Terminal Block Spring Support Integration
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Solution Overview
Problem
Existing connection terminals are not optimized for compactness and material efficiency, with complex designs that require additional components for conductor stops and mechanical reinforcement, leading to increased material usage and manufacturing costs.
Innovation Solution
The connection terminal features loop-shaped clamping springs that support each other, eliminating the need for additional conductor stops and insulating walls, allowing for a more compact and material-efficient design with integrated spring force clamps and a flat busbar configuration, which minimizes material usage and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional conductor stops and insulating walls are used to ensure proper conductor insertion, then conductor insertion control is improved, but device complexity and material usage increase
Solution Approach 1:
The patent combines the conductor stop function with the clamping spring structure itself. The clamping spring is designed with an integrated stop element that prevents over-insertion of conductors, eliminating the need for separate insulating walls or additional conductor stop components. This merging of functions reduces structural complexity while maintaining reliable conductor insertion control.
Solution Approach 2:
The clamping spring serves multiple functions: it provides clamping force to secure the conductor, acts as a mechanical stop to prevent over-insertion, and serves as a mounting element for attachment to the busbar. This multi-functionality eliminates the need for separate dedicated components for each function, thereby reducing device complexity and material usage.
2Reliability
If additional mechanical fixing means are used to secure clamping springs, then attachment reliability is improved, but manufacturing complexity and material costs increase
Solution Approach 1:
The mounting elements are integrated directly into the clamping spring structure as a single piece, eliminating the need for separate mechanical fixing means such as additional screws, clips, or retention mechanisms. This integration maintains secure attachment of the clamping spring to the busbar while significantly simplifying the manufacturing process and reducing material costs.
Solution Approach 2:
The clamping spring is designed with self-mounting capabilities through its integrated mounting elements that engage with the busbar structure. The spring's own geometry provides the attachment mechanism, allowing it to secure itself without requiring additional external fixing components, thereby reducing manufacturing complexity.
3Stability of the object's composition
If clamping springs are positioned farther apart to accommodate separate mounting structures, then attachment stability is improved, but device length increases
Solution Approach 1:
By integrating the mounting elements directly into the clamping spring structure, the patent enables closer spacing of adjacent clamping springs. The combined clamping and mounting functions in a single component reduce the space required for each spring assembly, allowing more compact arrangement while maintaining adequate attachment stability through the integrated design.
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 design enables a smaller, more user-friendly connection terminal with reduced material and manufacturing costs, improved electrical conductivity, and a simpler construction that ensures proper conductor insertion without additional mechanical fixing means.
Implementation Method 1
The first and second clamping spring can support each other, so that the first and the second clamping spring absorb print forces of the other clamping spring
Data Source
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AI summary
The invention relates to a terminal block for connecting at least two electrical conductors together, comprising the following features: a) the terminal block has an insulating housing with at least one first and one second conductor entry opening, b) the first and the second conductor entry openings are arranged on opposite sides of the insulating housing, c) a first spring-clamp terminal for electrically contacting a first electrical conductor inserted through the first conductor entry opening and a second spring-clamp terminal for electrically contacting a second electrical conductor inserted through the second conductor entry opening are arranged in the insulating housing, d) the first spring-clamp terminal is electrically connected to the second spring-clamp terminal via a busbar, e) the first spring-clamp terminal has at least one first clamping spring.which has a clamping leg for clamping the first electrical conductor against a first clamping point of the busbar and a support leg for supporting the clamping spring, f) the second spring-loaded clamping connection has at least a second clamping spring which has a clamping leg for clamping the second electrical conductor against a second clamping point of the busbar and a support leg for supporting the second clamping spring, g) the busbar has at least one through-opening which is arranged between the first and the second clamping point, h) wherein an extended end section of the support leg of the first and/or the second clamping spring is hooked in the through-opening of the busbar.