Tool-Free Electrical Connector With Spring Ring Expansion
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Solution Overview
Problem
Existing connectors for electrical cables and flexible conduits to electrical panels require tools for installation and removal, making the process time-consuming and labor-intensive, especially in construction projects where numerous connections are needed.
Innovation Solution
A connector design featuring a spring ring, shell, and insulator with angled insertion tabs and hook latches that allow for tool-free snap engagement and disengagement, providing secure connections to electrical panels and cables without the need for tools, utilizing spring buttons for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional threaded connectors with locknuts and lateral screws are used, then secure grounding and reliable connection are achieved, but tool usage and installation time increase significantly
Solution Approach 1:
The patent replaces the traditional threaded mechanical fastening system with a spring-ring expansion mechanism. The spring ring, when compressed, expands radially to engage with the knockout aperture walls, providing secure anchoring without requiring threads, locknuts, or lateral screws. This mechanical substitution eliminates the need for wrenches and screwdrivers while maintaining connection reliability.
Solution Approach 2:
The spring ring mechanism is self-actuating - when the connector is inserted into the knockout aperture, the spring ring automatically compresses and expands to engage with the aperture walls. The grounding tabs also automatically contact the panel surface upon insertion, establishing electrical continuity without requiring additional fastening operations. The entire connection process is self-service, requiring no tools or additional steps.
2Ease of operation
If snap engagement connectors are used to eliminate tools, then installation time is reduced, but significant effort and force are required for installation and removal
Solution Approach 1:
The spring ring provides a dynamic, progressive engagement mechanism. As the connector is inserted, the spring ring gradually compresses and then expands to engage the aperture walls, distributing the engagement force over time and distance rather than requiring a single high-force snap action. This dynamic process reduces the peak force required compared to traditional snap-fit connectors.
Solution Approach 2:
The spring ring allows the connector to transition through different states - uncompressed during insertion, compressed during engagement, and expanded during secure attachment. This parameter change in the spring ring's compression state enables the connector to adapt to the knockout aperture and engage smoothly without requiring excessive force.
3Reliability
If multiple fastening components are used, then secure connection is achieved, but device complexity and number of parts increase
Solution Approach 1:
The patent merges multiple fastening functions into a single integrated spring ring component. The spring ring simultaneously provides anchoring to the knockout aperture, structural support for the connector body, and electrical continuity through integrated grounding tabs. This consolidation eliminates the need for separate locknuts, screws, and grounding wires, reducing part count while maintaining connection security.
Solution Approach 2:
The spring ring serves multiple functions: it anchors the connector to the knockout aperture, supports the structural integrity of the connector assembly, and provides electrical grounding through integrated tabs. This multi-functionality reduces the number of components needed while achieving reliable mechanical and electrical connections.
4Reliability
If traditional connectors require tool removal, then secure connection is maintained, but removal time and effort increase for retrofits
Solution Approach 1:
The spring ring mechanism is self-releasing - when the connector is pulled outward, the spring ring automatically compresses and disengages from the knockout aperture walls. This self-service removal mechanism eliminates the need for tools during retrofit or disconnection operations, allowing contractors to quickly remove connectors by simply pulling them outward.
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 quick, secure, and tool-free connection and disconnection of electrical cables to panels, significantly reducing installation and removal time while maintaining excellent electrical conductivity and grounding, even in standard electrical panels and boxes.
Implementation Method 1
The spring ring has a base from which two insertion tabs bend at an angle around longitudinal central axis
Implementation Method 2
The resilient insertion tabs push the hook latches against the inner wall of the panel
Implementation Method 3
since the connector is made out of metallic material it creates a good electrical continuity (grounding) between the electrical panel and the cable
Data Source
AI summary
A connector for connecting an electrical cable to an aperture in an electrical panel having a spring, a shell, and a insulator along a longitudinal axis. The spring has a base from which two insertion tabs extend coaxial with the axis and a pressure tab extending from the base perpendicular to the two insertion tables having a pressure prong to provide a radial grounding force for the connector. The insertion tabs of the spring have hook latches extending past the insulator that lock the connector in the panel and the base of the spring has a hole to receive the cable where first and second clamping tabs clampingly lock the cable in the connector.