This disclosure generally relates to clamps for holding wires in place.
Wired connections require continuous contact between an exposed portion of a wire and an electrical contact. As such, it is important that once the wire is in position relative to the contact, the wire must be held or otherwise fixed in place.
Traditionally, when attaching a wire to a contact point, one of two methods is used. In a first, an exposed end of the wire is connected to a conductive ring, which is then slid onto a bolt like a nut. By virtue of its connection to the exposed end, the ring is an extension of the wire. Because this bolt may be the electrified contact point (or an extension of the electrified contact point), the connection of conductive ring to bolt provides an electrical connection. While the contact between the ring and bolt is generally strong due to the ring being relatively flush to the bolt, the connection between the exposed wire and the conductive ring may be weak or inconsistent without soldering to hold the wire to the ring. Soldering the connection is labor-intensive and requires an amount of precision.
In a second method, the exposed wire contacts the electrified bolt directly. Generally, this is accomplished by feeding the exposed wire into a channel, and then turning the bolt down from a top of the channel and onto the wire, such that the exposed wire is sandwiched between a wall of the channel and the electrified bolt. While this a quicker and easier connection that the soldering of the first method, the pressure of the bolt onto the wire often causes the wire to break or causes individual strands of the wire to spread out, which typically weakens the connection. As such, an improved clamping system for holding a wire in place is desired.
Referring now to the drawings, wherein like numerals refer to the same or similar features in the various views,
The wire hole 102 may be positioned on the front wall 101 of the base 110, and may pass entirely through the front wall 101. The wire hole 102 may be shaped and sized to receive relatively large-gauge wires for electronics or speaker applications, such that the wire hole 102 may be 10 mm in diameter (although larger or smaller diameter holes are intended to be within the scope of this disclosure). Furthermore, although the wire hole 102 is shown as a circular hole, the wire hole 102 may be any shape (e.g., square, oval, etc.) capable of receiving a wire and permitting passage of the wire through the hole. The wire hole 102 may be formed in the base 110 via a drill press or similar tool using an appropriately-sized bit, or may be formed during an initial mold of the base 110 (such that the base 110 is molded with the wire hole 102 already in position).
The wire stop 104 may be an indent or slot in the rear wall 103 of the base 110. The wire stop 104 may be sized and shaped similarly to the wire hole 102, such that the wire hole 102 and wire stop 104 may be machined by the same bit in the same press. In contrast to the wire hole 102, the wire stop 104 may not pass through the rear wall 103 of the base 110, such that the wire stop 104 includes a portion of the rear wall 103 as a stop or end point to impede further insertion of the wire. The wire stop 104 may be used as a guide for an amount of exposed wire to be inserted into the base 110. As discussed in depth below with regard to
The gap between the front wall 101 and rear wall 103 may include the cavity 112, such that endpoints for the cavity 112 may be defined by the front wall 101 on a front side and by the rear wall 103 on a rear side. The cavity 112 may be substantially parabolic from a side view (e.g., the view of
As shown in
The insert 120 may include a wire surface 122 and first and second bolt passages 123a, 123b (collectively “bolt passages 123”) that correspond to the bolts 124. The wire surface 122 may be substantially parabolic from a side view, such that a lowest point (relative to the view of
The bolts 124 may each include bolt caps 125a, 125b (collectively “bolt caps 125”) and threaded portions 126. The bolt caps 125 may have a larger diameter than the threaded portions 126, and may be configured to fit with a tool for rotation or turning the bolts 124. Although the bolt caps 125 are shown as substantially circular and configured for use with a hex-key, any shape (e.g., square, triangular, octagonal, etc.) and configuration for any tool (e.g., screwdriver, Allen wrench, etc.) may be considered within the scope of this disclosure. Additionally, although the bolt caps 125 are shown to include a recess for receiving a hex-key, the bolt caps 125 may alternatively include a protrusion for interaction with a tool (e.g., wrench). As described above, the threaded portions 126 may be threaded to interface with the bolt holes 114 of the base 110. In some embodiments, each of threaded portions 126a, 126b may have a same diameter, such that bolts 124a, 124b may be substantially the same bolt. In other embodiments, each of threaded portions 126a, 126b may have a different diameter, such that bolts 124a, 124b may be substantially different bolts. Similarly, each of bolt caps 125a, 125b may be substantially the same (e.g., the same size, be configured for the same tool), or may be substantially different.
