Telescopic Binding Screw for Stranded Aluminum Wire

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Stranded aluminum wires in wire connection assemblies are prone to damage and oxide layer penetration issues when using traditional binding screws, leading to poor electrical contact and increased risk of wire breakage.

Innovation Solution

A binding screw design with an inner and outer bolt featuring a penetration portion with conical sections to pierce through the wire without damaging it, and shear elements with breaking points to manage torque and prevent wire strand separation, ensuring secure and reliable electrical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional binding screw is used to clamp stranded aluminum wires, then the wire is compressed to establish electrical contact, but the wire strands are prone to breaking and ripping apart due to the turning movement of the screw

Engineering Contradiction:

Improvewire connection reliabilityVSAvoidwire strand strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The binding screw is divided into two separate parts: an inner bolt and an outer bolt. The inner bolt performs the clamping function while the outer bolt provides structural support and engages the threaded bore. This segmentation allows the inner bolt to apply compression force without the wire strands being subjected to the damaging turning movement of a single integrated screw, thereby preventing wire strand breakage while maintaining connection reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner bolt is nested within the outer bolt, with the inner bolt's outer thread engaging the outer bolt's inner thread. This nested configuration allows the inner bolt to rotate independently within the outer bolt during the clamping process, enabling the wire to be compressed between the inner bolt and receiving chamber walls without the wire strands being damaged by the rotation of the outer bolt that engages the threaded bore

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If the screw penetrates the aluminum wire to establish electrical contact, then proper electrical connection is achieved, but the oxide layer on the aluminum wire must be penetrated which increases the risk of wire damage

Engineering Contradiction:

Improveelectrical contact qualityVSAvoidoxide layer penetration risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The inner bolt is designed with a localized conical penetration portion at its tip that is specifically shaped to pierce through the aluminum oxide layer. This conical geometry concentrates the force at a small contact area, enabling effective penetration of the oxide layer to establish electrical contact with the underlying aluminum wire without requiring excessive force that would damage the wire strands. The rest of the inner bolt maintains a smooth surface to avoid wire damage during rotation

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10109930B2Wire connection assembly with telescopic binding screw

Publication Date: 2018.10.23 TYCO ELECTRONICS SIMEL

AI summary

A wire connection assembly comprises a connector body and a binding screw. The connector body forms a wire receiving chamber and has a threaded bore extending perpendicular to the wire receiving chamber. The binding screw has an inner bolt and an outer bolt. The inner bolt includes an outer thread and an inner breaking point. The outer bolt includes an inner thread engaging the outer thread, a threaded section engaging the threaded bore, and an outer breaking point.