Duplex Electrical Connector With Integral Spring Clip

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Solution Overview

Problem

Existing electrical connector assemblies for attaching cables and wires to electrical boxes are complex, often requiring multiple components and a straight insertion motion, which can lead to misalignment and increased complexity.

Innovation Solution

A duplex connector assembly with an integral spring clip and multi-function insert that provides both electrical insulation and mechanical alignment, allowing for a simple angled insertion and pivoting motion to secure the connector to the electrical box, eliminating the need for a threaded lock nut or snap fit structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a threaded lock nut or snap fit retaining structure is used to secure the connector to the electrical box, then the connector is securely retained, but the device complexity increases due to multiple components

Engineering Contradiction:

Improveconnector retentionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the connector body and retaining structure into a single integrated one-piece component. The connector body includes integrated retaining arms with retaining tips that directly engage the electrical box, eliminating the need for separate lock nuts or snap fit structures. This merging of functions reduces component count while maintaining secure retention.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector body serves multiple functions simultaneously: it provides electrical connection, structural support, and retention mechanisms. The retaining arms are integrated into the connector body itself, allowing a single component to perform both connection and retention functions, thereby reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If a straight insertion motion is used to insert the connector into the knock-out hole, then the connector is installed, but misalignment occurs and installation difficulty increases

Engineering Contradiction:

Improveinstallation easeVSAvoidalignment precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The retaining arms are designed with curved paths that guide the connector body through the knock-out hole during insertion. The curvature of the retaining arms allows the connector to be inserted at an angle and automatically aligns itself as it passes through the hole, eliminating the need for precise straight-line alignment and reducing installation difficulty.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If multiple separate components are used to construct the connector, then each component can be optimized for its specific function, but the overall connector complexity increases

Engineering Contradiction:

Improvefunctional optimizationVSAvoidconnector structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates multiple functions into a single connector body component. The connector body includes integrated retaining arms, cable gripping surfaces, and alignment features all formed as one piece. This eliminates the need for separate components while maintaining the ability to perform multiple functions effectively.

Inventive Principle:

Principle #5Merging (Combining)

4Device complexity

If a simple connector design with fewer components is used, then device complexity is reduced, but retention reliability may be compromised

Engineering Contradiction:

Improvenumber of componentsVSAvoidconnector retention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

While the connector body is a single integrated component, the retaining structure is segmented into multiple retaining arms with individual retaining tips. This segmentation within the integrated design allows each retaining tip to independently engage with the electrical box, providing redundant retention points that enhance reliability while maintaining a simple overall structure.

Inventive Principle:

Principle #1Segmentation

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 simplifies the connector assembly by reducing the number of components, ensuring proper cable alignment, and providing secure retention of cables and the connector to the electrical box through a single angled insertion motion, enhancing ease of installation and reliability.

Implementation Method 1

the free end of the spring clip being deflected prior to contact with a side wall of the junction box, then pivoting and further inserting the connector assembly into the junction box to release the free end and lock the connector body in place

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9640966B1Duplex electrical connector with insert

Publication Date: 2017.05.02 BRIDGEPORT FITTINGS LLC

AI summary

A duplex cable connector assembly including a connector body with an insert and spring clip including a first free end for engaging a side wall of an electrical box upon installation. The insert provides both a sleeve insulator at an end of the connector assembly and a cable divider portion to guide and separate cables. During insertion of the connector body the first free end is deformed so as to permit further insertion into the electrical box. Once the connector body is fully inserted, the spring clip cooperates with a lug on the connector body to hold the connector assembly onto the electrical box.