The bolt passages 123 may be substantially smooth, such that the bolts 124 are able to rotate freely within the bolt passages 123. In some embodiments, the bolt passages 123 have a diameter substantially equal to the diameter of the threaded portions of the bolts 124, such that the threaded portions of the bolts 124 may be positioned within the bolt passages 123 but the bolt caps 125 may be too large. In these embodiments, the bolt caps 125 may interface with a top surface 120a of the insert 120. As shown in
In either embodiment, the interaction with the bolt caps 125 and a corresponding surface (e.g., top surface 120a or lip 1233 within bolt passages 123) works in conjunction with the bolt holes 114 to cause the bolts 124 to draw the insert 120 into cavity 112 towards base 110. In particular, as the bolts 124 may be secured or turned into the base 110 via the bolt holes 114, the bolts 124 may move longitudinally into the base 110. As the bolts 124 move into the base 110, a distance between the bolt caps 125 and the base 110 may decrease due to the bolts 124 becoming functionally shorter. Because the bolt caps 125 may be interfacing with the insert 120, as described above, the bolt caps 125 may restrict the upward (relative to the view of
The contact 130 may extend laterally from the base 110 and may include an external contact 132. The external contact 132 may be an exposed or partially-exposed electrified surface that may be in connection with the inserted wire via the wire contact 116 (shown in
The wire 140 may be inserted into the wire hole 102. The wire 140 may be inserted for a desired amount, which may be based on an end of the exposed portion 144 abutting the wire stop 104. By then turning or securing at least one of the bolts 124 into the bolt holes 114, the insert 120 may be drawn, as indicated by the single arrow of
The method 900 may also include, at block 920, inserting a fastener into each of the at least two passages in the insert. The fastener may be a bolt (e.g., bolts 124), a screw, a pin, or any similar elongated member with securing capabilities.
The method 900 may further include, at block 930, positioning a wire within the cavity via the opening in the first base wall. The wire (e.g., wire 140) may be any wire carrying an electric current. Prior to positioning the wire, at least a portion of the wire may be stripped (e.g., the insulation around the strands of the wire removed), and the stripped portion may be positioned within the cavity. By stripping the wire, the exposed strands may be able to be in direct contact with the internal contact within the cavity. In those embodiments in which the second base wall includes a recess (e.g., wire stop 104), the wire may be inserted until the wire abuts the recess.
The method 900 may also include, at block 940, turning the fastener in each of the at least two passages. The fastener may engage with the holes in the cavity, which may be threaded, such that turning the fastener causes the fastener to move or be drawn into the holes. This movement of the fastener causes the insert to, in turn, move towards the holes, which compresses the wire against the internal contact to electrify at least a portion of the clamping system.
The systems and methods herein provide numerous benefits over traditional wire clamps. For example, the horizontal length of the wedge-shaped insert 120 enables the system 10 to secure wires 140 of various gauges, particularly large-gauge wires that may present problems for single-bolt clamps. Additionally, as described herein, the shape of the insert 120 distributes the compressing force across a larger surface of the wire 140, in contrast to the single point of applied force from single-bolt clamps, which not only improves the strength of the clamp but also reduces the risk of damage to the wire and improves the consistency of the connection.
In some embodiments, a wire clamping system includes a base comprising a first base wall; a second base wall; and a cavity defined by the first base wall and the second base wall, the cavity having a lower portion. The system also includes an insert configured to fit within the cavity, the insert comprising a first end shaped to be substantially flush with the cavity; a second end opposite the first end; and at least two passages therethrough. The system further includes at least two bolts 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 causes the first end of the insert to move towards the lower portion the cavity.
