Description:The present invention shall now be described in detail with the help of drawings. It is to be understood that several variations are possible around the inventive concept of the present invention and the detailed description of the preferred embodiment should not be construed to limit this invention in any way.
Figure 1, the present invention is an electrical terminal block (200) comprising a housing (100) and a stud sub-assembly (211), the stud sub-assembly (211) inventively disposed on the housing (100), and secured by an inventive locking pin (121). An appropriate lockable nut and appropriate washers provided thereon.
The electrical terminal block (200) is suitable for stacking side-by-side on a DIN rail, and mountable as well as removable only in a slidable manner from an end of the DIN rail due to application specific requirement.
The housing (100) of the preferred embodiment is a single-piece molded structure, and is a support framework for components of the electrical terminal block (200) and connections thereon.

Figure 2-9, the housing (100) comprises a partition wall (101) a seating platform (106) projecting from the partition wall (101), a guide channel (108) with a guide wall (108A) on either side of the seating platform (106). In the present embodiment, the seating platform (106) has a pair of restrictive stud-base grooves (107) with a respective barrier (144) of barrier height (146). The restrictive stud-base grooves (107) are shaped as per the preferred embodiment to match a threaded stud (120) which are square headed, and this embodiment is thus described. However, the present invention is not limited thereto and studs of any non-circular and or non-regular head perform present the invention equally effectively, and a profile of the stud-base groove is constructed accordingly. The restrictive stud-base groove (107) restricts a rotation of the threaded stud (120) and therefore any groove and stud-base profile combination which can result into easy undesired rotation of the threaded stud (120) by a permitted tightening/untightening torque must be avoided. A biasing projection (111) is provided on the seating platform (106) near one of the restrictive stud-base grooves (107).

At a prescribed gap from the seating platform (106), there is provided a pair of inclined profiles (152) forming a converging wedge opening of a converging angle (150) and ending in a narrow parallel slit of a slit width (154) with respect to the seating platform (106). The prescribed gap is at least a material thickness (148) of the conductor bar (115).

The inclined profiles (152) form a bottom face of a pair of edged walls (164), thus forming a duct (160) along with a face wall (166) and the partition wall (101). An inside of the duct (160) is a cylindrical cavity (105). There is provided an annular projecting ring (132) in the cylindrical cavity (105).
The seating platform (106) is provided with a cylindrical-conical room (130), narrowing towards a mounting end (170) with an access (162) at the mounting end (170). The cylindrical-conical room (130) has a plurality of inward projections (110).

Figure 9, the housing (100) has a pair of inward feet (109) at both sides of the mounting end (170), the inward feet (109) commensurate for disposition of the electrical terminal block (200) on an open c-type DIN rail (202) by sliding from one end (204) of the DIN rail (202).

An identification slot (137) is provided at a top of the partition wall (101), wherein an identification marker is insertable and stays put in vibrations.
A plurality of knock-outs (138) of the partition wall (101) are thin sectioned (102) thus configurable for non-reversibly removing the knock-outs (138) selectively to cater to application-specific inter-terminal block connection.

Figure 10, the stud sub-assembly (211) comprises a conductor bar (115) and a pair of threaded studs (120).
Figure 11,12, the conductor bar (115) is a flat, rectangular conducting platform of material thickness (148) and made of high conductivity metal or metallic alloy. The conductor bar (115) has an upper face (125), a lower face (125A) and a bent portion (119) on either side of the upper face (115). The bent portions (119) are orthogonal to the upper face (125) and mutually parallel to each other. Ends of the bent portion (119) are chamfered ends (131) or rounded ends (131). There are two fastener-receiving apertures (116) and a locking aperture (117) in-between. There is a biasing notch (118) corresponding to the biasing projection (111) in the housing (100). As a variation, the conductor bar (115) has a plurality of head restrainers (181) and head traps (182) to obviate rotation and gravity falling of the bolts during assembly, described later. These head restrainers (181) and head traps (182) are formed by lancing out an electrically insignificant cross-section from the lower face (125A) and or end portions (119).

