Power Cord Connector Clamp Spring for Screwless Wire Termination
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Solution Overview
Problem
Existing electrical wire terminations, such as direct pressure and screw and clamp types, are prone to issues like wire damage, strand relaxation, and increased resistance, leading to overheating and requiring re-torquing, which increases costs and reduces connection reliability.
Innovation Solution
The development of screwless connection terminals with a clamp spring mechanism that applies a constant load to wires, using a plunger to move the clamp spring between open and closed positions for secure wire termination, reducing the risk of wire damage and strand relaxation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct pressure type terminations are used, then the connection is simple to install, but the wire can be cut or nicked causing poor electrical connections and overheating
Solution Approach 1:
The terminal is divided into a fixed plate and a movable plate that work together to create a two-stage clamping mechanism. The movable plate with clamp spring provides progressive compression that gently secures the wire without direct high-pressure contact from the fixed plate, preventing wire damage while ensuring reliable electrical connection.
Solution Approach 2:
The clamp spring acts as a cushioning element between the wire and the rigid fixed plate. This spring mechanism provides gradual, controlled compression that cushions the wire against sudden high-pressure contact, preventing nicking and cutting while maintaining sufficient contact pressure for reliable electrical connection.
2Reliability
If screw and clamp type terminations are used, then the wire is clamped between plates, but strand relaxation occurs causing increased resistance and overheating
Solution Approach 1:
The terminal uses a dynamic clamp spring mechanism that can flex and adapt to wire variations. The spring maintains constant contact pressure while accommodating thermal expansion and contraction of the wire strands, preventing the rigid stress that causes strand relaxation in traditional screw and clamp terminations.
Solution Approach 2:
The clamp spring changes its compression parameter dynamically in response to thermal cycles and wire variations. This allows the terminal to maintain optimal contact pressure through temperature changes without imposing constant high stress on the wire strands, thereby preventing strand relaxation while ensuring secure connection.
3Reliability
If terminal screws are re-torqued to alleviate strand relaxation, then connection reliability improves, but installation costs increase
Solution Approach 1:
The clamp spring provides self-adjusting contact pressure that automatically compensates for strand relaxation over time. The spring's inherent elasticity allows it to maintain consistent compression force without requiring manual re-torquing, making the terminal self-sufficient in maintaining connection reliability throughout its service life.
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
This solution provides reliable, long-lasting electrical connections with reduced risk of overheating and eliminates the need for re-torquing, enhancing the durability and efficiency of electrical wiring devices.
Implementation Method 1
a clamp spring movable relative to the clamp brace between a closed position where a wire can be clamped between the clamp spring and the clamp brace
Implementation Method 2
The plunger is interactive with the clamp spring such that movement of the plunger in a first direction relative to the clamp brace causes the plunger to apply a mechanical load to the clamp spring
Data Source
AI summary
Electrical wiring devices that incorporate clamp-type wire terminal connections are described. The electrical wiring devices include for example, single and duplex blade-type electrical receptacles, blade-type locking electrical receptacles, single or multi-pole electrical switches, combination switches and blade-type receptacles, blade-type plugs for electrical cords and blade-type connectors for electrical cords. The electrical wiring devices include a plurality of contact assemblies. Each contact assembly includes a wire terminal and a plunger.