Screwless Wire Terminal Clamp Assembly for Stable Electrical Connections
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Solution Overview
Problem
Existing electrical wire terminations in electrical wiring devices, such as direct pressure and screw and clamp types, can lead to issues like wire cutting, nicks, increased resistance, and strand relaxation, resulting in overheating and requiring re-torqueing, which increases installation costs.
Innovation Solution
The use of screwless wire terminals with activating members that move between open and closed positions to securely clamp wires, using a clamp brace and force applying members, such as springs, to maintain a constant and continuous electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct pressure type terminations are used, then the wire connection is simple, but the wire can be cut or nicked resulting in poor electrical connections
Solution Approach 1:
The patent introduces a clamp assembly as an intermediary component between the wire and the terminal. The clamp assembly includes a clamp body and a clamp arm that work together to secure the wire without direct pressure on the conductor, thereby preventing wire cutting or nicking while maintaining 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 clamp assembly is designed to self-adjust to the wire size and automatically maintain proper clamping pressure. The spring-loaded mechanism provides continuous contact pressure that compensates for strand relaxation over time, eliminating the need for re-torqueing and preventing increased resistance and overheating.
3Reliability
If terminal screws are tightened to secure wires, then the electrical connection is secure, but re-torqueing is required after some duration of time increasing costs
Solution Approach 1:
The spring-loaded clamp assembly provides continuous clamping pressure on the wire without requiring periodic adjustment. The elastic deformation of the spring member maintains constant force on the wire, ensuring continuous secure electrical connection and eliminating the need for re-torqueing operations.
4Reliability
If screwless wire terminals are used, then strand relaxation is reduced, but the device complexity increases with activating members
Solution Approach 1:
The patent employs a dynamic spring-loaded clamp mechanism that automatically adjusts to wire insertion and provides continuous pressure. The activating member (push button) dynamically transitions between engaged and disengaged states to open and close the clamp, providing reliable operation while maintaining relatively simple overall structure.
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 secure, reliable, and cost-effective electrical connection that reduces the risk of overheating and strand relaxation, eliminating the need for re-torqueing and maintaining consistent conductivity.
Implementation Method 1
The wire terminal includes a clamp brace and a force applying member secured to the clamp brace. The force applying member is movable relative to the clamp brace between a closed position where a wire can be clamped between the force applying member and the clamp brace
Data Source
AI summary
Electrical wiring devices that incorporate screwless 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 an activating member.