Figure 13, the preferred embodiment of the present invention deploys the threaded studs (120) which are square headed, and this embodiment is thus described. However, the present invention is not limited thereto and studs of any non-circular or non-regular head perform present the invention equally effectively. The threaded stud (120) has a head height (124) such that the stud sub-assembly (211) is insertable in the converging wedge of the inclined profiles (152) only when the stud sub-assembly (211) enters the converging wedge at the angle (150). In such inclined assembly position, a stud base (126) of the threaded stud (120) can just move clear above the barrier (144) of the barrier height (146) to be able to then slide the conductor bar (115) of the stud sub-assembly (211) in the narrow parallel slit of a slit width (154) of the housing (100). A stud diameter (127) is commensurate with the fastener-receiving apertures (116) of the conductor bar (115). A head width (128) of the threaded stud (120) is configured for removable, snug seating in the restrictive stud-head grooves (107) of the housing (100).

Figure 14, 14A, a locking pin (121) is a prudent reinforcing structural component for precise alignment and locking of the conductor bar (115) within the housing (100) during assembly of the electrical terminal block (200), as described below. A lower portion of the locking pin (121) comprises a tapered cylindrical body (134) that facilitates guided insertion into the cylindrical-conical room (130) of the housing (100). The tapered cylindrical body (134) has a plurality of receptacles (123) complementary to the plurality of inward projections (110) in the housing (100). An upper portion of the locking pin (121), is cylindrical (135) with an annular recess (122) commensurate with the annular projecting ring (132) of the housing (100).

Figure 15A, 15B, 15C, A lockable nut (112), a wavy or crescent washer (113) and a plain washer (114) are essential elements to joining any electrical connection to the electrical terminal block (200), Figure 15A, the non-circular lockable nut (112), comprising a plurality of engageable surfaces for engagement with a tightening or untightening tool. The lockable nut (112) may have and an internal locking mechanism—typically a nylon insert or a deformable thread profile—that resists loosening under conditions of vibration or thermal cycling. As a variation, the lockable nut (112) is lockable by another lock-nut.

A crescent washer (113), also known as a wave washer, made of springy steel is generally installed between the lockable nut (112) and the plain washer (114). Its purpose is to provide axial flexibility and continuous preload in the bolted joint. The wavy surface of the crescent washer (113) adds to tightening torque to absorb minor jerks and vibrations, preventing loosening due to mechanical shock or thermal expansion.

A plain washer (114), which is generally deployable closest to the aperture (116) of the conductor bar (115). primarily to evenly distribute the compressive load applied by the nut and the wave washer. The plain washer (114) also prevents localized surface deformation or damage to the conductor bar (115).

Figure 16A, 16B, 16C, to assemble the stud sub-assembly (211) in the housing (100) and produce the electrical terminal block (200):
the two chamfered ends (131) of the bent portion (119) of the conductor bar (115) are rested at respective entrance of the guide channel (108) within the guide wall (108A) on either side of the seating platform (106), with both the stud base (126) clinging closely to the lower face (125A) of the conductor bar (115) and the biasing notch (118) of the conductor bar (115) facing the biasing projection (111) of the housing (100),
the stud sub-assembly (211) is pushed in the converging wedge of the inclined profiles (152) maintaining the upper surface (128) the conductor bar (115) touching the inclined profiles (152) of the housing, and thereby the stud sub-assembly (211) entering at the angle (150), when the stud base (126) of the threaded stud (120) moves unhindered above the barrier (144) of the seating platform (106) to be able to then slide the conductor bar (115) of the stud sub-assembly (211) in the narrow parallel slit of the slit width (154) of the housing (100), till
the biasing notch (118) of the conductor bar (115) engulfs the biasing projection (111) of the housing (100) and the conductor bar (115) touches partition wall (101).
Consequent to the above described inventive assembly step achievable due to the inventive construction, the stud sub-assembly (211) cannot get dislodged thereafter, when the electrical terminal block (200) is upright, particularly in the presence of gravity.

Figure 17, 18 such assembly is further robustized by interference and force fitment of the locking pin (121) after inserting the tapered cylindrical body (134) of the locking pin (121) in the duct (160) of the housing (100), ensuring by manipulation that the receptacles (123) of the locking pin (121) receive the inward projections (110) of the housing (115), thereby constraining the locking pin (121) against rotational freedom; the force fitment continued till the annular recess (122) of the locking pin (121) is sensed to engulf and click onto the annular projecting ring (132) in the cylindrical cavity (105) of the duct (160), thereby constraining the locking pin (121) against against axial freedom. The locking pin (121) therefore immunizes the assembly against multi-axis vibrations and jerks.

