Power Input Terminal Block with Integrated Spring Beam Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power input terminal blocks are costly and complex due to the use of threaded terminal lugs with set screws and female tab terminals, which occupy space and complicate the assembly process.
Innovation Solution
A power input terminal block design featuring a housing with terminal channels, clamp contacts with spring beams, and release levers that allow for quick and easy connection and disconnection of take-off wires without damaging them, reducing assembly complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded terminal lugs with set screws and female tab terminals are used, then reliable wire connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the terminal lug and tab contact into a single integrated terminal component. The terminal includes a body with a set screw for securing the supply wire and an integrated tab contact that extends from the body to receive the take-off wire, eliminating the need for separate female tab terminals and reducing assembly complexity while maintaining reliable electrical connections
Solution Approach 2:
The patent removes the female tab terminal component from the assembly, extracting only the essential functions into the terminal itself. The terminal's body provides the set screw connection for supply wires, while the integrated tab contact provides the connection point for take-off wires, simplifying the overall device structure
2Reliability
If female tab terminals are used to connect take-off wires, then electrical connection is established, but space occupation and assembly cost increase
Solution Approach 1:
The terminal integrates the tab contact directly into the terminal body, eliminating the need for separate female tab terminals. This integration reduces the overall space required for the terminal block while maintaining the electrical connection function, as the tab contact is formed as a continuous piece with the terminal body rather than being a separate component
3Productivity
If conventional terminal blocks are used, then wire distribution is achieved, but manufacturing cost and assembly time increase
Solution Approach 1:
The terminal combines multiple functions into a single component: the body houses the set screw for supply wire connection, the integrated tab contact provides take-off wire connection, and the overall structure serves as the terminal lug. This integration reduces the number of parts to be manufactured and assembled, lowering manufacturing costs and improving assembly efficiency
Solution Approach 2:
The terminal block is divided into multiple terminal channels, each containing an independent terminal. This segmentation allows for modular manufacturing and assembly, where terminals can be produced separately and then installed into the housing, reducing overall manufacturing complexity and cost
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
The design provides a cost-effective and reliable method for connecting and disconnecting wires, enhancing the assembly process efficiency and reducing the risk of wire damage, while maintaining electrical integrity.
Implementation Method 1
Each clamp contact has a base coupled to the take-off tab and a spring beam extending from the base
Implementation Method 2
a set screw wall adjacent the wire pocket holding a set screw movably received in the wire pocket to retain a supply wire in the wire pocket
Data Source
AI summary
A power input terminal block includes terminals received in terminal channels of a housing each having a main body defining a wire pocket receiving a supply wire and a take-off tab electrically connected to the main body. The power input terminal block includes clamp contacts coupled to the take-off tabs each having a base, a spring beam extending from the base, and a cap extending from the spring beam having a poke-in window configured to receive a take-off wire. An edge defining the poke-in window engages the take-off wire and pulls the take-off wire against the wire side of the take-off tab. The power input terminal block includes release levers coupled to the housing to move the spring beam to an extended position to allow loading and removal of the take-off wire from the clamp contact and the take-off tab.