Wiring Device Terminal with Wire Guide for Straight Installation
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Solution Overview
Problem
Existing wiring device terminals have limited torque capacity and are difficult to install due to the need to bend or wrap rigid wires around screws, making straight-wire installation challenging.
Innovation Solution
A wiring device terminal with a conductive plate and wire guide that uses a screw with an enlarged head and concave shape to draw the wire inward, along with a lever arm and ramp to resist torque, allowing for secure straight-wire installation without bending or wrapping, and a wire trap to guide the wire to the fastener.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional ground terminal with a screw is used, then the wire can be secured to the terminal, but the wire must be bent or wrapped around the screw which makes installation difficult and time-consuming
Solution Approach 1:
The terminal pre-forms a receptacle or channel that guides the wire into position before the screw is inserted. The wire is positioned in advance within the terminal structure, eliminating the need for bending or wrapping during the fastening operation.
Solution Approach 2:
A wire guide or channel acts as an intermediary element between the wire and the screw. This intermediary structure receives the straight wire and directs it to the proper position, facilitating easy installation without requiring the wire to be manually bent or wrapped.
2Strength
If an extended thin piece of metal is used as the ground terminal, then the structure is simple, but the torque capacity is limited
Solution Approach 1:
The terminal is divided into distinct functional segments: a support structure for torque resistance, a receptacle for wire positioning, and a fastening mechanism. This segmentation allows each part to be optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
The terminal combines different material properties or structural configurations to achieve both high torque capacity and electrical conductivity. The support structure may use thicker gauge metal or reinforced geometry while the contact surfaces maintain conductive properties.
3Reliability
If rigid wires are used, then the wire provides good electrical connection, but the wire is difficult to bend or wrap around the screw
Solution Approach 1:
The terminal structure prepares the wire path in advance by providing a pre-formed receptacle or channel. The rigid wire is inserted straight into this pre-prepared structure, eliminating the need for bending or wrapping that would compromise the wire's rigidity and connection quality.
Solution Approach 2:
Instead of requiring the wire to conform to the screw geometry (bending or wrapping), the invention inverts the approach by having the terminal structure conform to the straight wire. The receptacle is shaped to receive the straight wire, and the screw fastens the wire in this straight configuration.
Data Source
AI summary
A terminal of a wiring device includes a conductive plate, an arm, and a wire guide. The conductive plate has an opening formed therethrough. The conductive plate receives a fastener for securing a substantially straight wire to the conductive plate. The arm extends from the conductive plate and defines a mating element on the wiring device. The arm is an anchor of said conductive plate. The mating element of the arm is adapted to cooperate with a complementary mating element. The wire guide is in spaced relation to the fastener to position the substantially straight wire adjacent to the fastener.