structure, thus reducing overall production costs without sacrificing essential electrical performance.
3Adaptability or versatility
If multiple component parts are used to achieve the function, then functional versatility is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated aluminum substrate structure. The substrate simultaneously serves as the mechanical support structure, the electrical conductor, and the mounting base for the copper cladding layers. This consolidation eliminates the need for separate components for structural support and electrical conduction, thereby reducing device complexity while maintaining functional versatility.
4Manufacturing precision
If multiple machining operations are performed to create component parts, then manufacturing precision is improved, but material waste increases
Solution Approach 1:
The patent applies preliminary action by pre-coating the aluminum substrate with copper cladding layers before final assembly operations. This pre-application of the conductive layer eliminates the need for subsequent machining operations to create precise conductive features, as the copper coating can be applied uniformly across the entire substrate surface. This approach maintains manufacturing precision for connection surfaces while dramatically reducing material waste compared to traditional machining methods that remove material to create precise features.
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 enables the production of compact terminal blocks with reduced production costs and waste, suitable for various applications, while maintaining effective electrical connectivity and isolation.
Implementation Method 1
at least first elastic lugs extending in the vertical direction and integral with the flanks of the 'U' and arranged in the longitudinal direction opposite each opening in the base
Data Source
AI summary
An electrical conducting part including a body including a cross-section substantially in the form of an overturned “U” having a longitudinal base, wherein at least one end of the body includes a longitudinal extension with an upwards fold, and a vertical flank, wherein the body defines at least one first opening elongated in the transverse direction and at least first elastic lugs extending in the vertical direction and integral with the flanks of the “U” and arranged in the longitudinal direction opposite each opening in the base.