Electrical Connector Height Reduction via Nested Terminal Blocks
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Solution Overview
Problem
Conventional connectors face challenges in reducing height while maintaining creepage distances between terminals, as the stacking of terminal blocks increases the connector's height due to the interposition of insulating members between terminals.
Innovation Solution
The connector design features first and second holding portions that stack in a height direction, with the second holding portion covering the exposed surface of the first terminal, allowing resin to be interposed between terminals without covering the exposed surface, thereby reducing the connector's height while ensuring creepage distances through a convex-concave configuration of terminal block units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal blocks are stacked one over another in the height direction, then creepage distances between terminals are ensured, but the connector height is enlarged
Solution Approach 1:
The patent applies nesting by placing the first terminal block unit inside the second terminal block unit. The first terminal block unit with its terminals and insulating member is positioned within the hollow portion of the second terminal block unit, allowing compact arrangement while maintaining insulation distances through the resin coating and structural design.
Solution Approach 2:
The patent transitions from stacking terminal blocks in the height direction to arranging them in a nested configuration. By moving the first terminal block unit into the hollow portion of the second terminal block unit, the design utilizes internal space rather than external stacking, thereby reducing overall connector height while preserving creepage distances.
2Reliability
If insulating members are interposed between terminals in stacked terminal blocks, then insulation is ensured, but the connector height increases
Solution Approach 1:
The patent applies local quality by selectively coating only specific portions of terminals with resin rather than uniformly coating all terminals. The holding portions with resin coating are strategically positioned to ensure creepage distances where needed, while other areas maintain original terminal dimensions, thus preventing unnecessary height increase.
Solution Approach 2:
The patent changes the physical state and dimensions of terminals by selectively coating them with resin. The resin coating modifies the surface properties and dimensions of specific terminal portions to establish adequate insulation distances, while the uncoated portions retain their original parameters, allowing for compact overall design.
3Length of stationary object
If the connector is designed for height reduction, then compactness is improved, but creepage distances between terminals may be compromised
Solution Approach 1:
The nested configuration allows the first terminal block unit to be positioned within the second terminal block unit's hollow portion. This spatial arrangement reduces overall connector height while the resin-coated holding portions and insulating members ensure that creepage distances are maintained through careful positioning and structural design.
Solution Approach 2:
The resin coating acts as an intermediary substance between terminals, providing insulation without requiring additional spacing. By applying resin to specific holding portions, the patent creates an insulating barrier that enables compact terminal arrangement while preserving adequate creepage distances for electrical safety.
Data Source
AI summary
A connector (10) includes a first terminal (62) and a second terminal (32), and a first holding portion (72) and a second holding portion (42) configured to coat around the first terminal (62) and the second terminal (32) with resin. The first holding portion (72) and the second holding portion (42) are stacked one over the other in the height direction. The first terminal (62) has an exposed surface (62H) exposed on a resin surface of the first holding portion (72). The second holding portion (42) covers the exposed surface (62H) of the first terminal (62) while being stacked on or below the first holding portion (72).