Lever-Spring Wire Terminal for Tool-Free Secure Insertion
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Solution Overview
Problem
Existing wire termination mechanisms in wiring devices often require complex procedures and tools, and they struggle to securely retain wires during installation, leading to inefficiencies and potential errors.
Innovation Solution
A wire terminal design featuring a lever, cage, and spring mechanism that allows for easy wire insertion and secure retention without tools, using a pivotable lever to enlarge the wire receiving space and apply supplemental force to maintain contact with the electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire termination mechanisms (side-wire, back-wire, push-in) are used, then wire installation can be completed, but the process requires complex procedures and tools, and secure wire retention during installation is difficult to achieve
Solution Approach 1:
The wire terminal employs a dynamic lever mechanism that transitions between open and closed positions. The lever is movable between a first position (open) that allows wire insertion and a second position (closed) that secures the wire through spring pressure. This dynamic structure enables both easy wire installation and secure retention without requiring complex procedures or tools.
Solution Approach 2:
The spring-loaded mechanism automatically applies retention force to the wire once the lever is closed. The spring is compressed by the lever movement and automatically exerts pressure on the wire to maintain secure contact with the electrical contact. This self-service mechanism eliminates the need for additional tools or complex procedures to ensure wire retention security.
2Productivity
If traditional wire termination mechanisms are used, then wire installation can be completed, but it requires tools and complex procedures which reduces installation speed
Solution Approach 1:
The dynamic lever mechanism allows for rapid wire installation by simply moving the lever from the open to closed position. This single motion simultaneously completes the wire insertion and secures the wire, eliminating the need for multiple steps or tools. The simplicity of the operational sequence significantly increases installation speed despite the mechanical complexity of the internal components.
Solution Approach 2:
The wire terminal is divided into distinct functional components: the lever for operation, the spring for retention force, the cage for wire guidance, and the electrical contact for electrical connection. This segmentation allows each component to perform its specific function efficiently, contributing to overall installation speed while maintaining a manageable device structure.
3Ease of operation
If wire receiving space is small, then device size is reduced, but wire insertion encounters interference and resistance
Solution Approach 1:
The wire receiving space is dynamically adjusted through lever movement. In the open position, the lever moves the spring away from the electrical contact, enlarging the wire receiving space to facilitate easy wire insertion. When the lever closes, the space is reduced to maintain secure wire retention. This dynamic volume adjustment resolves the contradiction between insertion ease and space efficiency.
Solution Approach 2:
Before wire insertion, the lever is positioned in the open state, which preliminarily enlarges the wire receiving space by moving the spring away from the electrical contact. This preliminary action removes potential interference and resistance before the wire insertion process begins, ensuring smooth wire placement.
4Reliability
If spring pressure is high, then wire retention is secure, but wire insertion becomes difficult due to resistance
Solution Approach 1:
The spring pressure is dynamically controlled through lever position. During wire insertion, the lever is in the open position, which moves the spring away from the electrical contact and reduces spring pressure, allowing easy wire insertion. After insertion, the lever closes, compressing the spring to apply high retention pressure for secure wire holding. This dynamic pressure control resolves the contradiction between retention security and insertion ease.
Solution Approach 2:
The lever mechanism preliminarily counteracts the spring pressure by moving the spring away from the electrical contact before wire insertion. This preliminary anti-action reduces or eliminates spring resistance during the insertion process, making wire placement easy. After insertion, the lever releases this counter-action, allowing the spring to apply full retention pressure.
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
Facilitates quicker and more secure wire installation, accommodating various wire gauges and types, while minimizing interference and resistance during insertion, and providing additional retention force to ensure reliable electrical connectivity.
Implementation Method 1
a spring arranged and configured to be biased by the lever into contact with the electrical wire to secure the electrical wire between the lever and the electrical contact
Data Source
AI summary
The present disclosure relates to wire terminals and/or termination mechanisms arranged and configured for use with a wiring device The wire terminals may be used in any suitable line-voltage wiring device. The wire terminals are arranged and configured to selectively receive a distal end of a wire therein.