Releasable Electrical Connector Tool-Free Installation
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Solution Overview
Problem
Existing connectors for electrical cables and conduits require significant time and effort for installation and removal, often necessitating tools, and do not allow for easy connection of multiple cables or precise positioning within standard electrical panels and boxes.
Innovation Solution
A connector design featuring two springs, a shell, and an insulator with U-shaped profiles and hook latches that allows for tool-free installation and removal, enabling quick and secure connection of multiple cables to electrical panels without interfering with cable cladding, using resilient insertion tabs and a pressure prong for improved grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional threaded connectors with locknuts and lateral screws are used, then secure electrical continuity and grounding are achieved, but installation and removal require significant time and tool usage
Solution Approach 1:
The connector is divided into modular components: a connector body with integrated grounding elements, separate cable clamping mechanisms, and distinct insertion/removal interfaces. This segmentation allows each component to perform its function independently, enabling tool-free assembly while maintaining reliable electrical continuity through dedicated grounding paths.
Solution Approach 2:
The connector incorporates self-gripping mechanisms that automatically clamp cables and self-align features that guide proper installation without tools. The grounding contacts are pre-positioned to engage automatically with the cable metalclad, providing reliable electrical continuity through self-service operation during installation and removal.
2Ease of manufacture
If single cable connectors are used, then simple design and manufacturing are achieved, but multiple connectors are needed for multiple cables increasing overall complexity
Solution Approach 1:
The connector body is designed as a universal platform that can accommodate multiple different cable types and sizes through adjustable clamping mechanisms. A single connector design serves multiple functions: securing one or more cables, providing grounding for each cable, and enabling tool-free installation/removal, thereby reducing the number of different connector types needed in the system.
Solution Approach 2:
Multiple cable clamping functions and grounding functions are merged into a single integrated connector body. The design combines what would traditionally require separate connectors for each cable into one unified component, reducing system complexity while maintaining ease of manufacture through standardized production processes.
3Loss of time
If snap engagement connectors are used to eliminate tools, then installation time is reduced, but significant effort and force are required and tool-free removal is not possible
Solution Approach 1:
The connector employs dynamic spring-loaded clamping mechanisms that provide gradual engagement force during insertion, reducing the peak force required compared to rigid snap-fit designs. The same spring mechanisms enable easy release during removal by simply pushing the release tab, providing asymmetric force characteristics that facilitate tool-free operation in both installation and removal directions.
Solution Approach 2:
A cam-actuated release mechanism serves as an intermediary that converts a small pushing force on the release tab into a large releasing force that opens the cable clamps. This mechanical advantage intermediary allows tool-free removal with minimal effort, balancing the reduced installation time benefit against the force requirement.
4Reliability
If cladding is present on cables, then electrical protection and grounding are improved, but interference with snap mechanisms and conductor passage occurs
Solution Approach 1:
The grounding function is extracted from the cable clamping mechanism and implemented through separate grounding contacts that engage the metalclad independently. This allows the cladding to remain intact for protection while dedicated grounding elements make contact with it, eliminating interference between the cladding and the cable securing mechanism.
Solution Approach 2:
Guiding ribs and alignment features act as intermediaries that channel the conductors through the connector body without direct contact between the conductors and the clamping mechanism. The metalclad engages with dedicated grounding contacts while the conductors pass through guided pathways, preventing interference while maintaining both grounding integrity and ease of conductor installation.
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 rapid, tool-free connection and disconnection of multiple electrical cables to panels, reducing installation and removal time and effort, while maintaining secure electrical conductivity and compatibility with standard panel sizes.
Implementation Method 1
The resilient insertion tabs push the hook latches against the inner wall of the panel
Implementation Method 2
The pressure prong pushes against the aperture in the panel and the resultant radial force provides better electrical conductivity and hence better grounding between the panel, shell, and spring
Implementation Method 3
The insertion tabs are bent to form spring sections. The spring sections pop out of side openings in the shell to press and release the spring inside and out of the aperture hole of the panel
Data Source
AI summary
The present invention is a connector for connecting two electrical cables having cladding to an aperture in an electrical panel. The assembled connector has a two piece spring, a shell, and a insulator along a longitudinal axis. Each spring has a base from which an insertion tab extends coaxial with the axis and the insulator has two curved portions to prevent over-insertion of the cladding into the connector. The insertion tabs of the spring have hook latches and the insulator has a wall to prevent the electrical cables from interfering with the hook latches. The insulator also has a pressure prong for applying a radial grounding force to the connector.