Modular Electrical Conduit Coupling System for Tool-Free Installation
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Solution Overview
Problem
Current electrical conduit systems are cumbersome to install and require the use of tools, making them inefficient for protecting wires and installing electrical conduit in structures.
Innovation Solution
The development of a stud wire protector and electrical conduit coupling system that includes hollow cylindrical members with press-fitting and tapered fittings, allowing for tool-free installation and protection of wires by inserting the system into pre-drilled holes in studs, and conduit couplers that accept springs and electrical conduit ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical conduit systems are used, then wire protection is achieved, but installation becomes cumbersome and requires tools
Solution Approach 1:
The conduit system is divided into multiple modular sections (conduit bodies, elbows, tees, couplings) that can be independently installed and connected. Each section is a self-contained unit that fits together, eliminating the need for complex tool-based assembly while maintaining protective functionality.
Solution Approach 2:
The conduit system uses nested cylindrical structures where inner conduit sections fit within outer conduit bodies. The conduit couplings nest over the conduit ends, and the entire assembly fits within wall cavities and around studs, enabling tool-free insertion and connection while preserving wire protection.
2Reliability
If traditional conduit installation methods are used, then structural protection is provided, but installation time increases
Solution Approach 1:
The conduit sections are pre-manufactured with integrated coupling mechanisms and connection features. The modular components are prepared in advance with precision-fit interfaces, allowing installers to simply connect pieces together without on-site fabrication or tool-based assembly, thereby maintaining structural protection while dramatically increasing installation speed.
Solution Approach 2:
The invention combines multiple functions into single components: conduit bodies provide both wire protection and connection points; couplings provide both structural integrity and alignment; elbows and tees provide both directional changes and structural support. This merging of functions reduces the number of separate installation steps and accelerates productivity while maintaining protection.
3Ease of operation
If modular conduit sections are used, then installation simplicity is improved, but system complexity increases
Solution Approach 1:
The conduit system employs universal coupling mechanisms that work across all conduit section types (elbows, tees, straight sections). The same coupling design fits multiple conduit diameters and configurations, standardizing the connection process and reducing operational complexity despite the variety of modular components available.
Solution Approach 2:
The conduit components use asymmetric fitting interfaces with distinct male and female connection elements. This asymmetry provides foolproof alignment and prevents incorrect assembly, making the system easier to install correctly despite having multiple different component types. The asymmetric design ensures proper orientation without requiring complex alignment procedures.
Data Source
AI summary
The present invention provides a base electrical box, and an end portion. The end portion is added to the base electrical box to substantially complete the electrical box. The electrical box also includes at least one intermediate portion that is added to complete the electrical box. The at least one intermediate portion is placed between the base electric box and the end portion.