Multi-Directional Terminal Block for Flexible PSU Cable Orientation
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Solution Overview
Problem
Existing power supply units (PSUs) face increased manufacturing costs due to unique input connectors and limited orientation options for coupling cables, which are not compatible with standard connectors and require specialized designs.
Innovation Solution
A multi-position terminal block with a terminal housing and adaptable terminals that allow for multi-directional wire connections, using electrically conductive terminals with fastener openings and adaptable fasteners, enabling flexible installation and compatibility with various wire types and printed circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a power blade type input connector is used, then the PSU can receive power from a source, but the manufacturing cost increases due to unique design and specialty connector requirements
Solution Approach 1:
The terminal block is designed to accept multiple wire configurations (single wire, fork configuration, split configuration) and can be mounted in various orientations, replacing the need for specialized power blade connectors while maintaining reliable power input connection functionality
Solution Approach 2:
The terminal block divides the power input function into separate terminal openings that can independently accommodate different wire configurations, allowing flexible connection methods without requiring a unique integrated connector design
2Ease of manufacture
If a barrier type terminal block is used, then the manufacturing cost is reduced, but the orientation options for coupling cables are limited
Solution Approach 1:
The terminal block incorporates a split configuration capability where terminals can be separated or repositioned, and the housing allows for flexible mounting orientations, enabling the structure to adapt to different installation requirements while maintaining cost-effectiveness
Solution Approach 2:
The terminal block design allows cables to be coupled from multiple directions and orientations by utilizing vertical and horizontal terminal openings, effectively adding dimensional flexibility to an otherwise simple barrier-type structure
3Adaptability or versatility
If a unique input connector is used, then the PSU can be designed specifically for its power source, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The terminal block serves multiple functions within a single simple structure: it provides electrical connection, allows various wire configurations (single, fork, split), supports multiple mounting orientations, and can accommodate different cable types, thereby replacing multiple specialized connectors with one universal solution
Data Source
AI summary
A terminal block comprises a terminal housing having a plurality of walls forming a plurality of terminal openings and a plurality of terminals, each terminal positioned in a respective terminal opening of the plurality of terminal openings. Each terminal of the plurality of terminals is electrically conductive and includes a front portion having a front surface having a first fastener opening formed therein, a first side surface having a second fastener opening formed therein, and a rear surface opposite the front surface. Each terminal also includes a rear portion extending from the rear surface and an adaptor. The rear portion has an adaptor fastener opening formed therein, and the adaptor is coupled to the rear portion via an adaptor fastener positioned within the adaptor fastener opening.