Modular Terminal Block Alignment and Cover Retention

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Solution Overview

Problem

Modular terminal blocks face challenges with conductor misalignment due to manufacturing tolerances, leading to potential damage and installation issues, as well as cover bowing and failure to remain closed, especially in longer module stacks.

Innovation Solution

The introduction of an alignment member with movable conductors and support structures within the housing modules ensures accurate alignment and resistance to deflection, along with a cover retention system using conductor portions to maintain the cover in a closed position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If module stacks are made longer to increase connection capacity, then the number of conductors increases, but manufacturing tolerances cause conductor misalignment with vias

Engineering Contradiction:

Improvenumber of conductorsVSAvoidconductor alignment

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

An alignment member is introduced as an intermediary component between the module stack and circuit board. This alignment member includes alignment features that compensate for tolerance buildup, ensuring accurate positioning of conductors relative to vias even in long module stacks with many conductors.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The alignment member is installed on the module stack before the circuit board is attached. This preliminary action establishes accurate alignment relationships in advance, preventing misalignment issues during the subsequent circuit board installation process.

Inventive Principle:

Principle #10Preliminary action

2Quantity of substance

If module stacks are made longer, then more conductors are present, but conductor deflection during installation increases

Engineering Contradiction:

Improvenumber of conductorsVSAvoidconductor resistance to deflection

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The alignment member is installed beforehand to establish precise alignment and provide initial support to the conductors. This preliminary positioning prevents excessive deflection during the subsequent circuit board installation process.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the cover is used to close the terminal housing, then conductor protection is provided, but the cover bows upward and fails to remain closed in long module stacks

Engineering Contradiction:

Improvecover closureVSAvoidcover position stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The retention function is extracted from the cover itself and transferred to separate retention members. These retention members are attached to the module stack and engage with the cover, providing stable retention without relying on the cover's structural integrity alone.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Retention members serve as intermediary elements between the module stack and the cover. These members provide the retention force needed to keep the cover closed, compensating for the cover's tendency to bow upward in long module stacks.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution allows for reliable and automated installation of circuit boards in long module stacks without conductor damage, ensuring accurate alignment and maintaining the cover closed along the entire length, facilitating efficient assembly and preventing misalignment and damage.

Implementation Method 1

The alignment member includes a number of surfaces in a predetermined arrangement. The conductors are engageable with the surfaces to position the conductors in the predetermined arrangement

Methodology Applied

Scientific EffectMechanical engagement: Mechanical Force

Implementation Method 2

The conductors and vias are sized to generate a press fit that electrically connects the conductors with the circuit board

Methodology Applied

Scientific EffectPress fit: Mechanical Force

Implementation Method 3

The conductors are better supported in the housing modules to resist deflection of the conductors during attachment of the circuit board

Methodology Applied

Scientific EffectMechanical support: Mechanical Force

Data Source

PatentUS7491096B1Modular terminal block

Publication Date: 2009.02.17 PHOENIX CONTACT DEVELOPMENT & MANUFACTURING INC

AI summary

A modular terminal block for connecting leads or wires to an electrical body includes a module stack of side-by-side module assemblies and an alignment plate. Each module assembly includes a housing, a number of conductors extending from the housing, and a cover member to cover the conductors. The alignment plate accurately positions the conductors despite variations in housing dimension due to manufacturing tolerances. The housing includes walls supported on both sides when forming part of the module stack. The walls resist deflection of the conductors during installation of the alignment plate and electrical body. Each cover member engages and is held closed by a conductor extending from the housing.