Snap-in Connector Spiral Indentation Cable Retention
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Solution Overview
Problem
Existing snap-fit electrical connectors are complex, requiring multiple components and a linear insertion motion, which complicates manufacturing and does not provide sufficient retention force for cables, leading to potential voltage drop and pull-out issues.
Innovation Solution
A connector assembly featuring a multi-function spring clip that deforms during insertion to secure the connector body to an electrical box and engages a spiral indentation to enhance cable retention, providing additional retention force and reducing voltage drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (barrel body with separate sleeves or collars) are used to construct snap-fit connectors, then the connector can achieve retention function, but the device complexity increases and manufacturing time increases
Solution Approach 1:
The patent combines multiple separate components (barrel body, sleeves, collars, retaining rings) into a single integrated connector body with built-in retention features. The connector body includes integrated retention rings and cable retention features formed as part of the single molded structure, eliminating the need for separate assembly of multiple parts while maintaining the retention function.
Solution Approach 2:
The single connector body performs multiple functions: it provides the structural barrel, incorporates retention rings for box mounting, includes cable retention features, and integrates insulation barriers. This multi-functional design reduces component count while achieving all necessary functions in one piece.
2Ease of operation
If traditional linear insertion motion is used to insert connector into knock-out hole, then the insertion process is simple, but the retention force for cables is insufficient leading to pull-out issues
Solution Approach 1:
The patent introduces a spiral convolution feature with curved geometry that engages with the cable in a rotational manner during insertion. The spiral shape provides progressive engagement along the cable length, increasing retention force through the curved contact surfaces while maintaining a relatively simple insertion motion.
Solution Approach 2:
The retention mechanism transitions from simple linear contact to three-dimensional spiral engagement. The spiral convolution adds a rotational dimension to the retention force application, creating multiple contact points along the cable length rather than a single linear contact point, thereby increasing overall retention force.
3Ease of manufacture
If traditional connector design without spiral indentation is used, then manufacturing is simpler, but additional retention force for cable engagement is not provided resulting in voltage drop
Solution Approach 1:
The spiral indentation is added only in the specific region where cable engagement is needed, rather than redesigning the entire connector. This localized feature provides the necessary retention and electrical contact improvement while minimizing additional manufacturing complexity to a single molded feature in the connector body.
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 simplifies the connector design, reduces manufacturing complexity, and meets or exceeds UL pull-out force and resistance drop requirements by providing enhanced retention of cables and lower voltage drop across the connector.
Implementation Method 1
the spring clip is deformed during insertion of the connector body into a knock-hole. Once the connector body is fully seated, the free end cooperates with a locking lug on the connector body to hold the connector assembly onto the electrical box
Implementation Method 2
The spring clip functions to both retain the connector assembly upon an electrical box and also retain an electrical cable end received within the connector body
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. Once the connector body is fully inserted, the spring clip cooperates with a lug on the connector body to hold the connector assembly onto the electrical box. The connector body includes one or more spiral indentations for engaging a convolution of a metal cable. The spring clip biases the cable toward engagement with the spiral indentation to yield improved performance characteristics.