Electrical Connector Clamp Member for Wire Security
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Solution Overview
Problem
Existing electrical connectors for large diameter wires are inefficient in electrical current transfer and can damage stripped wire ends due to direct contact with rotatable set screws, leading to potential high resistance connections.
Innovation Solution
An electrical connector design featuring a clamp member with first and third clamping surfaces shaped to securely capture a wire between them, using a screw as a forcing member to exert clamping force, with an insert member transmitting this force to enhance electrical conductivity and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rotatable set screw is used to clamp the wire, then the wire can be securely attached to the terminal, but the set screw can damage the stripped wire end and create high resistance connections
Solution Approach 1:
The patent introduces a clamp member with a clamp surface that acts as an intermediary between the set screw and the wire end. The set screw applies force to the clamp member, which then transmits the clamping force through its curved clamp surface to the wire end, preventing direct contact and damage from the set screw while maintaining secure attachment.
Solution Approach 2:
The clamping function is segmented into multiple components: the set screw provides the forcing action, the clamp member provides the clamping structure with a specifically shaped clamp surface, and the wire end receives the clamping force. This segmentation allows each component to be optimized for its specific function, with the clamp surface designed to protect the wire end.
2Device complexity
If a simple clamp structure is used, then the device complexity is reduced, but the electrical current transfer efficiency decreases due to high resistance connections
Solution Approach 1:
The clamp member features a specifically shaped clamp surface with a curved portion that locally optimizes the contact area with the wire end. This local quality enhancement at the clamp surface increases electrical conductivity and reduces resistance at the critical connection point, while the overall clamp structure remains relatively simple.
3Reliability
If a clamp member with shaped clamping surfaces is used, then electrical conductivity is improved and wire protection is enhanced, but the device complexity increases
Solution Approach 1:
The clamp member combines multiple functions into a single component: it provides the clamping structure, the protective clamp surface, and the electrical conduction path. By merging these functions into one integrated piece, the patent reduces the number of separate parts needed while achieving improved electrical conductivity and wire protection.
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 secure wire capture without damaging the wire ends and improves electrical conductivity by reducing resistance at the connection points, ensuring efficient current transfer.
Implementation Method 1
a forcing member, such as a screw, which captures a conductor between the wire and another clamping surface
Data Source
AI summary
A connector combines a clamp member, an insert, and a conductor to provide a robust connection between a wire and an electrically conductive component. A set screw is used to provide a force in a clamping direction through the insert member and a segment of the conductor which is disposed in electrical communication and physical contact with an internal conductive portion of a wire.