Bidirectional Push-In Junction Box Connector for Old-Work Cable Entry
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Solution Overview
Problem
Existing push-in connectors for non-metallic electrical cables are limited to new-work situations where studs are exposed, as they require installation from the outside of the electrical box, making it difficult to install additional cables in old-work situations where the studs are covered by drywall.
Innovation Solution
A push-in electrical connector with a tubular body, flexible gripper jaws, and compressible arms that can be inserted through a knockout aperture from either the inside or outside of the electrical box, allowing secure attachment of one or more cables while avoiding burrs and providing strain relief, and can be manufactured at a low cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector is designed for installation from the outside of the box, then it can be easily installed in new-work situations, but it cannot be installed in old-work situations where drywall covers the studs
Solution Approach 1:
The connector body is designed with a symmetrical structure that allows it to be installed from either the inside or outside of the electrical box, making it universal for both new-work and old-work situations. The connector maintains functional equivalence regardless of installation direction, with cable access openings positioned to accommodate cables entering from any side.
2Adaptability or versatility
If the connector is designed to accommodate cables from any direction, then it increases versatility, but it may increase device complexity
Solution Approach 1:
The connector body is segmented into functional zones: a cylindrical body portion with cable access openings, a flange with mounting openings, and an integrated cable management structure. The cable access openings are positioned at specific locations to accommodate cables entering from different directions, while the dividing wall segments the interior to organize multiple cables. This segmentation achieves versatility without excessive complexity.
3Adaptability or versatility
If the connector includes multiple cable access openings, then it can handle multiple cables, but it increases manufacturing complexity
Solution Approach 1:
Multiple cable access openings are merged into a single molded body structure, allowing the connector to accommodate multiple cables through different openings while being manufactured as one integrated piece. The dividing wall and cable management features are also integrated into the single body, simplifying manufacturing while providing multi-cable capability.
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
Enables easy and tool-free installation of non-metallic electrical cables in both new-work and old-work situations, providing secure cable attachment, strain relief, and a low profile design, while avoiding burrs and minimizing installation time and cost.
Implementation Method 1
The inner body portion includes two flexible gripper jaws and an inner seat. The outer body portion includes two compressible arms and an outer seat.
Data Source
AI summary
A push-in electrical connector for connecting one or more electrical cables at a knockout of an electrical junction box or panel. The electrical connector includes a substantially tubular connector body with a sidewall, a flange, an inner body portion extending from the flange to an inner end, and an outer body portion extending from the flange to an outer end. The inner body portion includes two flexible gripper jaws and an inner seat. The outer body portion includes two compressible arms and an outer seat. The electrical connector body may include a dividing wall for maintaining separation between electrical cables. The gripper jaws and compressible arms enable secure attachment of one or more cables to an electrical panel or box.