Modular Wiring System with Rotational Locking Elements

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Solution Overview

Problem

Existing modular wiring systems lack a secure and efficient method for coupling functional units to wiring units, often resulting in miswiring and inadequate electrical connectivity.

Innovation Solution

A modular wiring system featuring electrically conductive locking elements, such as prongs and flanges, that allow for rotational coupling between functional and wiring units, ensuring both electrical and mechanical security and preventing miswiring through a locking mechanism that snaps into place.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional wiring systems are used without locking elements, then installation is simpler, but electrical connectivity and mechanical security are inadequate

Engineering Contradiction:

Improveelectrical connectivityVSAvoidcoupling mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines electrical connection and mechanical locking functions into a single integrated coupling operation. The locking elements (prongs and flanges) are built into the functional unit and wiring unit themselves, so that when the units are coupled together, both electrical connectivity and mechanical security are achieved simultaneously through the same rotational coupling action, eliminating the need for separate connection steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The locking mechanism is self-actuating through the rotational coupling motion. As the functional unit is rotated into place on the wiring unit, the locking elements automatically engage with the flanges on the wiring unit housing, securing the connection without requiring additional fasteners or manual locking steps. The design ensures that proper rotation automatically triggers the locking action.

Inventive Principle:

Principle #25Self-service

2Productivity

If modular units are designed for easy connection, then installation speed increases, but risk of miswiring increases

Engineering Contradiction:

Improveinstallation speedVSAvoidwiring accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The locking elements have asymmetric geometry that permits coupling only in the correct orientation. The prongs on the functional unit are shaped to engage with specific flanges on the wiring unit housing, and this asymmetric design prevents the functional unit from being installed in incorrect orientations that would cause miswiring. The rotational coupling mechanism itself enforces proper alignment before locking can occur.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The design incorporates preliminary guidance features that prevent misalignment before the locking action occurs. The coupling interface is designed so that only the correct orientation allows the locking elements to engage with the flanges, thereby preventing miswiring from occurring in the first place rather than relying on post-installation verification.

Inventive Principle:

Principle #9Preliminary anti-action

3Ease of operation

If locking elements are integrated into the functional unit, then electrical and mechanical coupling are achieved simultaneously, but manufacturing complexity increases

Engineering Contradiction:

Improvecoupling operationVSAvoidunit fabrication

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The locking elements serve multiple functions simultaneously: they provide electrical connectivity by forming conductive paths between the functional unit and wiring unit, and they provide mechanical security by locking the functional unit to the wiring unit housing. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process despite the integrated design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The system enables easy and secure connection and disconnection of functional units to wiring units, preventing miswiring and ensuring reliable electrical connectivity while allowing for intuitive locking and unlocking mechanisms.

Implementation Method 1

The prong is both electrically and physically coupled to the functional unit at a first end and to the wiring unit at a second end

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

When the functional unit is coupled to the wiring unit, the locking element or prong is both electrically and physically coupled to the functional unit

Methodology Applied

Scientific EffectMechanical coupling: Mechanical Fastener

Implementation Method 3

These flanges operate such that when the functional unit and the wiring unit are placed together, they are rotated to form a locking connection

Methodology Applied

Scientific EffectRotational movement:

Data Source

PatentUS8096818B2Modular wiring system with locking elements

Publication Date: 2012.01.17 LEVITON MFG CO INC

AI summary

A wiring system includes a wiring module and a functional module. The wiring module in at least one embodiment includes elongated holes or openings which are configured to engage or lock with prongs on a functional module to create a lockable connection. The wiring module and the functional module form both a physical and an electrical connection. In another embodiment, there is an adapter which is configured to connect the wiring module and the functional module or unit together.