Terminal Block Copper Comb Brass Bar Short Circuit Resistance

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Solution Overview

Problem

Terminal blocks face a contradiction in achieving mechanical strength, electrical conductivity, and thermal conductivity within a compact size, as materials with desirable mechanical strength, like brass, have average conductivities, while copper excels in conductivity but lacks mechanical strength, and smaller dimensions complicate performance.

Innovation Solution

A terminal block design featuring a one-piece copper comb with parallel teeth and a supporting bar, where each tooth is inserted into a corresponding orifice, sandwiching the floor between the comb and the cable, allowing for improved contact and mechanical, electrical, and thermal efficiency, and a brass bar maintains resistance to short-circuit currents and heat evacuation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If copper is used for the terminal block, then electrical and thermal conductivity is improved, but mechanical strength deteriorates

Engineering Contradiction:

Improveelectrical and thermal conductivityVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The terminal block combines copper and brass materials in a single structure. The copper portions (comb and cable contact areas) provide excellent electrical and thermal conductivity, while the brass bar provides mechanical strength and structural support. This composite approach allows simultaneous optimization of both conductivity and mechanical properties.

Inventive Principle:

Principle #40Composite materials

2Strength

If brass is used for the terminal block, then mechanical strength is improved, but electrical and thermal conductivity deteriorates

Engineering Contradiction:

Improvemechanical strengthVSAvoidelectrical and thermal conductivity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

Different materials are applied to different regions of the terminal block based on local requirements. Copper is used in areas requiring high conductivity (comb teeth, cable contact surfaces), while brass is used in areas requiring mechanical strength (supporting bar, structural framework). This local differentiation optimizes overall performance.

Inventive Principle:

Principle #3Local quality

3Volume of stationary object

If the terminal block dimensions are reduced, then compactness and material savings are improved, but mechanical strength and heat removal capability deteriorate

Engineering Contradiction:

ImprovecompactnessVSAvoidmechanical strength and heat removal

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

The terminal block is divided into functionally distinct segments: copper comb teeth for electrical connection and heat dissipation, brass supporting bar for mechanical strength, and integrated mounting structures. This segmentation allows each component to be optimized for its specific function while maintaining overall compactness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The combination of copper and brass in a compact integrated structure enables simultaneous achievement of high conductivity, mechanical strength, and compact dimensions. The copper-copper contact paths ensure low electrical resistance and efficient heat removal, while the brass framework provides structural integrity within a reduced overall volume.

Inventive Principle:

Principle #40Composite materials

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

This design achieves a balance of mechanical strength, electrical, and thermal conductivity while maintaining compactness, ensuring effective heat removal and resistance to short-circuit currents, enhancing material efficiency and ease of installation.

Implementation Method 1

each tooth of the comb is inserted into a corresponding orifice of the bar and bearing on the floor of this orifice, this tooth thus being, in service, interposed between this floor and the engaged cable in this orifice

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

copper, which is known to have excellent electrical and thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP2136437B1Terminal board with enhanced resistance to short circuits

Publication Date: 2010.11.17 LEGRAND FRANCE SA

Figure 1~2
Figure 3~4

AI summary

The invention relates to a terminal block comprising a longitudinal bar (1) with transversely pierced juxtaposed connection holes (11), each connection hole (11) being equipped with a screw (12) engaged in a corresponding thread of the bar (1) and adapted to clamp, in operation, a cable (K) inserted in this hole (11) against a wall (110) forming the floor of this hole (11). The terminal block of the invention further comprises a one-piece copper comb (2) formed of a row of teeth (21) and a bar (22) connecting and supporting the teeth (21), each tooth (21) being inserted in a corresponding hole (11) of the bar (1) and bearing against the floor (110), this tooth (21) thus being, in operation, interposed between this floor (110) and the cable (K) inserted in this hole (11).