Terminal Block with Integrated Ground Strap and Push-In Terminals

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Solution Overview

Problem

The existing terminal blocks for electrical power distribution in luminaire manufacturing require crimped connectors, additional leads, connectors, dedicated ground screws, and ground eyelets, making the assembly process impractical and costly.

Innovation Solution

A terminal block assembly with a housing, screw lug terminal assemblies, push-in terminal assemblies featuring a strain relief member and retention spring assembly, and an integrated ground strap, allowing stripped ends of leads to be directly inserted without tools or crimped connectors, eliminating the need for additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If crimped connectors and additional leads are used for terminal connections, then reliable electrical connection is achieved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (terminal block, connectors, leads, ground screws, eyelets) into a single integrated terminal block assembly. The terminal block directly receives both power line leads and driver leads without requiring external connectors or additional leads, eliminating the need for separate crimped connectors and reducing overall device complexity while maintaining reliable electrical connections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal block is designed with multi-functionality to serve multiple purposes: it provides power distribution connections, driver connections, and grounding all in one component. The housing contains multiple socket ports and terminal flag connections that can accommodate different types of conductors, making the terminal block a universal connection point that eliminates the need for dedicated ground screws and separate grounding components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If crimped connectors are assembled to driver leads, then secure electrical connection is achieved, but manufacturing time and labor cost increase

Engineering Contradiction:

Improveelectrical connection securityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The terminal block design enables self-service connections where driver leads with terminal flag connectors can be directly inserted into the terminal block without requiring separate crimping operations. The terminal flag connectors are pre-assembled to the driver leads in a simplified manner that eliminates the need for additional crimped connectors at the terminal block interface, significantly reducing assembly steps and labor time while maintaining secure electrical connections.

Inventive Principle:

Principle #25Self-service

3Reliability

If dedicated ground screws and ground eyelets are used, then proper grounding is achieved, but number of components and assembly steps increase

Engineering Contradiction:

Improvegrounding reliabilityVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The grounding function is merged into the main terminal block housing. The housing contains integrated grounding structures including grounding terminals and pathways that provide proper grounding without requiring separate ground screws or ground eyelets. This integration eliminates additional components and assembly steps while ensuring reliable grounding connections through the housing structure itself.

Inventive Principle:

Principle #5Merging (Combining)

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 solution simplifies the manufacturing process by reducing labor and component requirements, resulting in lower costs and improved efficiency for luminaire assembly.

Implementation Method 1

a retention spring assembly comprising a finger member and a conductor member

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a ground strap disposed within the housing and extending to the housing retention member, wherein the ground strap is electrically coupled to one screw lug terminal assembly

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9419352B2Terminal block with ground strap, spring force terminals, and screw lug terminal

Publication Date: 2016.08.16 GE LIGHTING SOLUTIONS LLC

AI summary

A terminal block assembly includes a housing, a housing retention member coupled to the housing, a plurality of screw lug terminal assemblies disposed within the housing and a plurality of push-in terminal assemblies disposed within the housing. A push-in terminal of the plurality of push-in terminal assemblies includes a strain relief member and a retention spring assembly. The retention spring assembly includes a finger member and a conductor member. The conductor member electrically couples the finger member to a corresponding screw-lug terminal assembly. A bottom portion of the strain relief member engages the conductor member of the retention spring assembly to retain the retention spring assembly within the housing. A ground strap is disposed within the housing.