Coaxial Ground Block Permanent Wire Attachment
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Solution Overview
Problem
Conventional bonding/ground blocks used in coaxial cable systems are prone to corrosion and mechanical disconnection due to inferior materials and inadequate contact resistance, posing safety risks from improper grounding and potential damage from RF ingress or electrical surges.
Innovation Solution
A ground block design featuring a metal ground plate with a non-detachable ground wire configuration, utilizing soldering, brazing, or mechanical bonding for permanent connections, and incorporating a seizure screw assembly for abnormal use scenarios, along with deformable clamping members for secure attachment, ensuring low contact resistance and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding blocks use set screw or threading clamping mechanisms to secure grounding wire, then installation is simple and device complexity is low, but contact resistance increases and mechanical disconnection risk occurs
Solution Approach 1:
The patent combines the grounding wire attachment function with the bonding block structure itself by integrating a grounding wire receptacle that receives and secures the grounding wire internally. This merging eliminates the need for separate set screws or clamping mechanisms, providing reliable electrical connection while simplifying the overall device structure.
Solution Approach 2:
The patent introduces a grounding wire receptacle as an intermediary component that mediates between the grounding wire and the bonding block. This receptacle provides a dedicated interface for secure electrical connection, improving reliability while maintaining simplicity through standardized connection geometry.
2Ease of manufacture
If bonding blocks are made of aluminum or zinc materials, then manufacturing cost is low and ease of manufacture is high, but corrosion resistance deteriorates quickly
Solution Approach 1:
The patent employs composite construction by combining stainless steel material for the bonding block body with separate grounding wire attachment components. The stainless steel provides superior corrosion resistance while maintaining manufacturability through standard fabrication processes, resolving the contradiction between material cost and long-term reliability.
Solution Approach 2:
The patent changes the material parameter from conventional aluminum or zinc to stainless steel, fundamentally improving corrosion resistance while maintaining ease of manufacture through standard metalworking processes. This parameter change transforms the material properties to achieve both durability and manufacturability.
3Ease of manufacture
If bonding blocks use inferior materials construction, then manufacturing cost is reduced, but contact resistance increases and mechanical strength decreases
Solution Approach 1:
The patent uses composite construction with stainless steel providing mechanical strength and corrosion resistance, combined with optimized grounding wire receptacle design. This composite approach maintains reasonable manufacturing cost while achieving superior mechanical connection strength and electrical conductivity compared to single-material conventional blocks.
Solution Approach 2:
The patent applies local quality by concentrating high-strength stainless steel material specifically at critical connection points and interfaces where mechanical strength and electrical conductivity are most needed, while optimizing overall structure for cost-effective manufacturing.
4Ease of operation
If grounding wire attachment uses removable clamping mechanisms, then ease of operation for installation is improved, but mechanical disconnection risk increases under harsh conditions
Solution Approach 1:
The patent merges the attachment function into the bonding block structure itself through an integrated grounding wire receptacle. This design provides permanent mechanical retention while maintaining ease of installation through simple wire insertion and securing operations, eliminating the need for separate removable clamping mechanisms.
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
The solution provides a reliable, long-term, low-contact-resistant mechanical connection that maintains electrical grounding integrity, reducing the risk of corrosion and mechanical disconnection, thus ensuring safety and performance in harsh environments.
Implementation Method 1
The connecting portion may include solder that solders the ground wire to the ground block
Implementation Method 2
filler metal that brazes the ground wire to the ground block
Data Source
AI summary
A ground block may include a metal ground plate and a ground wire fixedly coupled with the metal ground plate. The ground wire is configured to be non-detachable from the ground block during normal use of the ground block. The ground block may be formed by soldering, brazing, or clamping the ground wire to the metal ground plate.