Nonmetallic Push-In Connector for Multiple Wire Gauges

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Solution Overview

Problem

Existing connectors for residential light fixtures are cumbersome to install, particularly in smaller fixtures with lower profiles, and lack versatility in accommodating multiple wire gauges, leading to safety concerns and installation challenges.

Innovation Solution

A non-metallic push-in connector with a cylindrical body featuring longitudinal protrusions and a flexible design that allows secure accommodation of multiple wire gauges by rotating the connector body, eliminating the need for tools and accommodating different housing sizes through flexible exterior protrusions and an annular flange.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional metal connectors with screws and nuts are used, then secure electrical connection is achieved, but installation becomes cumbersome and time-consuming

Engineering Contradiction:

Improveelectrical connection securityVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the traditional mechanical screw-and-nut fastening system with a push-in connector that uses elastic deformation and friction. The connector body is inserted through the knock-out opening and secures wires through elastic retention mechanisms, eliminating the need for tools and multiple fastening components while maintaining secure electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the complex fastening components (screws, nuts, plates) from the connector assembly, leaving only the essential wire-conducting function. The simplified connector body performs both the electrical connection and the mechanical securing functions that were previously distributed across multiple components.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If fixed-groove connectors are used, then specific wire gauges are securely held, but versatility to accommodate multiple wire gauges is lost

Engineering Contradiction:

Improvewire gauge fit precisionVSAvoidwire gauge accommodation range

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent introduces dynamic, adjustable grooves within the connector body that can be repositioned or reconfigured to accommodate different wire gauges. The grooves are not fixed in rigid positions but can adapt their configuration, allowing the same connector to securely hold various wire sizes through simple adjustment mechanisms.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent designs the connector body with universal features that enable it to perform the same secure-holding function for multiple wire gauge types. The adjustable groove system allows a single connector design to serve multiple wire size applications, eliminating the need for different connector sizes for different wire gauges.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If rigid connector designs are used, then structural stability is maintained, but adaptability to different housing sizes and shapes is reduced

Engineering Contradiction:

Improveconnector structural stabilityVSAvoidhousing size compatibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent incorporates flexible elements within the connector body structure, such as elastic retention mechanisms and flexible mounting features. These flexible components allow the rigid connector body to adapt to different housing sizes and shapes while maintaining structural integrity and stable wire connections.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent divides the connector into modular segments or components that can independently adjust to fit different housing configurations. The segmented design allows each component to maintain its structural stability while the overall assembly adapts to various housing sizes and knock-out opening dimensions.

Inventive Principle:

Principle #1Segmentation

4Reliability

If connectors require multiple fastening components, then secure attachment is achieved, but device complexity increases

Engineering Contradiction:

Improveattachment securityVSAvoidconnector component count

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple separate fastening components (screws, nuts, plates, retention clips) into a single integrated connector body. The unified design performs all fastening and securing functions through one component, reducing the total part count while maintaining secure attachment through combined mechanical and elastic retention mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10950371B2Nonmetallic push-in connector

Publication Date: 2021.03.16 ANTONUCCI MARK

AI summary

A push-in connector generally having an interior channel equipped with longitudinal protrusions that run at least part of the length of the interior channel of the connector body to define grooves through which wires of a different gauges can be inserted. When the user rotates the connector body about its longitudinal axis, the interior channel defines a second gauge through which a wire of a second gauge can pass. The connector body has one or more incisions cut into one end of the connector body and a separate cuff that fits over the feed end. The interior channel contains teeth that grip the wire(s) or cable(s) once inserted. The exterior of the connector body has flexible exterior protrusions that can be pushed down when inserting the connector through the knock-out of a housing and spring back into place to secure the connector to the housing.