Terminal Block Device Flexible Wire Orientation
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Solution Overview
Problem
Existing terminal block devices restrict the orienting direction of wires, limiting freedom in wire connection and requiring molded resin supports that can lead to creep and increased manufacturing complexity due to the need for accurate wire bending to ensure insulation distance.
Innovation Solution
A terminal block device featuring a terminal block body and cover made of insulating material, with cylindrical relay terminals and a fastening mechanism that allows for flexible wire orientation and connection without applying axial force to the support, eliminating the need for molded resin with conductive members and enabling connection regardless of wire bending degree.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a molded resin support with embedded conductive members is used, then wire connection freedom is restricted, but manufacturing precision and structural stability are improved
Solution Approach 1:
The terminal block device is divided into separate components: a support body, terminal blocks, and mounting brackets. The terminal blocks can be independently mounted on the support body at different positions and orientations, allowing flexible wire connection directions without requiring a complex molded resin structure with embedded conductive members.
Solution Approach 2:
The support body serves multiple functions: it provides mechanical support, enables flexible mounting of terminal blocks at various orientations, and ensures proper insulation. The mounting brackets allow the terminal blocks to be positioned in different orientations (e.g., perpendicular to the support body surface), achieving wire connection freedom without complex molding.
2Reliability
If accurate wire bending is required to ensure insulation distance, then manufacturing complexity increases, but insulation reliability is improved
Solution Approach 1:
The terminal blocks are pre-mounted on the support body at predetermined positions and orientations using mounting brackets. This preliminary arrangement ensures that the insulation distance between terminals is guaranteed by the physical structure, eliminating the need for precise wire bending during assembly. The mounting brackets are designed to position terminal blocks at optimal orientations before wire connection.
Solution Approach 2:
The mounting brackets act as intermediaries between the support body and terminal blocks, ensuring proper positioning and orientation. These brackets provide a mechanical interface that guarantees sufficient insulation distance between adjacent terminals without requiring precise manual wire bending or complex molded features.
3Stability of the object's composition
If axial force is applied to the support during fastening, then structural stability is improved, but material creep occurs
Solution Approach 1:
The fastening function is extracted from the support body structure and implemented through separate mounting brackets and fastening members. The terminal blocks are secured to the support body using these brackets, which bear the mechanical loads and fastening forces, thereby preventing axial forces from being applied directly to the resin support body and avoiding creep deformation.
Solution Approach 2:
The mounting brackets are designed to flexibly accommodate assembly variations and provide progressive fastening. The fastening members (e.g., screws or rivets) allow controlled application of fastening force through the brackets, distributing loads away from the resin support body while ensuring stable terminal block mounting without causing support deformation.
Data Source
AI summary
A terminal block device to which a first wire and a second wire are to be connected includes a terminal block body made of an insulating material, a cover that is made of an insulating material and covers the terminal block body, a shaft member at which a terminal of the first wire and a terminal of the second wire are engaged, a cylindrical relay terminal through which the shaft member is inserted and which is inserted through the cover, a fastening member for fastening the terminal of the first wire and the terminal of the second wire to the relay terminal. The relay terminal includes a first seat surface that is contactable with the terminal of the first wire between the terminal block body and the cover and a second seat surface that is contactable with the terminal of the second wire outside the cover.