Screwless Terminal Block Insulation Penetration Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing terminal blocks require insulation stripping, are prone to corrosion, and suffer from connection failures due to temperature variations and mechanical stress, leading to costly damage and inefficiencies in manufacturing and installation.
Innovation Solution
Screwless terminal blocks with a slide mechanism that allows for easy insertion and secure clamping of lead wires without tools, using cutting edges to penetrate insulation and establish a firm connection, reducing exposure to corrosion and mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw-type connectors are used for terminal blocks, then reliable electrical connection can be achieved, but the complexity of operation increases due to insulation stripping and screw tightening requirements
Solution Approach 1:
The patent removes the screw and insulation stripping steps from the connection process. The terminal block uses a push-in connector design where wires are inserted directly into receptacles that automatically clamp and secure them, eliminating the need for pre-stripping insulation and manual screw tightening while maintaining reliable electrical connection.
Solution Approach 2:
The terminal block features self-clamping mechanisms with spring-loaded contacts that automatically grip and secure the inserted wires. The design includes built-in wire guides and insulation cutters that perform preparation functions automatically, reducing manual intervention and making the connection process simpler while ensuring reliable contact.
2Reliability
If insulation is stripped from lead wires to make screw connections, then proper electrical contact can be established, but exposure to corrosion increases
Solution Approach 1:
The patent eliminates the insulation stripping step entirely. The push-in connector design accepts wires with insulation intact and incorporates insulation cutters that cleanly sever the insulation at the precise point of contact, minimizing exposed conductor length and reducing corrosion exposure while ensuring proper electrical contact.
Solution Approach 2:
The terminal block includes built-in insulation cutters positioned at the wire insertion point. These cutters automatically sever the insulation as the wire is inserted, creating a clean cut immediately before the conductor makes contact with the electrical terminal, thereby minimizing the time and extent of conductor exposure to corrosive environments.
3Manufacturing precision
If terminal blocks are rigidly supported for accurate pitch alignment, then manufacturing precision is improved, but vulnerability to mechanical stress increases
Solution Approach 1:
The terminal block is designed as a modular assembly with individual wire receptacles that are precisely positioned for accurate pitch alignment during manufacturing. Each receptacle is a separate component that can flex independently, allowing the overall structure to absorb mechanical stress without compromising the precision positioning of the electrical contacts.
Solution Approach 2:
The terminal block incorporates flexible mounting structures and spring-loaded contacts that maintain precise pitch alignment while accommodating mechanical stress. The flexible elements allow the terminal block to flex and return to its original position, preventing damage from vibration and impact while preserving accurate wire positioning.
4Adaptability or versatility
If screw-type terminals are used for field connections, then adjustable connectivity is achieved, but vulnerability to abusive forces increases
Solution Approach 1:
The terminal block uses a push-in connector design with disposable wire receptacles that are designed to be replaced rather than repaired. This eliminates vulnerable screw threads and recesses that can be damaged by impact tools, providing durable connections that maintain reliability even in abusive field conditions where power screwdrivers or impact wrenches might be mistakenly used.
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 solution enables fast, reliable connections without insulation stripping, minimizes corrosion, and withstands temperature variations and mechanical stress, reducing manufacturing costs and installation time while ensuring secure and durable connections.
Implementation Method 1
the connector includes cutting edges positioned on an interior edge of the lead wire receiving opening
Implementation Method 2
a compression member positioned in the connector and compressible toward the PCB
Data Source
AI summary
A screwless terminal block and insulation displacement connector device includes a housing and slide slidably engaged in the housing, the device operable to receive a lead wire having lead wire conductors and an insulation layer, and to further receive a conductive connector. Movement of the slide to a closed position with a lead wire inserted in the device causes the lead wire to contact sharp connector edges, which, with continued downward force, cut the insulation layer. Continued downward force, to full closure of the device, forces lead wire conductors into compressed multiple electrical contact with the connector.