Snap-in Electrical Connector Spring Clip Design
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Solution Overview
Problem
Existing snap-fit electrical connectors are complex, requiring multiple components and additional manufacturing steps, and lack efficiency in securing to electrical boxes without separate fasteners.
Innovation Solution
A simplified snap-fit electrical connector assembly using a multi-purpose spring clip that deforms during insertion to secure the connector body to an electrical box, eliminating the need for separate fasteners and accommodating various cable diameters through a flexible clamp mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional snap-fit connectors use multiple separate components (barrel body, sleeves, collars, cable retainers, rivets), then the connector can achieve secure connection and cable retention, but the device complexity increases and manufacturing time increases
Solution Approach 1:
The patent combines multiple separate components (barrel body, cable retainer, and fastening mechanism) into a single integrated connector body. The connector body includes an internally threaded portion and a fastening member that can rotate within the body, eliminating the need for separate collars, sleeves, and rivets while maintaining secure connection and cable retention functionality
Solution Approach 2:
The connector body performs multiple functions simultaneously: it provides structural support, retains the cable through the internally threaded portion, and secures the connection through the rotatable fastening member. This multi-functional design replaces the need for specialized separate components for each function
2Reliability
If traditional snap-fit connectors use multiple separate components requiring assembly with rivets or fasteners, then the connector achieves secure assembly, but the manufacturing time and fabrication steps increase
Solution Approach 1:
The fastening member is integrated within the connector body as a single piece, eliminating the need for separate assembly steps involving rivets or external fasteners. The fastening member can be rotated and adjusted directly within the connector body, streamlining the assembly process into fewer steps
Solution Approach 2:
The rotatable fastening member allows for self-adjusting and self-securing during installation. The internally threaded portion enables the fastening member to engage and secure the connection through its own rotational movement, without requiring external fastening operations
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
The solution reduces manufacturing complexity and time by integrating a spring clip that secures both the connector and cable, providing a secure and versatile connection across a range of cable diameters without additional fasteners.
Implementation Method 1
the spring clip is initially deformed by contact with the side wall of the junction box and is then released after the spring clip end is within the junction box
Data Source
AI summary
A connector assembly including a connector body with a spring clip including a first free end for engaging a side wall of an electrical box upon installation. During insertion of the connector body the first free end engages the knock-out hole perimeter and deforms so as to permit further insertion. An alignment rib also engages the perimeter to improve continuity between the connector assembly and the electrical box.