Single-Piece Electrical Conduit Coupler for Versatile Installation
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Solution Overview
Problem
Conventional electrical conduit couplers require multiple pieces for installation, increasing labor and material costs, and are not suitable for unthreaded conduits, with potential misalignment causing damage to insulation jackets during wire pulling.
Innovation Solution
A single-piece electrical conduit coupler design with a body featuring a threaded bore for threaded conduits and a smooth bore for unthreaded conduits, using apertures and fasteners for securement, ensuring proper alignment and reducing parts count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multi-piece electrical conduit coupler is used, then the coupler can be assembled from separate components, but the installation process becomes more complex and labor costs increase
Solution Approach 1:
The patent combines multiple separate components (body, internal bushing, and nut) into a single integrated coupler unit. The body includes an internal threaded bore that directly receives the conduit, eliminating the need for separate internal bushings and nuts. This merging of components simplifies the installation process while maintaining the functional capabilities of the multi-piece design.
Solution Approach 2:
The single-piece coupler is designed to accommodate both threaded and unthreaded conduits through its universal bore design. The internal threaded bore can engage with threaded conduit ends, while the same bore structure can also receive unthreaded conduits, making the coupler versatile for different conduit types without requiring separate specialized components.
2Ease of manufacture
If conventional multi-piece couplers are used, then components can be separately manufactured, but material expenses and purchase costs increase
Solution Approach 1:
The patent consolidates three separate manufacturable components (body, internal bushing, nut) into one single-piece component. This reduces the total quantity of parts from three to one, directly lowering material expenses and purchase costs while maintaining ease of manufacture through standard machining processes for creating the internal threaded bore.
3Ease of operation
If conventional couplers are used, then installation can proceed with standard components, but misalignment of threaded ends may damage insulation jackets
Solution Approach 1:
The single-piece coupler design incorporates pre-configured alignment features in its internal threaded bore that automatically align the conduit ends during insertion. This preliminary alignment action prevents misalignment before wire pulling occurs, thereby protecting insulation jackets from damage while maintaining ease of operation during installation.
Data Source
AI summary
The present disclosure provides couplers used to connect one length of rigid electrical conduit to another length of rigid electrical conduit. The couplers include a body having a first coupling portion, a second coupling portion, a stop portion positioned between the first coupling portion and the second coupling portion, and a longitudinal bore extending from the first coupling portion through the stop portion to the second coupling portion. The longitudinal bore within the first coupling portion is a threaded bore capable of receiving a threaded end of a first threaded electrical conduit. The longitudinal bore within the second coupling portion has a diameter capable of receiving a threaded end of a second threaded conduit or an unthreaded end of an unthreaded conduit. The longitudinal bore within the stop portion has a diameter that provides a wire passage between the first threaded conduit and the second threaded conduit or the unthreaded conduit.