Multi-layer Conductor Body for Terminal Blocks
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Solution Overview
Problem
Existing electrical connection devices, such as terminal blocks, face challenges in high production costs and waste due to complex designs requiring machining and multiple machines for varying thickness and cross-sections, making them unsuitable for high-volume mass production.
Innovation Solution
A multi-layer conductor body composed of interchangeable components, such as outer, middle, and closing parts, formed through die-forming and shearing processes, allowing for continuous production of parts with customizable thickness and dimensions without further machining, enabling efficient and cost-effective mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional one-piece conductor parts are produced using moulding, drawing or pressure die-casting processes, then the parts can be manufactured with required thickness and cross-section for different current loads, but the production process becomes complex requiring multiple machines and further machining, increasing production waste and unit cost
Solution Approach 1:
The conductor body is divided into multiple individual layers that can be produced separately and then stacked together. Each layer can be manufactured using the same simple process, and the number of layers is adjusted based on the required current load, eliminating the need for complex multi-machine production processes while maintaining adaptability to different electrical specifications
Solution Approach 2:
A single universal production process is used to manufacture all conductor layers, regardless of the final application's current load requirements. The same basic tooling and equipment produce all layers, which are then differentiated by the number of layers stacked, making the production system universally applicable to different specifications without requiring specialized machines for each variant
2Reliability
If conventional conductor parts are produced with varying thickness and cross-section for different current loads, then the electrical requirements are met, but multiple machines are required increasing production costs
Solution Approach 1:
The conductor is segmented into identical basic layers that maintain consistent dimensions and electrical properties. By stacking a variable number of these standardized layers, different current load capacities are achieved without compromising electrical continuity, as each layer contributes uniformly to the overall conductive path
Solution Approach 2:
Instead of changing the physical dimensions (thickness and cross-section) of individual conductor parts to meet different current load requirements, the invention changes the parameter of the number of layers stacked. This allows a single production process to produce all variants by simply adjusting the stack height, dramatically improving mass production efficiency while maintaining the required electrical performance
3Manufacturing precision
If conductor parts require further machining after moulding or casting, then the finished parts can be mounted in terminal blocks, but production waste increases and unit cost rises
Solution Approach 1:
The conductor layers are produced with the final required dimensions, edges, and surface finish directly from the strip material through a single shearing operation. This preliminary completion of all necessary geometric features eliminates the need for subsequent machining operations, thereby preventing material waste and reducing production costs while maintaining the precision needed for mounting in terminal blocks
4Productivity
If conventional production processes are used for high-volume mass production, then production capacity is achieved, but the complex design and machining requirements make the unit cost incompatible with high-volume production
Solution Approach 1:
The conductor body is segmented into multiple identical layers that can be produced continuously from a strip of material using a single shearing operation. This segmentation allows for high-volume production through continuous feeding and automatic stacking, while the simplicity of producing identical repeated layers makes the process extremely easy to manufacture and highly suitable for mass production
Solution Approach 2:
The production system is designed so that the same basic equipment and tooling produce all conductor layers without requiring intervention, retooling, or adjustment for different specifications. The process serves itself by continuously producing standardized layers that are automatically stacked to the required number, eliminating the need for complex manufacturing procedures and enabling cost-effective high-volume production
Data Source
Figure 1a~2c
Figure 3a~4c
Figure 5~7
AI summary
Conductor body (1;2;3;4;5) comprising a first outer component (110) extending in the longitudinal direction (X-X) and provided with at least one tooth (111) projecting towards the ouside of the inner surface, said tooth (111) having an inner recess (112); at least one middle component (120) the same as the outer component (110); a closing component (130) provided with at least one opening (131) able to engage with the at least one tooth (121) of the middle component (120), which components are packed together in a transverse direction (Y-Y) so as to form a multi-layer body.