Push Wire Connector Angled Entry Spring Contact
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Solution Overview
Problem
Existing electrical wiring devices require significant time and skill to connect wires, and the large amount of wire needed for installations can be difficult to pack into electrical boxes, making the process inefficient.
Innovation Solution
The push wire connector system includes a housing with angled openings and a spring-biased contact assembly that allows wires to be inserted at an angle, facilitating quick and secure connection to electrical wiring devices, reducing installation time and increasing space within the electrical box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional twist-on wire connectors are used to connect each plug wire to a building wire, then reliable electrical connection is achieved, but installation time increases and skill requirement increases
Solution Approach 1:
The push wire connector enables the wire connection process to serve itself through a simple push motion. The spring-biased contact assembly automatically clamps the wire when pushed into the housing, eliminating the need for manual twisting or additional fastening steps. The connector self-regulates the clamping force through the spring mechanism, making the connection process intuitive and self-completing.
Solution Approach 2:
The invention extracts the complex twisting and fastening operations from the wire connection process, leaving only the essential push motion. By separating the clamping function into a dedicated spring-biased contact assembly that engages automatically, the patent removes the skill-intensive steps while maintaining connection reliability.
2Quantity of substance
If traditional wire connection methods are used, then adequate wire length is available for connections, but the electrical box becomes overcrowded and difficult to pack
Solution Approach 1:
The angled wire opening reorients the wire insertion path from a traditional straight-back configuration to an angled approach. This dimensional change in the insertion angle allows wires to be routed more efficiently through the connector, reducing the amount of wire that must be stuffed into the electrical box while maintaining adequate connection length.
Solution Approach 2:
The patent changes the geometric parameters of the wire opening angle and the contact assembly positioning to optimize wire routing. By adjusting these parameters, the connector achieves efficient wire utilization with reduced packaging volume requirements in the electrical box.
3Manufacturing precision
If skilled workers perform traditional wire connections, then connection quality is maintained, but the process requires significant skill and training
Solution Approach 1:
The spring-biased contact assembly performs the precision clamping function automatically when the wire is pushed in. The spring mechanism self-regulates the clamping force to ensure consistent electrical contact without requiring the installer to apply precise manual pressure or perform skilled twisting motions.
Solution Approach 2:
The spring-biased contact assembly acts as an intermediary between the installer's simple push motion and the requirement for precise electrical connection. It mediates by converting the crude push force into controlled, precise clamping action, eliminating the need for installer skill while maintaining connection quality.
4Reliability
If multiple wires are connected using traditional methods, then all connections are secure, but the installation process becomes increasingly time-consuming
Solution Approach 1:
Each wire connection is a self-service operation where the spring-biased contact assembly automatically secures the wire through a single push motion. This eliminates the need for repetitive skilled operations for each wire, allowing installers to quickly connect multiple wires at secure connection quality without increasing time proportionally.
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
This solution enables rapid and efficient wire termination, improving installation efficiency by allowing wires to be easily packed into electrical boxes and reducing the time required for connections while maintaining electrical continuity.
Implementation Method 1
The spring member has an end portion coupled to the contact member, at least one spring arm for clamping a wire between the contact body and the spring arm
Implementation Method 2
The spring member has an end portion coupled to the contact member, at least one spring arm for clamping a wire between the contact body and the spring arm
Data Source
AI summary
Configurations for push wire connectors and for electrical wiring devices that mate with or connect to the push wire connectors are disclosed. The push wire connectors have a housing and one or more contact assembly positioned within the housing. Each contact assembly has one or more contact openings to allow wires to pass through, and the housing has one or more wire entry openings that are angled so that wires that pass through the wire openings and the contact openings before engaging the contact assembly are angled.