Screwless Wiring Terminals With Spring Clamping Against Strand Relaxation
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Solution Overview
Problem
Existing electrical wire terminations in screw and clamp type connections are prone to strand relaxation, leading to increased resistance and overheating due to copper wire heating and cooling, necessitating re-torqueing, which is costly and inefficient.
Innovation Solution
A screwless connection terminal system using a clamp spring mechanism with a plunger that moves between open and closed positions to securely clamp wires, ensuring a constant and continuous electrical connection without the need for screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw and clamp type terminations are used, then electrical connection can be established, but strand relaxation occurs leading to increased resistance and overheating
Solution Approach 1:
The patent employs a dynamic spring mechanism that continuously applies pressure to the wire, allowing the termination to adapt to wire expansion and contraction from thermal cycling. The spring-loaded contact maintains constant electrical pressure without requiring periodic re-torquing, thereby preventing strand relaxation while maintaining reliable electrical connection.
Solution Approach 2:
The invention changes the pressure application parameter from a static screw clamp to a dynamic spring mechanism. This allows the termination to automatically adjust pressure in response to wire dimensional changes from heating and cooling, maintaining stable electrical connection without strand relaxation.
2Ease of operation
If direct pressure type terminations are used, then installation is simple, but wires can be cut or nicked increasing resistance
Solution Approach 1:
The patent introduces a spring-loaded contact as an intermediary between the termination and the wire. This intermediary component applies distributed pressure through the spring mechanism rather than direct point pressure, preventing wire damage while maintaining secure electrical connection and preserving wire integrity.
3Reliability
If terminal screws are re-torqued to alleviate strand relaxation, then connection reliability improves, but installation cost and time increase
Solution Approach 1:
The spring mechanism is pre-loaded during manufacturing to provide continuous pressure throughout the product lifecycle. This preliminary action eliminates the need for future re-torquing operations, as the spring automatically compensates for wire relaxation over time without requiring additional installation time or labor.
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 system provides a reliable and cost-effective solution by maintaining a stable electrical connection, reducing strand relaxation and overheating issues, and eliminating the need for frequent re-torqueing.
Implementation Method 1
a clamp spring movable between a closed position in which the wire is clamped between the clamp spring and the clamp brace and an open position in which the wire may be inserted between the clamp spring and the clamp brace
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.