Figure 20, the plain washer (114), the crescent washer (113) and the lockable nut (112) are thereafter roped onto the threads of the threaded stud (120), depending on the kind of conductor connection wiring lug including a ring lug, a fork lug.

As a variation, to ensure both the stud base (126) clinging closely to the lower face (125A) of the conductor bar (115) without having a tendency to fall during assembly the head trap is bent towards the stud base (126), before positioning the stud sub-assembly (211) for assembly onto the housing (100).

Figure 19, the above processes is summarized in following three major steps:
-Prepare stud sub-assembly (211).
-Insert stud sub-assembly (211) into housing (100) such that stud sub-assembly (211) cannot get dislodged thereafter, when the electrical terminal block (200) is upright, particularly in the presence of gravity.
- Force fit locking pin (121) into duct (105) of housing (100).

A critical inventive aspect in the assembly is to ensure proper orientation of the current bar (115). The biasing notch (118) is distinctly offset, making it asymmetrical. The purpose of biasing notch (118) is to act as a mechanical orientation key during assembly process. Its asymmetrical placement ensures that the current bar (115) can only be inserted into the corresponding housing in a single, intended orientation. This induced asymmetry in an otherwise symmetrical overall design is to offset the manufacturing tolerances unidirectionally thereby contributing to attaining closer manufacturing tolerances, minimal assembly gaps and better immunity to jerks and vibrations. Illustratively, it is preferred that both threaded studs are as much parallel as possible in equivalent insert molded assembly, which may ensure comparable uniform torque distribution and vibration resistance; implying contemporary thermal cycling withstand-ability, thereby the mechanical and electrical reliability of the system.
The electrical terminal assembly of the present invention can be effectively employed in railway track signaling and power distribution systems, where reliable, vibration-resistant, and secure electrical connections are critical. Its vertically layered geometry, anti-rotation locking pin design, and symmetric clamping mechanism make it ideal for withstanding the mechanical shocks and vibrations commonly encountered in rail environments. Additionally, the compact and modular housing facilitates quick installation and maintenance in confined railway enclosures, such as junction boxes, trackside cabinets, and control panels.
Importantly, to prevent undesired uprooting in use, these electrical terminal blocks (200) are particularly and consciously restrictedly mountable and dismountable in a plurality on the DIN rail (202) ONLY serially, and therefore in a slidable manner from an end (204) of the DIN rail (202).

Further, these electrical terminal blocks (200) have a provision to be connect the threaded studs (120) of adjacent terminal blocks (200) limitlessly, once mounted on the DIN rail (202) by providing a shorting link (not shown) after the plurality of thin sectioned (102) knock-outs (138) there between are removed. Such shorting links further reinforce immunity against vibrations and uprooting.

At the same time, the present invention is a cost effective product due to minimum material, minimum parts and components and assembly steps coupled with easy recyclability and carbon foot print, particularly by avoiding insert molding process, and therefore the present invention also caters to less stringent thermo-mechanical applications with effective economic significance.
, C , C , C , C , C , Claims:We claim:
1. A vibration resistant electrical terminal block (200) comprising a housing (100) having a partition wall (101), a stud type terminal, a locking nut and plurality of washers, the vibration resistant electrical terminal block (200) is stackable, mountable and dismountable on a DIN rail (202), characterized by:
a stud sub-assembly (211) comprising a conductor bar (115) and a plurality of threaded studs (120),
the housing (100) comprising
a seating platform (106) projecting from the partition wall (101), a guide channel (108) with a guide wall (108A) on either side of the seating platform (106), a pair of restrictive stud-base grooves (107) with a respective barrier (144) of barrier height (146),
a pair of inclined profiles (152) forming a converging wedge opening of a converging angle (150) and ending in a narrow parallel slit of a slit width (154),
a duct (160) above the seating platform (106), and
a cylindrical-conical room (130) through the seating platform (106) narrowing towards a mounting end (170) with an access (162) at the mounting end (170),
a locking pin (121) configurable for forceful fixation in the duct (160) and cylindrical-conical room (130) of the housing (100), constraining its own axial and rotational movement, the locking pin (121) configured for dis-assembly through the access (162) which is inaccessible after the vibration resistant terminal (200) is mounted on the DIN rail (202).

