Spring Terminal Block Layout to Reduce Housing Deformation
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Solution Overview
Problem
Existing connection terminals face challenges in minimizing deformation of plastic insulating material housings due to limited space and forces acting on the actuation lever and housing, which affects the clamping and conductor insertion processes.
Innovation Solution
The connection terminal design features an actuation axis offset from the conductor insertion axis by 5° to 30°, with a thicker actuation head and conical tapering sections to optimize space usage and support the actuation pusher, reducing deformation risks and improving force distribution on the clamping spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the actuating pushbutton and conductor entry opening are accommodated in limited space with parallel alignment, then the structure is simple, but deformation of the plastic insulating housing increases
Solution Approach 1:
The actuating axis is deliberately offset from the conductor insertion axis by 5° to 30°, creating an asymmetric arrangement that redistributes mechanical stresses away from concentrated load points on the insulating housing, thereby reducing deformation while maintaining compact dimensions
Solution Approach 2:
The actuating head is designed with increased thickness in the width direction, adding dimensional variation to redistribute forces through a larger volume of material and reduce stress concentration on the housing walls
2Manufacturing precision
If the actuating axis is offset from the conductor insertion axis by 5° to 30°, then housing deformation is reduced, but the device complexity increases
Solution Approach 1:
The actuating pushbutton features a localized thickening of the actuating head in the width direction, creating a region of increased structural rigidity precisely where the force application occurs, which compensates for the asymmetric alignment without requiring overall structural complexity
Solution Approach 2:
The angular offset parameter between the actuating axis and conductor insertion axis is optimized within the range of 5° to 30°, representing a controlled parameter change that balances deformation reduction with acceptable device complexity
3Manufacturing precision
If the actuating head is thicker in the width direction, then force distribution is improved and deformation reduced, but the available space for conductor entry is reduced
Solution Approach 1:
The actuating pushbutton is segmented into distinct functional zones: a thicker actuating head for force application and a narrower shaft for insertion, allowing the mass to be concentrated where needed while preserving clearance elsewhere
Data Source
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AI summary
A terminal block (1) with an insulating housing (2) is described, which has a conductor entry channel (3) extending in the direction of a conductor entry axis (L) with a conductor channel wall (4) arranged coaxially to the conductor entry axis (L) and at least partially circumferentially, and an actuating channel (5) arranged next to the conductor entry channel (3). The terminal block (1) further has a U-shaped leg spring (11) having a contact leg (12), a clamping leg (15) and a spring arc (13) connecting the contact leg (12) to the clamping leg (15), a busbar (8) and an actuating push button (6) which is longitudinally displaceable in the actuating channel (5).The mounting leg (12) is mounted on the busbar (8), and a clamping edge (17) of the clamping leg (15) forms a spring-loaded clamping connection with a contact area of the busbar (8) for clamping an electrical conductor inserted into the conductor entry channel (3). An actuation axis (B) defined by the longitudinal displacement direction of the actuating push button (6) in the actuating channel (5) and the conductor entry axis (L) are aligned at an angle of 5° to 30° to each other.