Lever-Actuated Terminal Block for Fast Reliable Wire Connection
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Solution Overview
Problem
Existing terminal blocks often require time-consuming and unreliable mechanical coupling processes, leading to incomplete connections, signal interruptions, and increased electrical impedance, especially in audio/visual systems.
Innovation Solution
A pluggable terminal block with a lever mechanism and a spring aperture system that allows for quick and secure electrical connections, using a lever to actuate the spring for wire retention and a busbar for conductive transfer, with a snap-fit or tongue-and-groove joint for assembly, and a socket design for stable pin connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw-based terminal blocks are used, then reliable wire connection can be achieved, but assembly time and complexity increase significantly
Solution Approach 1:
The patent replaces the traditional screw-based mechanical fastening system with a spring-loaded lever mechanism. The spring provides continuous contact pressure on the conductor, while the lever enables tool-free operation. This substitution maintains connection reliability through elastic force while dramatically reducing assembly time and complexity.
Solution Approach 2:
The spring mechanism automatically maintains contact pressure on the conductor without requiring user intervention to adjust or tighten connections. The lever mechanism self-latches into position, providing a secure connection that maintains itself without additional user action, thereby reducing assembly time while ensuring reliable electrical contact.
2Ease of operation
If traditional terminal blocks are used, then electrical connection can be established, but connection consistency and reliability deteriorate
Solution Approach 1:
The patent changes the contact force parameter from manual screw tightening (variable and user-dependent) to spring elastic force (consistent and predictable). The spring maintains a constant contact pressure on the conductor regardless of user skill level, ensuring consistent and reliable electrical connections while simplifying the operation to a simple lever action.
3Productivity
If pluggable terminal blocks are used for quick connection, then assembly speed improves, but connection reliability and security worsen
Solution Approach 1:
The spring acts as an intermediary between the lever mechanism and the conductor. It translates the brief lever actuation into sustained contact pressure, providing both the speed of pluggable connections and the reliability of secure electrical contact. The spring maintains continuous pressure without requiring the conductor to be permanently fixed.
4Strength
If screw-based terminal blocks are used, then secure wire retention is achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent segments the terminal block into distinct functional components: the spring element for contact pressure, the lever for operation, and the housing for structure. This segmentation allows each component to be optimized independently and assembled through simple snap-fit joints, reducing manufacturing complexity while maintaining wire retention strength through the dedicated spring mechanism.
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
Enables quick, reliable, and secure electrical connections without tools, reducing assembly time and ensuring consistent power and signal transfer in audio systems.
Implementation Method 1
The terminal block includes a lever mechanism that is able to quickly secure to and disengage from the wires. The lever is configured to actuate an internal spring. The spring includes an aperture configured to receive the wire when the lever is in the open position. The aperture is further configured to surround and retain the wire when the lever is in the second position.
Implementation Method 2
The terminal block generally includes a connector system configured to couple one or more terminal blocks together. The terminal block supports an electrical connection along one path. The busbar is configured to transfer electricity between conductors at either end of the terminal block.
Data Source
AI summary
A detachable terminal block configured to toollessly connect to a wire and an outlet. The terminal block includes a spring and a busbar. The spring is configured to selectively couple the busbar to the wire. The terminal block further includes a lever that is operable to compress and relax the spring. The busbar includes a socket that is configured to receive a pin in the outlet. The terminal block includes couplers that are configured to connect multiple terminal blocks together. In one example, the couplers include pegs and holes. The holes are configured to receive the pegs and couple multiple terminal blocks together using a friction fit. The terminal block is formed from two pieces that are configured to couple together. In one example, the pieces couple together using pegs and holes and/or a snap-fit connection.