2. A vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the threaded stud (120) has a square stud base (126).

3. A vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the threaded stud (120) has a non-circular or non-regular stud base (126).

4. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the partition wall (101) have a plurality of thin sectioned (102) knock-outs (138).

5. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the conductor bar (115) has a plurality of head restrainers (181) and head traps (182) to obviate rotation and gravity falling of the bolts during assembly, formed by lancing out an electrically insignificant cross-section from the lower face (125A) and or end portions (119).

6. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the thread stud (120) is provided with a plain washer (114), a crescent washer (113) and a lockable nut (112) depending on conductor connection wiring lug including a ring lug, a fork lug.

7. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the lockable nut (112) comprises a plurality of engageable surfaces for engagement with a tightening or untightening tool.

8. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the lockable nut (112) has and an internal locking mechanism including an elastic insert and or a deformable thread profile, and or the lockable nut (112) is lockable by another lock-nut.

9. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein a method to assemble the vibration restraint terminal block (200) comprises the steps of:
resting chamfered ends (131) of both bent portions (119) of the conductor bar (115) at respective entrance of the guide channel (108) within the guide wall (108A) on either side of the seating platform (106), with the heads of both the stud base (126) clinging closely to the lower face (125A) of the conductor bar (115) and the biasing notch (118) of the conductor bar (115) facing the biasing projection (111) of the housing (115),
pushing the stud sub-assembly (211) in the converging wedge of the pair of inclined profiles (152) maintaining an upper surface (128) the conductor bar (115) touching the inclined profiles (152) of the housing (100), and thereby the stud sub--assembly (211) entering at the angle (150), and
moving the stud base (126) of the threaded stud (120) unhindered above the barrier (144) of the seating platform (106) to be able to then slide the conductor bar (115) of the stud sub-assembly (211) in the narrow parallel slit of a slit width (154) of the housing (100), till the biasing notch (118) of the conductor bar (115) engulfs the biasing projection (111) of the housing (100) and the conductor bar (115) touches partition wall (101),
inserting a tapered cylindrical body (134) of the locking pin (121) in the duct (160) of the housing (100), passing through a locking aperture (117) of the conductor bar (115), next ensuring by manipulation that the receptacles (123) of the locking pin (121) receive the inward projections (110) of the housing (115), thereby constraining the lockable pin (121) against rotational freedom, and
force fitting the locking pin (121) till the annular recess (122) of the locking pin (121) is sensed to engulf and click onto the annular projecting ring (132) in the cylindrical cavity (105) of the duct (160), thereby constraining the locking pin (121) against axial freedom., the locking pin (121) therefore immunizing the vibration resistant electrical terminal block (200) against multi-axis vibrations and jerks.

10. The vibration resistant electrical terminal block (200) as claimed in claim 5, wherein the head traps (182) of the conductor bar (115) are bent towards the respective stud base (126) of the threaded studs (120) after the threaded studs (120) disposed on the conductor bar (115) ensuring both the stud bases (126) clinging closely to the lower face (125A) of the conductor bar (115).

11. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the stud sub-assembly (211) is constrained against getting dislodged, when the electrical terminal block (200) is upright, particularly in presence of gravity pull.

12. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein a biasing projection (111) of the housing (115) causes orientation specific placement of the stud sub-assembly (211), the assembly steps thus configured for offsetting manufacturing variations in the non-intended orientation of assembly.

13. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the vibration resistant electrical terminal block (200) are restrictedly mountable and dismountable in a plurality on the DIN rail (202) serially in a slidable manner.

14. The vibration resistant electrical terminal block (200) as claimed in claim 1, wherein the threaded studs (120) of a plurality of vibration resistant electrical terminal blocks (200) mounted on the DIN rail (202) are configured for providing a shorting link after a plurality of thin sectioned (102) knock-outs (138) there between are removed.