Screwless Connection 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 susceptible to strand relaxation, leading to increased resistance and overheating, necessitating re-torqueing, which is costly and inefficient.
Innovation Solution
A screwless connection terminal system using a clamp spring mechanism 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 manual adjustment, thereby preventing strand relaxation while maintaining reliable electrical connection.
Solution Approach 2:
The spring mechanism automatically compensates for wire dimensional changes through its inherent elasticity, eliminating the need for external intervention or re-torqueing. The system self-regulates the clamping force to maintain optimal electrical contact despite thermal expansion and contraction of the wire strands.
2Ease of operation
If direct pressure type terminations are used, then installation is simple, but wires can be cut or nicked causing poor electrical connections
Solution Approach 1:
The patent introduces a clamp member as an intermediary between the terminal and the wire, which distributes the clamping force over a larger surface area. This intermediary component prevents direct point-contact pressure that could cut or nick the wire, while still maintaining secure electrical connection through the distributed force applied by the spring-loaded clamp.
3Strength
If screw and clamp type terminations are used, then wire clamping force can be applied, but re-torqueing is required increasing costs
Solution Approach 1:
The spring mechanism provides continuous clamping force without interruption or degradation over time. Unlike screw terminations that lose tension and require periodic re-torqueing, the spring-loaded system maintains constant electrical pressure throughout its service life, eliminating maintenance requirements and reducing loss of time for re-torqueing operations.
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, low-maintenance electrical connection that reduces strand relaxation and overheating, maintaining consistent conductivity and eliminating the need for re-torqueing.
Implementation Method 1
The clamp spring is 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.