Tool-Free Feedthrough Connector with Spring-Locked Cam
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Solution Overview
Problem
Existing connectors for electrical cables and flexible conduits require tools for installation and removal, are time-consuming, and often interfere with cable conductors, making them inefficient for wiring installations.
Innovation Solution
A connector design featuring a spring, shell, and optional insulator with angled insertion tabs and hook latches that allow for tool-free, snap-and-press connections to electrical panels, providing secure grounding and easy conductor passage without rotational screwing or locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional threaded connectors with locknuts and lateral screws are used, then secure grounding and electrical continuity are achieved, but tool usage and installation time increase significantly
Solution Approach 1:
The patent replaces the traditional mechanical screw-and-locknut system with a spring-loaded cam mechanism. The cam, when rotated, forces the spring to compress and the locking tabs to engage with the panel aperture edges, achieving secure mechanical and electrical connection without requiring wrenches or screwdrivers.
Solution Approach 2:
The spring mechanism provides self-latching functionality where the cam rotation automatically compresses the spring and engages the locking tabs into the panel aperture. The design allows the connector to self-secure without external tool assistance, while maintaining reliable electrical continuity through the metallic spring and tab structure.
2Loss of time
If snap engagement connectors are used to eliminate tools, then installation time is reduced, but excessive force and effort are required for installation and removal
Solution Approach 1:
The patent employs a dynamic spring-cam system where the spring progressively compresses during cam rotation, distributing the engagement force over time rather than requiring instantaneous high force. The cam's rotational motion converts small incremental forces into the gradual compression of the spring and engagement of locking tabs, reducing peak force requirements compared to rigid snap-fit mechanisms.
3Strength
If conventional connectors with lateral screws are used, then cable securing is achieved, but conductor passage is interfered with and positioning precision is reduced
Solution Approach 1:
The connector is segmented into distinct functional zones: the spring-loaded cam mechanism for panel mounting, the metallic body for structural support and grounding, and the trailing end opening for cable insertion. This segmentation allows the cable to be secured at the trailing end by the metallic body's grip features without interference from the cam mechanism, which is positioned at the leading end for panel engagement.
4Reliability
If connectors require tool-based locking mechanisms, then secure connection is achieved, but device complexity and number of components increase
Solution Approach 1:
The patent merges multiple functions into the cam mechanism: it serves as both the actuating element for spring compression and the locking element that engages with the panel aperture edges. The spring itself serves dual purposes as both the force-generating element and part of the electrical continuity path. This merging reduces the number of separate components compared to traditional connectors that require distinct locknuts, screws, and mounting brackets.
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, secure, and tool-free connections and disconnections of electrical cables to panels, significantly reducing installation and removal time and effort, while maintaining effective grounding and conductor passage.
Implementation Method 1
The spring has a base and two insertion tabs that bend at an angle around a longitudinal central axis... The resilient insertion tabs push the hook latches against the inner wall of the panel
Data Source
AI summary
The present invention is a connector for connecting an electrical cable having cladding to an aperture in an electrical panel. The assembled connector has a spring, a shell, and a insulator along a longitudinal axis. The spring has a base from which two insertion tabs extend coaxial with the axis and two clad blocking tabs extending perpendicular from the two insertion tabs to prevent over-insertion of the cladding into the connector. The insertion tabs of the spring have hook latches extending past the insulator that lock the connector in the panel, and the base of the spring has a hole to receive the cable where clamping tabs clampably lock the cable in the connector.