High-Contact Section Terminal Block Manufacturer

What Are The Production Steps For The High-Contact Section Terminal Block?

The manufacturing of a high-contact section terminal block, designed for electrical connectivity and mechanical strength, is a multi-stage process that prioritizes precision and quality control.

• 1. Material Selection and Preparation: The process begins with choosing the right materials. The conductive parts, typically the contact plates and screws, are stamped from high-conductivity copper alloy. This raw material is often supplied in large rolls or sheets. This copper alloy is then frequently plated with a layer of tin or silver. This plating enhances corrosion resistance, improves solderability, and ensures a stable, low-resistance contact surface. The housing is molded from a high-grade engineering plastic, such as polyamide (nylon) or polycarbonate, chosen for its durability, high dielectric strength, and resistance to heat and chemicals.
• 2. Stamping and Forming the Metal Components: Using precision progressive die stamps, the plated copper alloy sheet is punched and formed into the specific shapes required for the current bar and the clamping plates. This automated stamping process creates the intricate features of the contact section in a single, efficient operation. The stamped parts are then often put through a secondary process to achieve their final three-dimensional form, such as bending the clamping plate to create its spring tension. This ensures the part is ready to provide consistent clamping force.
• 3. Injection Molding the Housing: The plastic housing is created through injection molding. Granules of the raw plastic material are heated until molten and then injected under high pressure into a custom-designed mold. This mold defines the block's external shape, internal chambers for the metal components, and the wire entry points. Precise control of temperature and pressure is critical here to prevent defects and ensure the housing has the necessary mechanical strength and insulating properties.
• 4. Automated Assembly and Final Testing: In the final assembly stage, the stamped metal components are automatically inserted into the newly molded plastic housings. Robotic systems often handle this to ensure speed and accuracy. Once assembled, the terminal blocks undergo rigorous testing. This includes automated checks for dielectric strength (hi-pot testing), where a high voltage is applied to ensure the insulation is effective, and gauging to verify that the clamping force and screw torque meet specified standards. This final quality control step is essential to guarantee performance and safety before packaging.

What Changes Have The Neutral Connector Terminal Block Undergone?

The neutral connector terminal block, a key component in electrical distribution, has undergone significant evolution to meet increasing demands for safety, space efficiency, and installation speed.

1. Enhanced Safety and Functionality: Early neutral blocks were simple, unmarked brass or copper bars. The critical change has been the integration of advanced safety features. A major development was the creation of the dual-level terminal. This design features two separate connection points under a single screw, allowing the neutral and protective earth (PE) conductors to be connected in one location while maintaining electrical isolation between the two circuits. This prevents incorrect wiring and improves overall system safety. Furthermore, modern blocks now include standardized, clear markings for "N" (neutral) identification, reducing the risk of installation errors.

2. Design for Efficiency and Density: The push for more compact control panels and switchboards has driven a redesign of the neutral block's form factor. Traditional blocks were large and bulky. Modern versions are designed for high density, allowing many circuits to be connected in a minimal amount of space on a DIN rail. This is achieved through slimmer profiles and more efficient internal layouts. Alongside this, the connection method itself has been improved. While the classic screw clamp remains reliable, many manufacturers now also offer versions with spring-clamp or push-in technology. These allow for much faster wire insertion without tools, significantly reducing installation time and labor costs while maintaining a secure, vibration-resistant connection.