Resilient Cable Connector for Junction Box Installation
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Solution Overview
Problem
Existing connectors for securing electrical cables to junction boxes require tools for installation, are costly due to complex manufacturing processes, and are inconvenient for use in tight spaces.
Innovation Solution
A cable connector with an elongated body made of resilient sheet material, featuring flexible legs and prongs that secure within a wall aperture and cable groove without tools, and a bushing and sleeve for easy assembly and insulation, allowing single-handed installation without tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connectors are used that require crimping or screw fasteners, then secure cable connection is achieved, but tool usage and installation complexity increase
Solution Approach 1:
The connector features self-gripping prongs that automatically engage and secure the cable without requiring external tools. The resilient body allows the prongs to flex outward during insertion and then grip the cable firmly once inserted, enabling the connector to secure itself to both the cable and junction box without crimping tools or screwdrivers.
Solution Approach 2:
The connector incorporates resilient material and flexible prongs that can dynamically adapt to the cable and junction box geometry. The body resiliently flexes to allow easy insertion, while the prongs dynamically adjust to grip the cable securely, providing both ease of installation and reliable retention through mechanical compliance.
2Manufacturing precision
If cast metal or molded plastic connectors are used, then manufacturing precision and connection quality are improved, but manufacturing cost increases
Solution Approach 1:
The connector is formed from a resilient sheet or strip of material that is bent and folded into the final configuration with prongs and body sections. This thin-film approach eliminates the need for expensive casting or injection molding processes, allowing for simpler, more cost-effective manufacturing while maintaining functional precision through the material's inherent elasticity and formability.
Solution Approach 2:
The invention changes the manufacturing approach from high-precision casting/molding to a process that utilizes material elasticity and forming. By selecting resilient material and designing the connector to be formed through bending and folding operations, the manufacturing process achieves sufficient precision at lower cost, transforming the production method rather than relying on expensive tooling.
3Reliability
If multiple steps and tool handling are required for connector installation, then secure attachment is achieved, but installation time increases
Solution Approach 1:
The connector combines multiple functions into a single integrated component: the body provides structural support and insertion capability, while the integrated prongs provide automatic cable gripping. The legs extend to engage the junction box wall, combining cable securing and box mounting functions in one piece, eliminating the need for separate fasteners or multi-step assembly operations.
Solution Approach 2:
The connector performs self-alignment and self-securing during installation. The resilient body automatically flexes to accommodate insertion variations, the prongs self-adjust to grip the cable at the correct position, and the legs automatically engage the junction box wall features, allowing rapid single-handed installation without tool handling or multiple adjustment steps.
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
Facilitates easy, tool-free installation of cables in junction boxes, reducing manufacturing costs and installation time, while maintaining secure connections.
Implementation Method 1
The body (102) is preferably at least partially formed of sheet material, most preferably a sheet of spring steel or other resiliently flexible material
Implementation Method 2
insertion of the insertion end (114) within the wall aperture (202) causes the leg (106) to flex inwardly until the electrical box wall (204) is received within the channel (132), at which point the leg (106) will flex outwardly to secure the leg (106) on the electrical box wall (204)
Implementation Method 3
Owing to the inward bend of the prongs (108), the prongs (108) flex outwardly as a cable (300) is inserted from the receiving end (116) of the inner body passage (104), but will offer resistance to the withdrawal of a cable (300)
Data Source
AI summary
A connector for affixing cables within an electrical box has a body with an insertion end and an opposing receiving end. The insertion end bears outwardly-sloping legs resembling leaf springs, with each leg bearing a channel, so that an electrical box wall may slide over the insertion end with the legs flexing inwardly until the electrical box wall snaps into the channels. The receiving end bears prongs which slope inwardly into an inner body passage, with the prongs also resembling leaf springs, so that the prongs flex outwardly as a cable is inserted into the passage, but at the same time they resiliently flex inwardly to grasp the cable. The body may be formed of a piece of sheet material cut to define a series of petal-like body sections surrounding the insertion end, with the body sections then being bent about the insertion end to define a generally cylindrical body.