One-Piece Electrical Fitting Eliminates Die-Casting Costs
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Solution Overview
Problem
Existing quick-connect electrical fittings require expensive die-casting and secondary assembly processes, increasing production costs and complexity.
Innovation Solution
A one-piece electrical fitting formed from a single sheet metal blank, rolled into a cylindrical body with locking tabs and grooves, and a hinged cap for secure connection, eliminating the need for separate components and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die-casting and secondary assembly processes are used for quick-connect electrical fittings, then the connector body can be formed with precise dimensions and complex geometry, but production costs increase and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple separate components (connector body, locking mechanism, grounding elements, cable retention features) into a single integrated electrical fitting formed from one piece of conduit material. This eliminates secondary assembly processes and die-casting operations, reducing production costs while maintaining manufacturing precision through direct forming of the unified structure.
Solution Approach 2:
The electrical fitting is designed as a multi-functional component that simultaneously provides connection, locking, grounding, and cable retention functions within a single integrated structure. This eliminates the need for separate components and assembly operations, addressing both the precision and cost concerns by consolidating multiple manufacturing processes into one.
2Manufacturing precision
If die-casting and secondary assembly processes are used for quick-connect electrical fittings, then the connector body can be formed with precise dimensions and complex geometry, but device complexity increases
Solution Approach 1:
The patent integrates the connector body, locking mechanism, grounding elements, and cable retention features into a single unified component formed from one piece of conduit material. This eliminates the need for secondary assembly processes and multiple separate parts, reducing device complexity while maintaining manufacturing precision through direct forming.
3Reliability
If traditional multi-component electrical fittings are used, then electrical continuity can be established between cables and junction boxes, but production costs and assembly time increase
Solution Approach 1:
The patent creates a single integrated electrical fitting that combines all necessary functions (connection, locking, grounding, cable retention) into one component. This eliminates secondary assembly steps and die-casting operations, reducing production costs and assembly time while maintaining reliable electrical continuity through the integrated conductive structure.
Solution Approach 2:
The electrical fitting is pre-formed as a complete integrated unit with all features (locking mechanisms, grounding elements, cable retention) already in place during the initial forming process. This preliminary integration eliminates the need for subsequent assembly operations, improving productivity while ensuring reliable electrical continuity is built-in from the start.
Data Source
AI summary
A one-piece electrical fitting for connecting an electrical cable to a junction box, the electrical fitting formed from a single, flat blank of metal into a cylindrical connector body. The connector body includes a leading end, a trailing end, a cap, an inner bore, and one or more grounding tangs, locking tangs, and flanges extending radially outward from the connector body. According to one embodiment, the flanges extend from the grounding tangs and the locking tangs include free ends. According to a further embodiment, the locking tangs extend from an interior base of the locking tangs. In a further embodiment, a seat extends between the flanges of the grounding tangs and the free end of the locking tangs. One or more cable retaining tangs extend inward from the connector body into the inner bore. The one-piece electrical fitting is stamped and formed from a flat blank of metal. A tab and groove arrangement on the blank facilitates forming the blank into the cylindrical connector body, which is held together by a locking arrangement between the cap and the cylindrical connector body.