Modifiable Electrical Connector Lug With Segmented Design
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Solution Overview
Problem
Existing electrical connectors with two-hole lugs, when modified to one-hole lugs by cutting, risk voiding UL approval due to aggressive material removal, leading to inconsistent and unsafe modifications.
Innovation Solution
An electrical connector design featuring a lug with multiple portions and weakened sections between them, allowing controlled removal of one portion to reconfigure the connector without compromising UL approval, using recesses or indentations to facilitate safe and repeatable modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If installers cut two-hole lugs with saws to make one-hole lugs, then the lug length is reduced to fit particular applications, but UL approval is voided and material removal becomes inconsistent
Solution Approach 1:
The lug is divided into multiple separable portions (first lug portion and second lug portion) connected by a weakened section. This segmentation allows the lug to be cleanly divided into a one-hole configuration by removing the first lug portion, while the remaining second lug portion maintains the structural integrity and UL approval of the original two-hole lug design.
Solution Approach 2:
The weakened section is pre-formed between the lug portions during manufacturing, creating a predetermined break point. This preliminary action ensures that when the lug is modified, the separation occurs cleanly at the intended location without requiring aggressive cutting, thereby preserving UL approval and ensuring consistent modification results.
2Adaptability or versatility
If installers cut two-hole lugs with saws to make one-hole lugs, then the lug is adapted to specific applications, but too much material may be removed causing safety issues
Solution Approach 1:
The lug is segmented into removable and retained portions, allowing adaptability to different applications (one-hole or two-hole configurations) while ensuring that the retained second lug portion maintains sufficient strength through its original designed structure and connection to the connector body.
Solution Approach 2:
The weakened section is pre-formed to guide clean separation at the exact intended location, preventing over-removal of material. This ensures that the remaining lug portion retains its full designed strength and structural integrity, avoiding safety issues from excessive material removal.
3Adaptability or versatility
If two-hole lugs are modified by cutting, then one-hole configuration is achieved, but modifications are inconsistent and unsafe
Solution Approach 1:
The lug is pre-segmented into distinct portions with a predetermined weakened section, ensuring that modification to a one-hole configuration produces a consistent, repeatable result. The weakened section guarantees clean separation at the exact same location for every lug, eliminating variability in manual cutting operations.
Solution Approach 2:
The weakened section is created during manufacturing as a predetermined break point with specific geometric features (recesses, indentations, or reduced cross-section). This preliminary action ensures that all lugs modify consistently when broken at the weakened section, achieving uniform one-hole configurations without the inconsistency of manual cutting.
Data Source
AI summary
An electrical connector including a first connection section adapted to connect the electrical connector to a first conductor; and a second connection section connected to the first connection section. The second connection section includes a lug with a plurality of lug portions with at least one weakened section between the lug portions. Each lug portion has a hole adapted to be located onto a respective mounting post. A first one of the lug portions can be removed from a second one of the lug portions at the weakened section to reconfigure the second connection section to have one less lug portion.