Wedge-Shaped Wire Clamp for Secure Connections Without Fraying
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Solution Overview
Problem
Existing methods for securing wires to electrical contacts are either labor-intensive due to soldering requirements or prone to weak connections and wire damage from concentrated pressure.
Innovation Solution
A wedge-shaped clamp system comprising a base and insert, where bolts secure the insert into the base, distributing compressive force across a larger surface area to hold the wire securely and reduce fraying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bolt is turned down onto the wire to secure it, then the wire is held in place, but the concentrated pressure causes the wire to break or strands to spread out
Solution Approach 1:
The clamp is divided into a base and a wedge-shaped insert that can be independently positioned and secured. This segmentation allows the compressive force to be applied through a distributed surface area rather than a single concentrated point, preventing wire damage while maintaining connection reliability
Solution Approach 2:
The wedge-shaped insert is pre-positioned within the base to define a specific insertion depth for the wire before the bolt is tightened. This preliminary positioning ensures the wire is held securely without requiring excessive clamping force that could damage the wire strands
2Reliability
If soldering is used to connect the wire to the contact, then a strong electrical connection is achieved, but the process becomes labor-intensive and requires precision
Solution Approach 1:
The invention replaces the thermal/mechanical process of soldering with a purely mechanical clamping system. The wedge-shaped insert secured by a bolt provides both mechanical retention and electrical contact through direct pressure, eliminating the need for soldering equipment and skilled labor while maintaining reliable electrical connection
Solution Approach 2:
The clamp combines the functions of mechanical retention and electrical connection into a single integrated component. The wedge-shaped insert simultaneously holds the wire in position and provides the electrical contact surface, eliminating the need for separate soldering or connection steps
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
Provides a stable and secure wire connection that is less likely to damage the wire, improving consistency and reducing the risk of fraying, especially for large-gauge wires.
Implementation Method 1
distributing compressive force across a larger surface area to hold the wire securely
Data Source
AI summary
A wire clamping system includes a base and an insert. The base includes a first base wall; a second base wall; and a cavity defined by the first base wall and the second base wall. The cavity has a lower portion. The insert is configured to fit within the cavity, and includes a first end shaped to be substantially flush with the cavity; a second end opposite the first end; and at least two passages therethrough. At least two bolts are configured to be received by the second end of the insert and at least two holes positioned in the lower portion of the cavity. Securing the at least two bolts to the at least two holes in the cavity causes the first end of the insert to move towards the lower portion of the cavity.