Elliptical Wire Clamp for Flexible Routing and Bend Protection
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Solution Overview
Problem
Existing wire management solutions, such as zip ties and wire clips, fail to effectively organize wires in a way that prolongs their lifespan and allows for easy access and movement, often leading to wire damage and failure due to improper routing and contact with sharp edges.
Innovation Solution
A wire clamp comprising a bottom piece with an elliptical barrier and legs, and a top piece with flanges and a protrusion, designed to be mounted on a rail using a self-tapping fastener, which creates channels for wire routing that allow for flexible orientation and minimize wire pinching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wire clips are used to manage wires, then wires can be secured to rails, but the clips can only manage wires in a single direction parallel to the rail and require many clips which are expensive
Solution Approach 1:
The wire management system is divided into modular clamp units, each capable of independent wire management. Each clamp can handle multiple wires in different directions, replacing the need for numerous single-direction clips while maintaining organized wire routing along the rail structure.
Solution Approach 2:
Each wire clamp is designed as a multi-functional device that can manage wires in multiple directions simultaneously. The clamp structure includes channels and openings that accommodate wires running parallel to the rail, perpendicular to the rail, and at various angles, eliminating the need for separate clips for different routing directions.
2Reliability
If traditional wire management methods are used, then wires can be routed, but wires may contact sharp edges and suffer damage reducing their lifespan
Solution Approach 1:
The wire clamp acts as an intermediary protective element between the wires and the rail structure. The clamp's body with its channels and barriers provides a protective interface that guides wires away from sharp edges and potential damage sources while maintaining proper wire routing and organization.
Solution Approach 2:
The clamp design incorporates protective barriers and rounded channel edges that prevent wire contact with sharp surfaces before damage can occur. The structure provides pre-established protection by positioning wires within protected channels and using the clamp body as a cushioning element between wires and potentially harmful surfaces.
3Stability of the object's composition
If wires are tightly clamped to prevent movement, then wire organization is improved, but access and movement of wires becomes difficult for maintenance
Solution Approach 1:
The wire clamp incorporates dynamic features including adjustable clamping mechanisms and accessible wire openings that allow the clamp to maintain stable wire organization during normal operation while enabling easy wire access when needed for maintenance or reconfiguration.
Solution Approach 2:
The clamp design includes pre-positioned wire openings and access points that are built into the structure, allowing wires to be easily accessed for maintenance without requiring disassembly of the entire clamp. The preliminary design of access pathways maintains organization while facilitating future wire movement.
Data Source
AI summary
A wire clamp may include a bottom piece having: a first base portion defining a first aperture, an at least partially elliptical barrier extending from the first base portion about the first aperture, and a plurality of legs extending from sides of the first base portion; a top piece having: a second base portion, a protrusion extending from the second base portion, the protrusion defining a second aperture, and a plurality of legs extending from sides of the second base portion; and a fastener. The first aperture and the second aperture may be configured to align and receive the fastener therethrough. A first side of the partially elliptical barrier and a first portion of the plurality of legs may define a first wire channel, and a second side of the partially elliptical barrier and a second portion of the plurality of legs may define a second wire channel.