Push-fit Electrical Connector for Rapid Multi-core Cable Termination
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Solution Overview
Problem
Conventional electrical junction boxes require significant time and specialist knowledge to wire, are difficult to access in confined spaces, and often necessitate additional support for cables, making them cumbersome and costly to maintain, especially as lighting technology evolves and access holes become smaller.
Innovation Solution
An electrical connector featuring a shuttle member with resilient clip members and a body portion with shaped terminal connections that allow for quick, screw-free connection of multi-core cables, enabling easy installation and maintenance without the need for specialized knowledge, and accommodating smaller access holes through its elongated design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screw terminals are used in junction boxes, then secure electrical connection is achieved, but wiring time increases significantly and specialist knowledge is required
Solution Approach 1:
The patent replaces the screw-terminal mechanical system with a push-fit system. The cable insertion triggers an automatic clamping mechanism where spring-loaded jaws grip the cable conductors, eliminating the need for screw tightening while maintaining secure electrical connection. This substitution reduces wiring time from minutes to seconds and removes the requirement for specialist knowledge.
Solution Approach 2:
The connector incorporates self-aligning features where guide channels automatically position the cable cores into the correct terminals. The spring-loaded clamping mechanism self-activates upon cable insertion, and the insulated body automatically provides isolation. These self-service features eliminate the need for manual positioning and adjustment by skilled workers.
2Ease of operation
If conventional junction boxes are installed in ceiling voids or between flooring, then cable connection is achieved, but access for maintenance becomes difficult or impossible
Solution Approach 1:
The patent describes a connector designed for permanent installation where the cable connection is made irreversible through the push-fit mechanism. Once cables are inserted and clamped, the connector cannot be easily reopened, effectively making it a single-use component. This resolves the accessibility issue by eliminating the need for future maintenance access, though it sacrifices reconfigurability.
3Manufacturing precision
If multiple cable cores are positioned under terminal screws simultaneously, then proper wiring configuration is achieved, but the task becomes extremely difficult especially with limited access
Solution Approach 1:
The connector divides the cable connection process into separate independent channels, each with its own guide and clamping mechanism. Instead of requiring all cable cores to be positioned simultaneously under a single terminal, each core is independently guided and secured. This segmentation dramatically simplifies the operation, allowing cables to be inserted one at a time without manual positioning difficulty.
4Reliability
If twin and earth cable is used with conventional junction boxes, then earth conductor connection is achieved, but additional sleeving or sheathing is required to insulate the core
Solution Approach 1:
The patent merges the insulation function into the main connector body. The insulated housing of the connector encloses all cable cores and their connections, eliminating the need for separate sleeving or sheathing of the earth conductor. The connector body itself provides the necessary insulation barrier between conductors, simplifying the wiring procedure while maintaining insulation integrity.
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
Facilitates rapid, safe, and maintenance-free connection of multiple cables, reducing installation time, eliminating the need for specialist knowledge, and ensuring compliance with regulatory requirements for cable support, while allowing access through smaller holes, thus enhancing accessibility and reducing maintenance costs.
Implementation Method 1
a resilient clip member for each of the stripped cores to be received... each connection having a shaped contact to receive a respective clip member of the shuttle member; wherein each shaped contact defines a jaw member operable to compress a respective clip member when the shuttle member is fully engaged with the body portion to thereby grip the stripped cores
Data Source
AI summary
The present invention provides an electrical connector, comprising a shuttle member for receiving a stripped multi-core cable (such as a twin and earth conductor cable), the shuttle member including a core guide means and a resilient clip member for each of the stripped cores to be received. A body portion is configured to support at least one shuttle member in sliding engagement and includes an array of terminal connections, each connection having a shaped contact to receive a respective clip member of the shuttle member. Each shaped contact defines a jaw member operable to compress a respective clip member when the shuttle member is fully engaged with the body portion to thereby grip the stripped cores of the multi-core cable. The electrical connector has particular application as an electrical junction box for lighting circuits.