Modular Cable Connector Assembly for Safer Building Wiring
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Solution Overview
Problem
The installation of electrical wiring and wiring devices in industrial, commercial, and residential buildings is labor-intensive, requiring skilled electricians and posing safety hazards due to live electrical connections.
Innovation Solution
An electrical cable connecting system comprising a cable protector and connector that facilitates the connection of pre-cut, factory-terminated building electrical cables to wiring devices with reduced labor, using a modular design that includes a slidable cover and clamp terminals for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical cable installation procedures are used, then electrical wiring devices can be installed with reliable electrical connections, but the installation process becomes labor-intensive and requires skilled electricians
Solution Approach 1:
The cable is pre-cut and factory-terminated with connectors attached before installation. This preliminary preparation of electrical connections eliminates the need for field stripping, twisting, and connecting of individual conductors, dramatically reducing installation labor while maintaining connection reliability through factory-controlled termination processes
Solution Approach 2:
The connector integrates multiple functions into a single component: it provides mechanical coupling between cable and device, electrical connection through integrated terminals, and structural support. This merging of functions into one assembly eliminates the need for separate pig-tail jumpers and individual wire connectors, reducing installation complexity and labor requirements
2Ease of manufacture
If conventional installation procedures with exposed conductors are used, then electrical connections can be made, but safety hazards arise from live electrical connections during installation
Solution Approach 1:
The connector serves as an intermediary component that receives and isolates the exposed conductors from the installer. The cable protector acts as an additional intermediary barrier that covers and insulates exposed conductors during installation, allowing workers to handle the assembly without direct contact with live electrical parts, thereby eliminating electrical shock hazards while maintaining installation simplicity
Solution Approach 2:
The cable protector is installed over the cable end before any electrical connections are made, proactively preventing exposure to live conductors. This preliminary protective action blocks access to hazardous electrical parts throughout the installation process, eliminating safety hazards before they can affect workers
3Adaptability or versatility
If individual wire stripping and pig-tail connections are made, then electrical devices can be connected to building cables, but the installation process requires high skill levels and significant labor
Solution Approach 1:
The connector is pre-assembled with all necessary electrical terminals and connection elements attached to the cable end at the factory. This preliminary configuration provides adaptability to connect with various wiring devices through standardized interfaces while eliminating the complexity of field assembly, stripping, and termination work
Solution Approach 2:
The connector design incorporates universal mounting features and standardized electrical interfaces that enable connection with multiple types of wiring devices. The modular design with integrated terminals provides multi-functional capability to handle different electrical connection requirements without increasing installation complexity
Data Source
AI summary
An electrical cable connecting system includes a modular electrical or electronic wiring device assembly, in which an electrical or electronic wiring device and a connector may be electrically coupled via pig-tail jumper electrical wires. The connector may be coupled to cable electrical wires fitted with a cable protector to protect the electrical wire conductors therein. The connector may include internal electrical terminals for electrically coupling building electrical cable wires with corresponding jumper electrical wires. The connector may be mechanically and electrically coupled to and directly terminate one or more building electrical cables, which may provide power to or from one or more electrical or electronic wiring devices by establishing an electrical pathway from a source of electrical power, through the building electrical cable wires, the connector, the pig-tail jumper electrical wires and an electrical or electronic wiring device.