Terminal Block Conductive Bar Layout for Multi-Strand Wire Retention
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Solution Overview
Problem
Existing terminal blocks with conductive bars face challenges in reliably connecting multi-stranded conductors due to strand deviation and complex constructions, requiring a simpler and more efficient solution for maintaining electrical contact.
Innovation Solution
A terminal block design featuring an insulating casing with a lateral recess, a conductive bar with a support leg and cooperating leg, and a leaf spring with undulations, which guides and maintains conductors laterally, reducing strand deviation and simplifying the connection process while using a minimal amount of conductive material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional accessories and complex constructions are used to guide multi-stranded conductors, then the risk of strand deviation is reduced, but the device complexity increases
Solution Approach 1:
The conductive bar integrates multiple functions into a single component: it provides electrical conduction, mechanical support, and lateral guidance for conductors. The lateral portion and support legs are merged into the conductive bar structure itself, eliminating the need for separate guidance accessories and reducing overall device complexity while maintaining reliable conductor positioning
Solution Approach 2:
The conductive bar serves multiple purposes simultaneously: it acts as the electrical conductor, the structural support element, and the lateral guidance mechanism for inserting conductors. This multi-functional design replaces what would traditionally require multiple separate components, thereby reducing device complexity while ensuring reliable conductor placement
2Device complexity
If a conductive bar with limited material is used, then the device complexity is reduced, but the ability to guide and maintain conductors laterally is compromised
Solution Approach 1:
The conductive bar is segmented into distinct functional portions: a base portion for electrical connection, lateral portions for top-down guidance, and support legs for lateral maintenance. This segmentation allows each part to perform its specific function efficiently, enabling reliable conductor guidance with minimal material usage by optimizing the distribution of material where it is most needed
Solution Approach 2:
The conductive bar extends in multiple dimensions to provide comprehensive guidance: laterally through support legs for side-to-side maintenance, and vertically through lateral portions for top-down alignment. This multi-dimensional approach ensures reliable conductor positioning using minimal material by leveraging spatial efficiency rather than adding more material
3Ease of operation
If the conductive bar extends laterally parallel to the main plane, then the conductor insertion is facilitated, but the amount of conductive material increases
Solution Approach 1:
The lateral guidance function is segmented into discrete lateral portions that extend only where needed for insertion facilitation, rather than creating a continuous extensive lateral structure. This segmentation reduces the total amount of conductive material required while maintaining ease of conductor insertion at critical locations
Solution Approach 2:
The conductive bar features localized lateral portions at specific positions where conductor insertion guidance is needed, rather than uniformly extending laterally throughout. This local quality approach provides ease of operation at critical insertion points while minimizing the overall quantity of conductive material used
Data Source
Figure 1~2
Figure 3~4
AI summary
Terminal block (1) comprising an insulating casing (3), a conductive bar (5) and a retaining spring (7), the insulating casing (3) extending according to a main plane (9) and presenting a lateral recess (11) arranged for an insertion of the conductive bar (5) and the retaining spring (7) transversally to the main plane (9) into a mounted position, the conductive bar (5) presenting in mounted position a base portion extending according to a middle plane (15) transversal to the main plane (9) and a lateral portion (17) attached to the base portion (13) and extending parallel to the main plane (9), the conductive bar (5) further comprising a support leg (19) attached to the base portion and configured to cooperate with a support part of the retaining spring (7) and a cooperating leg (23) attached to the base portion and configured to cooperate with a conductor (25) inserted in a plug (27) of the terminal block (1) when the conductor (25) is maintained by the retaining spring (7), the support leg (19) and cooperating leg (23) being transverse to the middle plane (15) and extending in opposite directions transversally to the middle plane (15), the lateral portion (17) and the cooperating leg (23) extending according to the same direction transversally to the middle plane (15).