Terminal Block Vertical Busbar Connection via Offset Housing
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Solution Overview
Problem
The existing multi-level electrical terminals with laterally offset busbars cannot utilize standard straight potential connectors for connections between busbars, limiting connection options and flexibility.
Innovation Solution
Curving at least one busbar between conductor connections allows for the use of simple, unbent metal sheets as potential connectors, enabling various connection techniques like soldering and screwing, and providing vertically aligned plug-in openings for detachable jumpers and easy connection testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If busbars are arranged laterally offset to ensure accessibility of lower screw connections, then ease of operation is improved, but the ability to use standard straight potential connectors for electrical connection between busbars deteriorates
Solution Approach 1:
The patent introduces vertically aligned plug-in openings in the terminal housing that align with openings in both the lower and upper busbars. This vertical dimension allows standard straight potential connectors to pass through the housing and connect the offset busbars, resolving the contradiction by adding a new spatial dimension for connector routing.
Solution Approach 2:
The terminal housing acts as an intermediary structure that provides vertically aligned plug-in openings. These openings serve as mediation points that enable standard potential connectors to bridge the lateral offset between busbars, allowing the housing to mediate the connection between components that would otherwise be incompatible.
2Ease of manufacture
If busbars are curved to enable use of simple unbent metal sheets as connectors, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The patent segments the connection function between the busbars and the potential connector. Instead of requiring the busbars themselves to be curved, the system divides the connection task into separate components: straight busbars provide electrical connection points, while the potential connector (or jumpers) provides the lateral offset accommodation. This segmentation allows manufacturing simplicity to be maintained.
Solution Approach 2:
Rather than curving the busbars to accommodate straight connectors, the patent inverts the approach by using straight busbars with offset positions and allowing the connectors (jumpers/potential connectors) to bridge the offset. This inversion maintains busbar simplicity while achieving the same functional result.
3Adaptability or versatility
If vertically aligned plug-in openings are provided in the terminal housing, then adaptability for detachable connections is improved, but device complexity increases
Solution Approach 1:
The vertically aligned plug-in openings serve multiple functions: they enable detachable jumpers for testing, provide routing paths for potential connectors, and maintain structural integration with the terminal housing. This multi-functionality justifies the additional housing features by providing versatile capabilities that serve several purposes simultaneously.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The terminal (1) has a terminal housing (2) formed with housing walls. Line connectors (4,5) are arranged and installed at the opposite sides of the terminal housing for electrical connection with the conductors (6,7). The conductors are curved between the line connectors towards the housing walls.