Snap-in Connector with Integral Elastic Tabs
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Solution Overview
Problem
Conventional snap-in connectors for electrical boxes are difficult to attach and remove, especially in limited spaces, and require access to the box interior for uncoupling, which affects efficiency and increases labor costs.
Innovation Solution
A tubular snap-in connector with elastically mounted retaining tabs integrally formed with the connector body, allowing easy attachment and removal without interior access, featuring a ramped portion that snaps into place and a rear flange for external uncoupling, along with alignment flanges for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional snap-in connectors with locking tabs are used, then the connector can be securely retained in the box, but the connector cannot be easily removed without accessing the box interior
Solution Approach 1:
The locking mechanism is segmented into two functional parts: a retention portion that engages the box wall to secure the connector, and a release portion that extends through the box wall to enable external operation. This segmentation allows the connector to be both securely retained and easily removed by accessing only the external release portion.
2Productivity
If threading operations are used to attach cable clamps, then secure attachment is achieved, but the process is time-consuming and difficult in limited spaces
Solution Approach 1:
The threading operation is replaced with a snap-in mechanism that uses elastic deformation and geometric interlocking. The connector body is inserted into the box opening and secured through the elastic engagement of the locking tabs with the box wall, eliminating the need for threading operations and associated tools.
Solution Approach 2:
The connector performs its own attachment function through the snap-in mechanism. The elastic locking tabs automatically engage with the box wall upon insertion, and the alignment flanges guide the connector into proper position, eliminating the need for separate attachment operations or tools.
3Reliability
If additional components like locking tabs on a ring or sleeve are added, then the connector can be retained in the box, but manufacturing cost and complexity increase
Solution Approach 1:
The locking tabs are merged with the connector body as an integral structure rather than being separate components. The locking tabs are formed directly from the connector body material, eliminating the need for separate rings or sleeves and reducing the number of parts to be manufactured and assembled.
Solution Approach 2:
The connector body serves multiple functions: it provides the structural housing for the connector, contains the locking mechanism through integrated locking tabs, and includes alignment features. This multi-functionality reduces the need for additional specialized components.
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 secure and efficient coupling and uncoupling of the connector to electrical boxes without interior access, reducing installation time and labor costs while simplifying the removal process.
Implementation Method 1
one or more elastically mounted retaining tabs formed integrally with the connector
Implementation Method 2
the wall of the box depresses a ramp portions of the retaining tabs and continuing to advance until the wedge portions pass the wall
Implementation Method 3
The alignment flanges help keep the connector aligned with the junction box during insertion and can frictionally engage the connector with the junction box and reduce unwanted rotation
Data Source
AI summary
A tubular snap-in connector includes one or more elastically mounted retaining tabs formed integrally with the connector. The retaining tabs permit the connector to be selectively connected to an electrical junction box by inserting a body of the connector into an appropriate opening in the junction box, advancing the body of the connector forward so that a wall of the junction box depresses a ramp portion of the retaining tabs, and continuing to advance the body of the connector forward until a wedge portion of the retaining tabs passes the wall of the junction box, at which point the retaining tabs spring outwards. A rear wall of each wedge engages an inner wall of the junction box to retain the connector within the box.