In some of these embodiments, the first base wall comprises an opening shaped to receive a wire for placement therethrough into the cavity. In other of these embodiments, the second base wall comprises a recess shaped to receive the wire and impede further movement of the wire through the opening in the first base wall. In some of these embodiments, the first end is substantially wedge-shaped. In other of these embodiments, the first end comprises a parabolic side profile with a relative center of the first end being a farthest anterior extension of the first end.
In some of these embodiments, the at least two bolts each comprise a threaded portion; each of the at least two holes are threaded to match the threaded portion of the at least two bolts; and the at least two passages of the insert are unthreaded permitting rotation of the at least two bolts. In some of these embodiments, the at least two bolts each further comprise a cap, the threaded portion of at least one of the at least two bolts having a first diameter and the cap of at least one of the at least two bolts having a second diameter larger than the first diameter, at least one of the at least two passages comprises a first portion having a diameter substantially equal to the first diameter, a second portion having a diameter substantially equal to the second diameter, and a lip defined by a transition from the first portion to the second portion, and the cap abuts the lip as each of the at least one of the at least two bolts is received by each of the at least two passages. In some of these embodiments, the abutting cap applies a force to the lip as the at least two bolts are secured to the at least two holes, and the applied force causes the first end of the insert is caused to move towards the lower portion of cavity by the interface of the cap with the lip.
In some of these embodiments, the system further includes an external contact in electrical connection with a contact positioned in the cavity. In some of these embodiments, the external contact is configured to receive a fuse holder.
In some embodiments, a wire clamping system includes a cavity having a lower portion; and an insert having an end and two passages therethrough, the end shaped to fit within the cavity. Two holes and an internal contact may be positioned adjacent to the lower portion of the cavity. Each of the two passages is configured to receive a fastener, each of the two holes is configured to interface with the fastener, and turning the fastener causes the insert to move within the cavity.
In some of these embodiments, the insert end is substantially wedge-shaped. In other of these embodiments, the insert end comprises a parabolic side profile with a relative center of the first end being a farthest anterior extension of the first end.
In some of these embodiments, the fastener comprises a threaded portion; the two cavity holes are threaded to match the threaded portion; and the two passages of the insert are unthreaded permitting rotation of the fastener.
In some of these embodiments, the fastener further comprises a cap, the threaded portion having a first diameter and the cap having a second diameter larger than the first diameter, the two passages each comprise a first portion having a diameter substantially equal to the first diameter of the fastener, a second portion having a diameter substantially equal to the second diameter of the fastener, and a lip defined by a transition from the first portion to the second portion of the passages, and the cap abuts the lip as each of the fastener is received by each of the two passages. In some of these embodiments, the abutting cap applies a force to the lip as the fastener is turned, and the applied force causes the insert to move towards the lower portion of the cavity.
In some of these embodiments, the system further includes an external contact in electrical connection with the internal conductive contact. In some of these embodiments, the external contact is configured to receive a fuse holder.
In some embodiments, a method for clamping a wire includes providing a wire clamping system that includes a base comprising a first base wall having an opening; a second base wall; a cavity defined by the first base wall and the second base wall, the cavity having a lower portion; and at least two holes and an internal contact positioned adjacent to the lower portion of the cavity. The system further includes an insert configured to fit within the cavity, the insert comprising a first end shaped to be substantially flush with the lower portion of the cavity; a second end opposite the first end; and at least two passages therethrough. The method further includes inserting a fastener into each of the at least two passages via the second end for the fastener to engage with each of the at least two holes; positioning a wire within the cavity via the opening of the first base wall; and turning the fastener, the turning causing the first end of the insert to compress the wire against the internal contact.
In some of these embodiments, the wire clamping system further comprises an external contact in electrical connection with the internal contact, and the method further includes coupling a second wire to the external contact.
While this disclosure has described certain embodiments, it will be understood that the claims are not intended to be limited to these embodiments except as explicitly recited in the claims. On the contrary, the instant disclosure is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the disclosure. Furthermore, in the detailed description of the present disclosure, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it will be obvious to one of ordinary skill in the art that systems and methods consistent with this disclosure may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure various aspects of the present disclosure.