Terminal Block Manufacturing via Injection Molding
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Solution Overview
Problem
The telecommunications industry faces inefficiencies and labor-intensive processes in manufacturing terminal blocks, particularly due to the need for hand-poured potting and manual wrapping of wires around electrical connectors, which are time-consuming and lack flexibility.
Innovation Solution
An integrally molded terminal block manufacturing method using a mold with projections to remove insulation from electrical contacts and inject a dielectric material, eliminating the need for hand-poured potting and manual wire wrapping, and allowing for robotic positioning and pressure molding of dielectric materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hand-poured potting process is used to provide environmental and mechanical protection for terminal block connections, then protection quality is improved, but manufacturing time and labor intensity increase significantly
Solution Approach 1:
The patent replaces the manual hand-poured potting process with an automated injection molding system. The injection mold automatically injects potting material into the terminal block housing, eliminating the need for manual pouring operations while maintaining consistent protection quality. This mechanical automation directly resolves the contradiction by substituting manual mechanical operations with automated machinery.
Solution Approach 2:
The patent changes the process parameters from manual pouring (variable, craft-sensitive) to automated injection molding (controlled, consistent). The injection molding process parameters such as injection pressure, temperature, and material flow rate are precisely controlled, ensuring consistent protection quality while dramatically improving manufacturing efficiency and reducing labor intensity.
2Reliability
If manual wire wrapping around electrical connectors is performed, then wire connection reliability is improved, but installation time and labor intensity increase
Solution Approach 1:
The patent replaces manual wire wrapping with an automated wire insertion and crimping system. The terminal block design includes built-in features that guide wires into position and automatically secure them through crimping or clamping mechanisms, eliminating the need for manual wrapping operations while ensuring reliable electrical connections.
Solution Approach 2:
The terminal block structure incorporates self-guiding features and automatic securing mechanisms that enable the wiring process to be performed without manual manipulation. The design allows wires to be automatically positioned and secured through the block's inherent structural features, reducing dependency on skilled manual labor.
3Adaptability or versatility
If conventional terminal blocks with separate potting and wiring processes are used, then flexibility in wire types is maintained, but manufacturing complexity and labor requirements increase
Solution Approach 1:
The patent designs a universal terminal block structure that can accommodate multiple wire types and gauges through standardized opening sizes and configurations. The injection molding process and block design are configured to handle various wire specifications without requiring separate manufacturing processes, thereby maintaining flexibility while reducing overall manufacturing complexity.
Solution Approach 2:
The terminal block is designed with modular openings and segmented structures that can be configured for different wire types. The standardized modular design allows the same basic block structure to serve multiple wire termination requirements, simplifying the manufacturing process while maintaining adaptability to different wire specifications.
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 method reduces labor intensity, increases efficiency, and enhances flexibility in producing terminal blocks, enabling faster and more reliable production of terminal blocks with improved environmental and mechanical protection.
Implementation Method 1
a plurality of projections extending from the first half into the cavity, wherein the plurality of projections are adapted to remove a portion of insulation from the electrical contact positioned within each of the openings
Implementation Method 2
injecting a dielectric material into the mold containing the substrate and insulated electrical contact to form a terminal block
Data Source
AI summary
A method of manufacturing a terminal block for a telecommunication cable, which includes providing a housing having a front side and a back side and positioning multiple pairs of electrical connectors in the housing such that one end of each of the electrical connectors is exposed on the front side of the housing and one end of the connector is exposed on the back side of the housing. Each of electrical connectors having an insulation displacement contact terminal on the end exposed on the back side of the housing, and connecting multiple pairs of insulated electrical wires to the connectors on the back side of the housing. A dielectric material is pressure molded on the back side of the housing to encapsulate the connections of the wires and the connectors on the back side of the housing.