Tool-Free Conduit Connector with Spring Tangs
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Solution Overview
Problem
Current electrical conduit connectors, particularly two-part locknut connectors, are labor-intensive to install, require tools, and can lead to safety issues due to loose connections, cross-threading, and space constraints within enclosures, while snap-in connectors often fail to provide a rigid connection, posing electrical continuity problems.
Innovation Solution
A conduit connector design featuring a body with a hollow center, a spring with engagement tangs, and an antishort bush that allows for easy installation and removal without tools, providing a secure connection to junction boxes without requiring access to the interior and accommodating various conduit types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two-part locknut connectors are used, then a rigid connection is established, but the installation becomes labor-intensive and requires tools
Solution Approach 1:
The connector is divided into two functional parts: a body portion that interfaces with the conduit and a spring-loaded tang portion that interfaces with the junction box. This segmentation allows the connector to be installed in a single operation without requiring separate threading operations, eliminating the need for tools while maintaining rigid connection through the spring tang's engagement with the box opening.
Solution Approach 2:
The spring-loaded tang mechanism automatically engages with the junction box opening when the connector is inserted through the conduit. The spring force provides self-tightening action that secures the connector rigidly to the box without requiring external tools or manual threading operations, making the installation self-service and tool-free.
2Reliability
If two-part locknut connectors are used, then a secure connection is achieved, but the installation time increases due to disassembly and reassembly
Solution Approach 1:
The spring tangs are pre-loaded with elastic energy during manufacturing, storing the force needed for secure engagement. This preliminary action eliminates the need for time-consuming threading and tightening operations during installation, as the spring automatically engages and secures the connector to the junction box in a single insertion motion.
3Ease of repair
If locknut connectors are disassembled, then the locknut can be dropped or misplaced, but the connector becomes reusable
Solution Approach 1:
The spring and tangs are integrated as a single unit with the connector body, forming an inseparable assembly. The spring tangs extend through the body and are retained by the spring's elastic properties, making it impossible to detach or lose any component during installation or removal. This merging ensures that the entire connector can be safely removed and reused without risking loss of parts.
4Ease of operation
If snap-in connectors are used, then quick installation is achieved, but rigid connection and electrical continuity are not provided
Solution Approach 1:
The connector uses a spring-loaded mechanical engagement system that transforms the installation process from a simple snap-fit to a controlled elastic deformation process. The spring tangs flex during insertion and then rebound to create a rigid, metal-to-metal connection with the junction box, providing both quick installation and reliable electrical continuity through the spring's elastic recovery force.
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 solution enables quick, tool-free installation and secure, reusable connections that reduce labor costs and safety risks, while ensuring electrical integrity by providing a rigid attachment to junction boxes, thus addressing the limitations of existing connectors.
Implementation Method 1
a spring disposed within the hollow center and extending out of the connecting end
Data Source
AI summary
In one embodiment, the conduit connector can comprise: a body comprising a hollow center capable of receiving a conduit in a receiving end, wherein the hollow center extends from the receiving end to the connecting end; a spring disposed within the hollow center and extending out of the connecting end, wherein the spring comprises engagement tangs extending into the hollow center, toward the connection end, and spring tangs extending past the connection end and spaced apart a distance greater than or equal to an opening diameter in a junction box; and an antishort bush located in the connecting end of the body, retaining the spring in the body.