Electrical Bushing for Junction Box Wiring Adaptation
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Solution Overview
Problem
Existing electrical junction box installations face difficulties in adding additional electrical lines when only a large orifice is available, but a matching large flex cord and end connector are not available, leading to insecure connections and potential falling of the end connector during installation.
Innovation Solution
An electrical bushing with a collar is used, which increases the outer diameter and threaded length of the flex cord end connector, allowing it to be securely fitted into a larger orifice and preventing the end connector from falling by sandwiching the wall with a nut, ensuring a snug fit and stable attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a smaller end connector is used with adapters (washer, nut, T-shaped adapter) to fit a larger orifice, then the end connector can be installed in the larger orifice, but the installation becomes complex and the end connector may fall into the junction box during installation
Solution Approach 1:
The patent introduces an electrical bushing as an intermediary component between the smaller end connector and the larger orifice. The bushing has an outer diameter that fits the larger orifice and an inner diameter that receives the smaller end connector, eliminating the need for multiple adapters and providing a secure installation path that prevents the end connector from falling into the junction box
Solution Approach 2:
The electrical bushing is designed with a nested structure where the smaller end connector is inserted into the inner diameter of the bushing, which itself is inserted into the larger orifice. This nested arrangement simplifies the installation by combining multiple functional elements into a single integrated component
2Adaptability or versatility
If adapters (washer, nut, T-shaped adapter) are used to increase the diameter of the end connector, then the end connector can fit the larger orifice, but the threaded length available for securing the connection is reduced
Solution Approach 1:
The electrical bushing serves as a mediator that provides additional threaded length on its outer surface. This allows the nut to be secured over a longer threaded portion, ensuring a strong and reliable connection between the end connector and the junction box wall, while the inner diameter of the bushing accommodates the smaller end connector
3Ease of operation
If a smaller end connector is used in a larger orifice without proper adaptation, then the installation is simpler, but the connection becomes insecure and the end connector may fall
Solution Approach 1:
The electrical bushing acts as a mediator that maintains installation simplicity while ensuring connection security. It provides a snug fit in the larger orifice and a secure receiving structure for the smaller end connector, eliminating the need for complex adapter assemblies while maintaining reliable mechanical and electrical connections
Data Source
AI summary
An installation for extending an electrical wiring into a junction box comprises an electrical bushing including a bushing body having an outer diameter corresponding to an inner diameter of an orifice in a junction box. A bushing bore extends through the bushing. A bushing collar terminates the bushing body. Exterior bushing threads are on the bushing body adjacent to the bushing collar. In a typical junction box installation, an end connector on a flex cord may be coupled to the bushing body, for instance by threading of the end connector onto interior bushing threads in the bushing body. The electrical bushing may be inserted through and secured in an orifice in a junction box by threading a nut on the exterior bushing threads. Accordingly, the electrical bushing prevents the end connector on the flex cord from inadvertently falling from the orifice in the junction box.