Terminal Block Insulation Walls Two-Stage Molding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing terminal block manufacturing methods face challenges in ensuring reliable electrical insulation between nuts due to voids and resin inclination, leading to potential resin peeling and uneven resin coverage, which affects durability.

Innovation Solution

A terminal block design featuring primary molding for insulation walls and secondary molding to cover and fix these walls, with exposed portions and fillet-like inclines to prevent resin peeling and ensure even coverage, reducing the likelihood of voids and improving durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If one molding process is used to shape the terminal block, then productivity is improved, but voids are produced in the partition walls and insulation between nuts is compromised

Engineering Contradiction:

Improvemolding efficiencyVSAvoidelectrical insulation reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The molding process is divided into two separate stages: primary molding forms the insulation walls with precise insulation properties, while secondary molding adds the partition walls. This segmentation allows each molding process to optimize for its specific function, avoiding voids and ensuring reliable insulation between nuts.

Inventive Principle:

Principle #1Segmentation

2Reliability

If secondary molding is used to form partition walls with insulation walls inside, then insulation between nuts is ensured, but the insulation walls may incline due to injection pressure causing uneven resin coverage and peeling

Engineering Contradiction:

Improveelectrical insulation reliabilityVSAvoidresin coverage uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The insulation walls are formed in advance during primary molding with precise dimensions and proper alignment. This preliminary action ensures that the insulation walls are already in their final, correct position before secondary molding begins, preventing any inclination that could cause uneven resin coverage or peeling.

Inventive Principle:

Principle #10Preliminary action

3Strength

If the secondary molding resin is applied to cover the insulation walls, then the insulation walls are protected, but the injection pressure may cause the insulation walls to incline and the resin may not cover them sufficiently

Engineering Contradiction:

Improveprotection of insulation wallsVSAvoidresin coverage uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The secondary molding resin is applied with different thicknesses at different locations: thinner at the bottom and thicker at the top. This local quality variation compensates for the inclination of insulation walls, ensuring uniform coverage and preventing peeling while maintaining adequate protection of the insulation walls.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8622772B2Terminal block and method of molding it

Publication Date: 2014.01.07 SUMITOMO WIRING SYSTEMS LTD

AI summary

A terminal block (10) fastens conductors by placing the conductors one above another and fastening bolts and includes a plurality of nuts (30) on which the conductors are to be placed and partition walls (50) partitioning between adjacent nuts (30). Each partition wall (50) includes an insulation wall (24) provided in an insulation plate (20) arranged below the nuts (30) and a molded resin portion (60) covering the upper surface of the insulation wall (24) and the side surface of the insulation wall (24). Exposed portions (27A), which are exposed upper end parts of a projecting portion (27) provided on the insulation wall (24), are provided on the upper end surface of the molded resin portion (60).