Modular Terminal Block Assembly for Faster Design Changes

Solution Overview

Problem

Conventional terminal blocks require a complete redesign when even a minor design change is needed, leading to increased time and cost.

Innovation Solution

A modular design where the base member and single terminal units are separate, allowing individual redesign of either component without affecting the other, and utilizing coincident insertion and displacement for assembly to reduce assembly time and space requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the base member and single terminal units are integrated by insert molding, then the terminal block has a unified structure, but the entire terminal block must be redesigned when a design change is required for only one component

Engineering Contradiction:

Improvestructural unityVSAvoiddesign change time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The terminal block is divided into separate components: a base member and multiple single terminal units. These components are assembled together rather than integrated by insert molding, allowing independent design changes to individual components without requiring redesign of the entire terminal block.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If the base member and single terminal units are integrated by insert molding, then the terminal block has a unified structure, but the manufacturing cost increases for design changes

Engineering Contradiction:

Improvestructural unityVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The terminal block is divided into separate components: a base member and multiple single terminal units. These components are assembled together rather than integrated by insert molding, allowing independent design changes to individual components without requiring redesign of the entire terminal block, thereby reducing manufacturing costs for design changes.

Inventive Principle:

Principle #1Segmentation

3Stability of the object's composition

If the single terminal units are fixed to the base member in a non-displaceable manner, then the structure is stable, but it is difficult to insert the single terminal units into the fitting holes

Engineering Contradiction:

Improvestructural stabilityVSAvoidinsertion ease

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The single terminal units are supported by the base member in a displaceable manner, allowing them to move during insertion into the fitting holes. This dynamic support enables easy insertion while maintaining structural stability once assembled.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12562617B2Terminal block

Publication Date: 2026.02.24 TOYOTA JIDOSHA KK

AI summary

A terminal block may electrically connect a motor and an inverter. The terminal block may include a base member configured to be attached to a motor case that houses the motor and a plurality of single terminal units, each of which is independent of each other and is assembled to the base member. Each of the plurality of single terminal units may include a terminal member constituted of a conductive material and a terminal holder fixed to the terminal member and engaged with the base member.