Terminal Block Lever Assembly for Compact High-Cross-Section Wiring
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Solution Overview
Problem
Existing terminal blocks with direct-plug compression spring connections face challenges in achieving a compact, stable design suitable for connecting conductors with large cross-sections while ensuring easy assembly and cost-effective manufacturing.
Innovation Solution
A terminal block design featuring multiple connection devices with direct-plug compression springs, each equipped with a single-armed lever actuating device, allowing for ergonomic operation and compact assembly, and a shared busbar for efficient current conduction, along with force- and form-locking mechanisms for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If terminal blocks are designed with direct-plug compression spring connections for easy assembly, then ease of operation is improved, but device complexity increases due to the need for additional clamping mechanisms
Solution Approach 1:
The patent combines multiple functions into a single integrated housing structure that accommodates multiple connection devices with compression springs. The housing serves as both the structural framework and the mounting platform for all connection devices, eliminating the need for separate clamping mechanisms and reducing overall device complexity while maintaining ease of assembly.
Solution Approach 2:
The terminal block is divided into multiple independent connection devices, each with its own compression spring and actuating mechanism. This segmentation allows each connection device to be assembled independently and inserted into the housing, simplifying the assembly process while maintaining functional independence of each connection point.
2Volume of moving object
If terminal blocks are designed to be compact for space efficiency, then volume is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The connection devices are nested within the housing structure, with each connection device containing its own nested components (compression spring, actuating device, clamping element). This nested arrangement maximizes space utilization and achieves compact dimensions while using standard off-the-shelf components that do not require high-precision manufacturing.
Solution Approach 2:
The compression spring parameters (wire diameter, coil density, free length) are optimized to provide sufficient clamping force within the compact housing dimensions. By adjusting spring parameters rather than housing dimensions, the patent achieves compact size without compromising clamping effectiveness or requiring high manufacturing precision.
3Reliability
If terminal blocks are designed for stable construction with multiple connection devices, then reliability is improved, but device complexity increases
Solution Approach 1:
The housing structure is designed as a universal platform that can accommodate multiple different types of connection devices (different current ratings, different conductor sizes) using the same basic mounting interface. This multi-functionality approach ensures stable and reliable connections while avoiding the need for complex specialized structures for each connection type.
Solution Approach 2:
The compression springs provide dynamic clamping force that automatically adjusts to maintain optimal contact pressure between the clamping element and the conductor/busbar. This dynamic adaptation ensures reliable electrical connection under varying conditions (temperature changes, vibration, conductor variations) without requiring complex adjustment mechanisms.
4Ease of operation
If actuating devices are designed with larger lever arms for ergonomic operation, then ease of operation is improved, but volume of the terminal block increases
Solution Approach 1:
The actuating devices utilize rotational motion in a circular arc path rather than linear extension. By pivoting about a fixed axis, the actuating lever achieves mechanical advantage through angular displacement rather than requiring a long linear lever arm. This dimensional change from linear to rotational actuation provides ergonomic operation within compact housing dimensions.
Solution Approach 2:
The actuating lever is pre-positioned in a retracted state within the housing, and the user applies force to rotate it into the actuating position. This preliminary positioning allows the lever to achieve its mechanical advantage position without occupying excessive space in its resting state, maintaining compact volume while providing ergonomic actuation when needed.
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
The design results in a stable, compact, and cost-effective terminal block with easy assembly, efficient current conduction, and minimal operational effort, suitable for connecting conductors with large cross-sections.
Implementation Method 1
the clamping spring is designed as a compression spring with which a conductor end inserted into the connection device can be pressed against the contact zone
Implementation Method 2
the actuating devices are designed in the manner of a single-armed lever, which have an actuating section and an attack contour acting on the clamping leg when the clamping spring is tensioned
Implementation Method 3
an actuating device that can be pivoted in the housing about a rotational axis
Implementation Method 4
a retaining and detent spring on which the clamping spring can be locked in the tensioned state
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The present invention relates to a terminal block comprising several terminal blocks that can be connected in series and are clamped and/or snap-fit, each having a housing (1) and each having a plurality of two or more connection devices (2) inserted into the respective housing (1), which are designed as direct-plug compression spring terminals for connecting a respective conductor end (3), wherein the multiple connection devices (2) for connecting a conductor end each have at least the following: a busbar (21) which has at least one contact zone (210) for contacting the respective electrical conductor end, wherein the clamping spring (23) is designed as a compression spring, and wherein each connection device (2) has an actuating device (20) that is pivotable in the housing (1) about a rotational axis, wherein the actuating devices (20) are designed in the manner of a single-arm lever.which have an actuating section (201) and an attack contour (202) acting on the clamping leg (233) when the clamping spring (23) is tensioned.