Terminal Block Contact Structure for Stranded Conductor Alignment
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Solution Overview
Problem
Existing terminal blocks are complex in construction due to multiple parts, which complicates the process of maintaining efficient and reliable electrical contact, especially with multi-stranded conductors, where strand deviations during insertion are a significant issue.
Innovation Solution
A simplified terminal block design featuring an insulating casing with a conductive bar having a base portion, support leg, and cooperating leg that engages with a retaining spring, guiding conductors accurately and preventing deviations, while maintaining efficient electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple parts and components are used in the terminal block construction, then reliable electrical contact can be maintained, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated conductive bar structure that includes the base portion, support leg, and cooperating leg. This merging of components maintains the reliability of electrical contact while reducing the overall device complexity by eliminating the need for separate retaining springs and additional guiding accessories.
Solution Approach 2:
The conductive bar is designed as a multi-functional component that simultaneously provides electrical conduction, mechanical support, conductor guidance, and retention functions. The support leg guides the conductor during insertion while the cooperating leg maintains electrical contact, making the single component perform multiple roles that previously required separate parts.
2Manufacturing precision
If dedicated walls and accessories are added to guide the conductor, then conductor placement precision improves, but the device complexity increases
Solution Approach 1:
The conductive bar features locally optimized geometries at specific positions: the support leg provides localized guidance at the insertion point, while the cooperating leg provides localized contact at the electrical connection point. This local quality approach achieves precise conductor placement without requiring complex overall structures or additional dedicated guiding walls.
Solution Approach 2:
The patent extracts the guiding function from separate dedicated walls and accessories and integrates it directly into the conductive bar structure itself. The support leg and cooperating leg are formed as integral parts of the conductive bar, eliminating the need for separate guiding components while maintaining precise conductor placement capability.
3Device complexity
If a simplified construction with minimal parts is used, then device complexity is reduced, but the ability to prevent conductor strand deviations may be compromised
Solution Approach 1:
The conductive bar is designed with flexible yet structurally sound legs that can dynamically adapt to the conductor insertion process. The support leg and cooperating leg have geometries that allow them to flexibly guide and secure multi-stranded conductors during insertion, preventing strand deviations while maintaining a simplified single-component construction without rigid complex structures.
Data Source
AI summary
A terminal block includes an insulating casing defining a recess receiving a conductive bar and a retaining spring. The conductive bar includes a base portion, a support leg attached to the base portion and a cooperating leg attached to the base portion. In a mounted position of the conductive bar and the retaining spring within the recess, the support leg engages with a support part of the retaining spring, and the cooperating leg is positioned to engage with a conductor inserted into a plug of the terminal block.