Push-Lock Coupler for Corrosion-Resistant Electrical Conduits
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Solution Overview
Problem
Current interface components for electrical conduits in corrosion-prone environments face challenges in providing both mechanical stiffness and electrical continuity while maintaining a sealed interface, often relying on threading or additional materials like O-rings and adhesives.
Innovation Solution
A push-lock coupler design featuring an annular metal insert within a cylindrical polymeric housing, which includes grooves for mechanical locking and sealing, utilizing a knurled surface for enhanced extraction strength and corrosion resistance, and a smooth outer surface for easy installation and cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threading or set screws are used to connect interface components, then mechanical stiffness is achieved, but corrosion resistance deteriorates in harsh environments
Solution Approach 1:
The coupler employs a composite structure combining a polymeric outer housing with corrosion resistance and a metal insert providing mechanical strength and stiffness. This multi-material construction resolves the contradiction by assigning each material its optimal function: the polymer protects against corrosion while the metal insert delivers the required mechanical stiffness for secure electrical conduit connections.
2Reliability
If O-rings or adhesives are added to provide sealed interfaces, then sealing performance is improved, but device complexity increases
Solution Approach 1:
The coupler's polymeric housing itself provides the sealing function through its material properties and geometric design. The polymer material inherently resists corrosion and provides sealing without requiring additional O-rings or adhesives. The smooth outer surface and integrated groove design enable the housing to serve multiple functions simultaneously, eliminating the need for separate sealing components.
3Strength
If grooves are added for mechanical locking, then extraction strength is improved, but manufacturing complexity increases
Solution Approach 1:
The coupler incorporates longitudinal grooves that segment the inner surface, creating distinct locking zones that engage with the conduit. These grooves are integrated into the molding process, allowing the polymeric housing to be formed in a single operation. The segmentation provides enhanced mechanical locking and extraction strength while maintaining ease of manufacture through process integration.
4Strength
If knurled surface is applied to enhance extraction strength, then mechanical grip is improved, but surface finish quality deteriorates
Solution Approach 1:
The coupler features a knurled surface on the outer housing that provides enhanced grip and extraction strength at the contact points. The knurling is applied locally to specific regions where mechanical engagement is required, while other surfaces maintain smooth finishes for ease of installation and aesthetic purposes. This localized application of surface treatment optimizes both functional performance and overall quality.
Data Source
AI summary
A push-lock coupler includes an annular metal insert with a coaxial profile complementary to a conduit; a cylindrical polymeric housing molded over the annular metal insert and having a first and second end and an inner surface; and wherein the first and second end are capable of deforming to the coaxial profile of the conduit inserted into either the first or second end, and the inner surface of the cylindrical polymeric housing has at least one groove disposed between the annular metal insert and the first end.