Dual-Lock Split Washer for IP-Rated Cable Gland Replacement
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Solution Overview
Problem
Existing washers for electrical junction boxes require mechanical disconnection and reconnection of cables and glands for replacement, leading to high costs and downtime due to safety regulations, especially for junction boxes needing IP X8 water ingress protection.
Innovation Solution
A unitary piece dual lock split washer with a resilient and flexible material, featuring a split design and integrated locking mechanisms, allowing installation without disconnecting cables, and providing a seal through engagement of locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional washer is used at an electrical termination, then ingress protection (IP rating) is provided, but washer replacement requires mechanical disconnection and reconnection of cables and cable glands, leading to significant downtime and cost
Solution Approach 1:
The washer is designed as a split washer with a longitudinal split that allows the two ends to be separated. This segmentation enables the washer to be installed or replaced by simply opening the split ends without requiring disconnection of the cable gland or cable, thus resolving the contradiction between maintaining ingress protection and reducing replacement time
Solution Approach 2:
The washer incorporates a joint structure with locking mechanisms that can dynamically transition between locked and unlocked states. The first and second locking mechanisms with their respective parts allow the ends to be easily separated for replacement and then securely locked back together, enabling quick maintenance while maintaining the seal for ingress protection
2Reliability
If a washer with secure locking is used to maintain seal integrity, then ingress protection is ensured, but the structure becomes more complex
Solution Approach 1:
The locking structure is segmented into multiple independent locking mechanisms (first and second locking mechanisms with respective parts on different ends). This segmentation allows each locking mechanism to be simple in itself while collectively providing robust seal integrity, avoiding the need for a single complex locking structure
Solution Approach 2:
Multiple locking functions are merged into a unified joint structure that integrates the first and second locking mechanisms within the same washer body. This merging provides comprehensive seal integrity while keeping individual components simple, resolving the contradiction between reliability and complexity
3Loss of time
If a split washer design is used to enable easy replacement, then installation time is reduced, but maintaining a substantial seal across the split becomes more difficult
Solution Approach 1:
The joint structure incorporates dynamic locking mechanisms that transition from an open state (for easy installation) to a locked state (for maintaining seal integrity). The first and second locking mechanisms with their respective parts enable the ends to be easily separated during installation and then securely locked together to maintain a substantial seal across the split
Solution Approach 2:
The locking mechanisms are designed to automatically engage when the ends are brought together during installation. This preliminary action of pre-positioning the locking parts ensures that the seal is maintained without requiring additional sealing components or complex assembly steps, resolving the contradiction between easy installation and seal integrity
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
Enables quick and efficient washer replacement without shutting down electrical systems, maintaining IP ratings, and reducing downtime and costs associated with traditional washer replacement methods.
Implementation Method 1
a single piece body made of a resilient and flexible material, the body having an inner circumferential edge, a radially outer peripheral edge and a split extending between the inner and out edges
Implementation Method 2
the joint structure has a first locking mechanism and a second locking mechanism each locking mechanism having respective parts on the first and second ends
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A washer (20) comprises a single piece body (22) made of a resilient and flexible material. The body (22) has a split (28) extending between an inner circumferential edge (24) and a radially outer peripheral edge (26) to provide the body with first and second ends (30), (32). The end (30) has circumferentially extending and radially spaced fingers (54) and (64). The end (32) has circumferentially extending and radially spaced fingers (56) and (66). A joint structure (40) is integrally formed with the first and second ends. The joint structure has a first locking mechanism (42) and a second locking mechanism (44). The second locking mechanism is only engageable after the first locking mechanism is fully engaged. The first locking mechanism (42) comprises teeth (48) on the finger (54), and teeth (52) on the finger (56). The second locking mechanism (44) comprises a recess (58) carried by the finger (56) and a protrusion (62) carried on the finger (64). When the washer (20) is fully engaged the finger (54) fits into the gap between the fingers (56) and (66) of the second end (32) and finger (56) fits into the gap between the fingers (64) and (54) of the second end (32) with the teeth (48) and (52) fully engaged and the protrusion (62) can be pushed into the recess (58).