Offset Terminal Cages in Electrical Connection Devices
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Solution Overview
Problem
Existing modular circuit breakers with high rating connections (e.g., 32-63 A) are bulky due to constraints of electrical connection elements, occupying excessive space and requiring complex assembly processes.
Innovation Solution
A compact electrical connection device with offset terminal cages and screws, allowing for the use of connection blocks that can be stacked and reused, featuring guide systems for easy mounting and a removable partition for insulation, reducing device width and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cage terminals and screws are mounted separately in series on the assembly line, then the electrical connection is reliable, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple separate components (terminal cage, terminal screw, and associated mounting elements) into a single pre-assembled terminal unit. This unit is designed to be mounted as one piece into the modular device, eliminating the need for separate assembly steps on the production line while maintaining electrical connection reliability.
2Reliability
If traditional electrical connection elements are used for high rating devices (32-63 A), then the electrical connection is secure, but the device width increases to 63mm making it bulky
Solution Approach 1:
The patent repositions the terminal screw from a lateral mounting position to a longitudinal mounting position within the device. This dimensional change allows the terminal components to be arranged along the length of the modular device rather than across its width, thereby reducing the device width from 63mm to 45mm while maintaining secure electrical connection for high rating applications.
3Ease of manufacture
If multiple components are assembled separately, then each component can be optimized independently, but the overall device size increases due to space required for all components
Solution Approach 1:
The patent integrates the terminal cage, terminal screw, and mounting structure into a single compact terminal unit. This merging eliminates the need for separate spaces for each component and their associated mounting features, significantly reducing the overall device volume while preserving the ability to optimize each sub-component's design during the unit's manufacturing phase.
Data Source
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AI summary
The device has a connection block (17) arranged to receive two terminals (21, 22), where each terminal comprises a cage terminal (21a) and screws (21b, 22b). The connection block comprises two opposite sides (29, 30) with two openings (31, 32) for accessing two housings (19, 20). Each terminal is offset with respect to another terminal along longitudinal direction of a support and along height direction of the device, where the height direction is defined as belonging to a mounting plane and extends perpendicularly to the longitudinal direction of the support.