Terminal Block Spring Element Mechanical Assembly
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Solution Overview
Problem
Existing terminal blocks with protective elements require complex and costly assembly processes, especially when miniaturization demands smaller dimensions, making assembly more difficult and increasing production costs.
Innovation Solution
A terminal block design featuring a conductive spring element connected to a current bar via a positive mechanical assembly, utilizing a Z-shaped tongue for secure attachment, allowing for a purely mechanical assembly process without soldering, and incorporating a thermally disconnecting connection for overcurrent protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect the spring element to the current bar, then reliable electrical connection is achieved, but assembly complexity and production cost increase
Solution Approach 1:
The patent replaces the thermal/chemical joining process (soldering) with a mechanical connection system. The spring element features a deformation section that can be mechanically deformed to create a firm connection to the current bar, eliminating the need for soldering while maintaining reliable electrical connection.
Solution Approach 2:
The patent changes the connection method from a thermal process (soldering) to a mechanical deformation process. The spring element's deformation section is mechanically deformed during assembly to create a secure mechanical and electrical connection, simplifying the assembly process while ensuring reliability.
2Volume of moving object
If miniaturization is implemented to reduce terminal block dimensions, then compact form factor is achieved, but assembly difficulty increases
Solution Approach 1:
The patent divides the spring element into functional sections: a deformation section for mechanical connection and a contact section for electrical connection. This segmentation allows the compact spring element to be assembled through simple deformation of the designated section, making miniaturization feasible without increasing assembly difficulty.
Solution Approach 2:
The spring element's deformation section is designed to be self-assembling through mechanical deformation. The element itself provides the means for its own secure attachment to the current bar through its deformable structure, eliminating the need for complex external assembly tools or processes even in miniaturized configurations.
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 simplifies and automates the assembly process, reduces production costs, and ensures reliable overcurrent protection with a secure and efficient electrical connection, while maintaining a compact form factor.
Implementation Method 1
the second end section of the spring element moves due to the spring force of the spring element into a position in which it is separated from the second connection of the protective element
Implementation Method 2
If a specified limit temperature of the protective element is exceeded, the thermally separating connection between the second end section of the spring element and the second connection of the protective element breaks
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A terminal block (1) with a housing (2), with at least one connection element (3, 4), with at least one current bar (5, 6), with a protective element (7) and with an electrically conductive spring element (8) is shown and described, wherein the first terminal (7a) of the protective element (7) is electrically connected to the at least one connection element (3, 4), wherein the first end section (9) of the conductive spring element (8) is electrically connected to the at least one current bar (5), and wherein the second end section (10) of the conductive spring element (8) is electrically connected to the second terminal (7b) of the protective element (7) via a thermally isolating connection (11) in the normal state of the protective element (7).and wherein, when a predetermined limit temperature of the protective element (7) is exceeded, the thermally separating connection (11) between the second end section (10) of the conductive spring element (8) and the second terminal (7b) of the protective element (7) separates and the second end section (10) of the conductive spring element (8) moves due to the spring force of the spring element (8) into a position in which the second end section (10) is spaced away from the second terminal (7b) of the protective element (7). To further simplify the construction and assembly of the terminal block (1), it is provided that at least one recess (15) is formed in the current bar (5) and that the first end section (9) of the conductive spring element (8) has at least one Z-shaped tongue (16) extending from the top of the current bar (5) through the recess (15) to the underside of the current bar (5), so that the free end (17) of the tongue (16) rests against the underside of the current bar (5).