Screwless Connection Terminal With Wire Manager for Strand Relaxation
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Solution Overview
Problem
Existing electrical wire terminations in screw-type and direct pressure connections are prone to issues such as wire nicking, poor connections, and strand relaxation, leading to increased resistance and overheating, necessitating re-torqueing, which is costly and inefficient.
Innovation Solution
A screwless connection terminal system featuring a wire manager and a clamp spring mechanism that allows for secure clamping of wires between a clamp brace and spring, with a plunger mechanism to control the clamping force, ensuring 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 connection is simple and quick to install, but the wire can be cut or nicked resulting in poor electrical connections and increased resistance
Solution Approach 1:
The patent introduces a compression terminal with a compression member and a stationary contact as intermediary elements between the wire and the electrical connection system. The compression member applies controlled pressure to the wire without direct screw contact, while the stationary contact provides a stable electrical pathway. This intermediary mechanism prevents wire nicking and cutting while maintaining reliable electrical connections.
2Strength
If screw and clamp type terminations are used, then the wire is clamped securely between plates, but strand relaxation occurs due to heating and cooling under stress causing connection loosening
Solution Approach 1:
The patent employs a compression member that is biased by a spring element, creating a dynamic clamping mechanism. The spring continuously applies compressive force to the wire, compensating for thermal expansion and contraction of the stranded wire. This dynamic adjustment prevents connection loosening and maintains stable electrical contact despite temperature variations and strand relaxation.
Solution Approach 2:
The patent changes the clamping force parameter from a static screw torque to a dynamic spring-based compressive force. The spring constant and pre-compression force are carefully selected to maintain optimal contact pressure on the wire throughout operational temperature ranges, preventing both excessive force that could damage the wire and insufficient force that would allow connection loosening.
3Ease of manufacture
If traditional terminations are used, then the initial installation is straightforward, but re-torqueing is required after some duration to alleviate strand relaxation increasing costs
Solution Approach 1:
The patent implements a self-adjusting termination system where the spring-biased compression member automatically compensates for strand relaxation over time. The spring continuously applies compressive force, maintaining optimal contact pressure without requiring manual re-torqueing or maintenance. This self-service mechanism eliminates the need for periodic maintenance interventions and reduces long-term operational costs.
4Adaptability or versatility
If screw-type terminations are used, then the connection can be adjusted and secured, but the wire is subjected to mechanical stress and potential damage from the screw
Solution Approach 1:
The patent introduces a compression member as an intermediary between the adjustment mechanism and the wire. This compression member applies distributed compressive force to the wire insulation and conductor, preventing localized stress concentrations that would cause nicking or cutting. The stationary contact provides the adjustment capability while the compression member protects the wire from direct mechanical damage.
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 efficient wire termination that minimizes wire damage, reduces strand relaxation, and maintains consistent electrical contact without the need for re-torqueing, thereby preventing overheating and improving connection reliability.
Implementation Method 1
a clamp spring 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
Implementation Method 3
The wire manager is positioned on the clamp brace in close proximity to where the wire can be clamped 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 having a wire manager and a plunger.