Terminal Block: Reliable Guarantee For Efficient Voltage Transmission
1、 The core function and importance of Terminal blocks
Terminal blocks are key components in electrical connections, and their core function is to achieve reliable connections between wires and between wires and equipment through mechanical fixation and electrical contact, ensuring efficient transmission of voltage/current. Its importance is reflected in the following aspects:
Reduce contact resistance
High quality Terminal blocks control contact resistance at the micro ohm level (μΩ) by optimizing contact surface design (such as silver plating, gold plating treatment) and pressure control, avoiding heat generation, voltage drop, and energy loss caused by poor contact. For example, in industrial motor control systems, an increase of 1 μ Ω in contact resistance may result in an increase of several kilowatt hours in annual power consumption.
Enhance security
The Terminal blocks are protected from short circuits, arcs, and accidental contact risks by insulated enclosures, anti electric shock structures, and locking devices. In high-voltage distribution systems, terminals that comply with the IEC 60947 standard can withstand voltages above 1000V, ensuring personal and equipment safety.
Extend equipment lifespan
A stable electrical connection can reduce looseness caused by vibration, thermal expansion and contraction, and avoid wire oxidation and contact surface erosion. In the new energy photovoltaic system, the reliability of the Terminal blocks directly affects the power generation efficiency of the inverter within its 25 year service life.
2、 Technical Implementation and Advantages of Terminal blocks
The reliability guarantee of efficient voltage transmission is achieved through the collaborative optimization of materials, structures, and processes for Terminal blocks
Material selection
Conductive material: High purity copper (conductivity ≥ 58MS/m) or copper alloy is used to reduce resistance loss.
Contact plating: Tin plating (anti oxidation), silver plating (low resistance) or gold plating (corrosion-resistant) treatment, suitable for different environmental requirements.
Insulation material: Made of flame retardant PC/ABS, nylon 66 and other high-temperature resistant materials, certified by UL94 V-0 level.
Structure Design
Spring terminal: Provides constant pressure through elastic clips, suitable for 0.08-16mm ² wires, with a contact force of 5-10N.
Screw terminal: M3-M8 screws are used with a torque control range of 0.5-2.5Nm to ensure a secure crimping of the wires.
Puncture terminal: No need to strip the wire, connect by piercing the insulation layer, and increase construction efficiency by more than 50%.
process innovation
Crimping technology: using hexagonal crimping or ultrasonic welding to form an airtight connection between the wire and the terminal, with a tensile strength of ≥ 100N.
Modular design: supports terminal block combination, realizes multi-channel signal integration, and saves more than 30% of distribution cabinet space.
Identification system: Laser marking or labeling technology, clearly marking line numbers and voltage levels to reduce the risk of misoperation.
3、 Application scenarios and selection suggestions for Terminal blocks
According to the needs of different industries, the selection of terminal blocks should comprehensively consider factors such as voltage level, current capacity, and environmental conditions
Typical Application Scenarios Recommended Types Key Parameters
Industrial control cabinet with high vibration, frequent insertion and removal of spring type terminals, protection level IP20, current 10-32A
New energy photovoltaic system with UV resistant, salt spray resistant tin plated copper terminals and stainless steel shell, working temperature -40 ℃~+125 ℃, UL certified
The high reliability and anti electromagnetic interference shielding terminal of the rail transit signal system has a shielding effectiveness of ≥ 60dB and a flame retardant level of V-0
Small and easy to install smart home system with micro plug-in terminal size ≤ 10mm × 10mm, voltage ≤ 300V
The cost of building distribution boxes is sensitive, and the unit price of screw terminals used in large quantities is less than 0.5 yuan. The service life is ≥ 500 times of insertion and extraction
Selection suggestion:
Voltage matching: Ensure that the rated voltage of the terminals is ≥ the maximum voltage of the system (e.g. 600V terminals are required for 400V systems).
Current redundancy: Select the rated current of the terminal based on 1.5 times the actual current (e.g. load 20A, select 30A terminal).
Environmental adaptation: Choose heat-resistant PC materials for high temperature environments and IP68 protection level for humid environments.
4、 Industry Trends and Future Prospects of Terminal blocks
Intelligent integration
Intelligent terminals with temperature/voltage monitoring functions have been applied in data centers to provide real-time feedback on connection status and prevent faults.
Miniaturization and High Density
5G base stations and electric vehicles are driving the development of terminal sizes towards 2.54mm spacing, with a single row of terminals capable of integrating 48 signals.
Green and Sustainable
Lead free production (compliant with RoHS 2.0) and recyclable materials (such as bio based plastics) have become standard in the industry.
Standardization and interchangeability
The unification of standards such as DIN 46228 and GB/T 14048 promotes global supply chain collaboration.
5、 Conclusion
As the "nerve endings" of electrical connections, the performance of terminal blocks directly affects voltage transmission efficiency and system reliability. Through material innovation, structural optimization, and process upgrades, modern Terminal blocks have achieved breakthroughs in contact resistance<0.5m Ω, temperature rise<35K, and lifespan>10000 insertions and removals. Driven by Industry 4.0, new energy, and smart grids, terminal blocks are evolving towards intelligence, miniaturization, and greenness, providing a more solid guarantee for efficient voltage transmission.
