Overmolded Terminal Block Assembly for Vibration-Resistant Wiring
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Solution Overview
Problem
Power tools experience vibration due to motor and hammer assembly actions, leading to poor soldered electrical connections that can become disconnected over time, requiring repair and maintenance.
Innovation Solution
A terminal block assembly for power tools comprising a terminal block, a substrate with electrical connectors, and an overmold that covers the connectors and wires, providing mechanical and electrical security, and allowing for relative movement to maintain contact during vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered electrical connections are used in power tools experiencing vibration, then electrical connectivity is achieved, but the connections become disconnected over time due to poor soldering quality and vibration stress
Solution Approach 1:
The patent replaces traditional soldered mechanical connections with a molded electrical connector system. The connector is mechanically inserted into the terminal block and secured through molding, eliminating the need for manual soldering. This substitution provides more consistent and reliable electrical connections that can withstand vibration without requiring high skill-level manual soldering operations.
Solution Approach 2:
The patent changes the connection method from temporary soldered joints to permanent molded connections. The molding process creates a rigid, vibration-resistant connection that maintains electrical connectivity under vibrational stress. This parameter change from soft solder joints to hard molded structures directly addresses the reliability issue in vibrating power tool environments.
2Ease of manufacture
If manual soldering is used during assembly, then electrical connections can be made, but connection quality varies depending on worker skill leading to repairs and maintenance
Solution Approach 1:
The patent replaces the manual soldering process with an automated molding process. The electrical connector is inserted into the terminal block and then molded in place, creating a permanent mechanical and electrical connection. This eliminates the need for skilled manual soldering operations while ensuring consistent connection quality across all production units.
Solution Approach 2:
The molding process performs multiple functions simultaneously: it secures the electrical connector mechanically, provides electrical insulation, and creates the electrical connection all in one automated operation. This self-service approach eliminates the need for separate soldering steps and reduces dependency on worker skill levels.
3Strength
If rigid electrical connections are used in vibrating power tools, then electrical connectivity is established, but the connections are prone to disconnection due to vibration-induced stress
Solution Approach 1:
The patent changes the connection from a purely rigid soldered joint to a hybrid molded connection that combines rigid structural support with flexible stress absorption. The molded connector body provides rigidity for electrical connectivity, while the molding process creates stress distribution that prevents connection failure under vibration.
Solution Approach 2:
The patent uses a composite construction where the molded electrical connector combines different material properties. The connector body material provides mechanical strength and vibration resistance, while the molded joints provide electrical conductivity and structural attachment. This composite approach creates connections that maintain both strength and durability under vibrational stress.
Data Source
AI summary
A terminal block assembly for a power tool comprises a terminal block having at least one primary terminal configured for electrical connection with a battery and at least one secondary terminal in electrical connection with the at least one primary terminal. A substrate is mountable on the terminal block. The substrate has at least one first electrical connector electrically connectable with the at least one secondary terminal and at least one second electrical connector in electrical connection with the at least one first electrical connector. At least one wire is electrically connected to the at least one second electrical connector. An overmold is configured to cover the at least one second electrical connector and at least a portion of the at least one wire.