Reconfigurable Electrical Ground Connector for NEC Compliance
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Solution Overview
Problem
Existing intersystem bonding termination connectors lack versatility and flexibility to be easily connected to various structures such as electrical service equipment and exterior house surfaces, and fail to meet the requirements of accessible connection and inspection as per National Electric Code (NEC) Article 250.94, especially in not interfering with the opening of service or metering equipment enclosures.
Innovation Solution
A reconfigurable electrical ground connector assembly featuring a bus bar with multiple wire connections and a combined electrical connection and mounting post assembly that can be adapted to attach to different structures, allowing for cantilevered support and connection to either internal or external conductors, meeting NEC standards by providing multiple configuration options for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional bonding termination connector is used, then the connection is simple, but the connector lacks versatility to be attached to different structures and interferes with opening enclosures
Solution Approach 1:
The bonding termination connector is designed with a universal mounting bracket system that can be attached to multiple different structures including metal enclosures, wooden surfaces, and concrete walls. The bracket includes adjustable mounting holes and multiple attachment method options (screws, adhesives, mechanical anchors) to accommodate various installation scenarios, making the connector adaptable to different installation locations without requiring multiple specialized connectors.
Solution Approach 2:
The connector is divided into separate functional modules: a bonding termination section for electrical connections, a mounting bracket section for structural attachment, and an adjustable positioning section. This segmentation allows the electrical bonding function to be separated from the mounting function, enabling the connector to be attached to various structures without interfering with enclosure opening while maintaining simple electrical connectivity.
2Ease of operation
If the connector is designed to be accessible for inspection, then the connection is accessible, but the connector interferes with opening service or metering equipment enclosures
Solution Approach 1:
The mounting bracket is designed with dynamic positioning capabilities, allowing it to be installed in various positions (inside or outside the enclosure, on different surfaces) depending on the specific installation context. The bracket can be configured to mount on the exterior surface of the enclosure or on adjacent structural elements, providing flexibility in placement that ensures accessibility for inspection while avoiding interference with the enclosure opening mechanism.
Solution Approach 2:
The mounting bracket acts as an intermediary between the bonding termination connector and the enclosure structure. It provides a separate attachment interface that does not interfere with the enclosure door or opening mechanisms. The bracket can be mounted on the enclosure exterior or on adjacent structural elements, serving as a mediator that enables secure attachment while maintaining full accessibility to the bonding termination connection points for inspection and maintenance.
3Adaptability or versatility
If a reconfigurable connector design is used, then the connector can be used in different locations, but the manufacturing process becomes more complex
Solution Approach 1:
The connector is manufactured as separate modular components (bonding termination section, mounting bracket, fastening elements) that can be independently produced using standard manufacturing processes. These pre-fabricated modules are then assembled through simple mechanical connection or adhesive bonding, allowing the final reconfigurable product to be manufactured without complex tooling or processes. Each module can be mass-produced independently, reducing overall manufacturing complexity while maintaining reconfigurability.
Data Source
AI summary
An electrical ground connector assembly including a bus bar adapted to have a plurality of electrical wires separately connected thereto; and a combined electrical connection and mounting post assembly directly connected to the bus bar. The combined electrical connection and mounting post assembly is adapted to directly connect an electrical conductor thereto. The combined electrical connection and mounting post assembly extends from the bus bar in a generally cantilever fashion and is configured to supportingly attach the bus bar to a structure. A portion of the combined electrical connection and mounting post assembly could be mounted to extend through a hole in the structure, or alternatively a portion of the combined electrical connection and mounting post assembly could be mounted to an exterior side of the structure.