Flat Cable Junction Box With Repositionable Contact Pins

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Solution Overview

Problem

Existing solutions for connecting multi-core flat cables to terminals face challenges in accommodating varying conductor orders and assignments, requiring flexible and reliable positioning of contact pins to ensure correct electrical connections while maintaining waterproof and dustproof integrity.

Innovation Solution

A junction box with a support surface for multi-core flat cables, featuring contact blades that pierce the cable jacket to contact cores, and terminal rails with holes for contact pins, allowing for adjustable pin positioning to connect any wire to any terminal, with cross-connectors and insulating bodies to prevent incorrect connections and ensure IP-rated protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If contact pins are fixed in position to ensure reliable electrical connection, then connection reliability is improved, but adaptability to different conductor orders deteriorates

Engineering Contradiction:

Improveconnection reliabilityVSAvoidadaptability to different conductor orders

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The contact pin is made movable along the terminal rail through a groove, allowing dynamic repositioning. The pin can be inserted at different positions on the rail to match different conductor orders while maintaining reliable electrical connection through the spring-loaded contact mechanism

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connection system is divided into separable components: the contact pin, the terminal rail with multiple holes, and the groove mechanism. This segmentation allows the pin to be independently positioned at different locations to accommodate various conductor arrangements

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If the junction box structure is simplified to reduce complexity, then ease of manufacture is improved, but protection against dust and water deteriorates

Engineering Contradiction:

Improveease of manufactureVSAvoidprotection against dust and water

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

A sealing membrane is used to close the opening of the junction box, providing dust and water protection while maintaining a simple overall structure. The membrane acts as a flexible barrier that protects internal components without requiring complex sealing mechanisms

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentEP3923417B1Junction box

Publication Date: 2024.04.17 WOERTZ

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AI summary

Junction box for connecting a multi-core flat cable to multiple terminals of a terminal. The junction box includes a contact surface for the multi-core flat cable to be connected, as well as several contact blades for one-sided, strip-free contact. The junction box also includes several terminals and several terminal rails connected to the terminals, each terminal rail having at least one hole through which a contact pin is inserted. Each contact pin is provided for a conductor-to-terminal connection. The placement of contact pins in the terminal rail holes defines which conductor of the flat cable is connected to which terminal. An electrical contact between the contact blades and the terminal rails is established via one or more contact pins.