Wall Feed-Through Connector With Spring Contacts
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Solution Overview
Problem
Existing wall connector assemblies in harsh environments require frequent and time-consuming tightening of screw contacts to connect conductors, leading to high maintenance costs and part diversity.
Innovation Solution
A connector assembly featuring first and second housings with a conductive comb member having pin portions that extend through bores for electrical engagement with spring contacts, reducing the need for multiple parts and simplifying installation and maintenance by using a single conductive part on each plug connector, where conductor ends are soldered or connected via bayonet-type connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw contacts are used to connect conductors to plug connectors, then reliable electrical connection is achieved, but frequent tightening is required in harsh environments leading to high maintenance costs
Solution Approach 1:
The patent replaces the mechanical screw tightening system with a spring contact system that uses elastic force to maintain continuous pressure on the conductor. The spring contacts automatically compensate for thermal expansion and contraction of conductors in harsh environments, eliminating the need for periodic manual tightening while maintaining reliable electrical connection.
Solution Approach 2:
The spring contact mechanism serves itself by using the elastic deformation of the spring to automatically maintain contact pressure. As conductors expand or contract due to temperature changes, the spring automatically adjusts its force to maintain consistent electrical connection without requiring external intervention or maintenance.
2Adaptability or versatility
If multiple conductor ends or bus bars are connected to plug connectors, then electrical distribution is achieved, but part diversity increases
Solution Approach 1:
The spring contact mechanism serves multiple functions: it provides electrical connection, maintains contact pressure through elastic force, compensates for conductor movement, and accommodates different conductor types. This single multi-functional component replaces the need for multiple specialized parts including screw contacts, bus bars, and various fastening elements.
Solution Approach 2:
The patent merges the functions of electrical conduction, mechanical fastening, and contact pressure maintenance into a single spring contact component. This integration eliminates the need for separate screw fasteners, contact elements, and bus bars, thereby reducing part diversity while maintaining electrical distribution capability.
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 provides a simplified, low-maintenance connector assembly that efficiently transmits electrical energy through a wall opening with reduced part complexity and ease of installation, eliminating the need for frequent screw tightening.
Implementation Method 1
spring contacts arranged in corresponding aligned first bores contained in the first housing
Data Source
AI summary
A connector assembly for transmitting electrical energy through a wall opening, including a horizontal generally-rectangular first connector housing arranged on one side of the wall with a collar portion of the first housing extending through the wall opening. The collar portion contains a plurality of horizontal parallel coplanar first through bores in which are mounted a plurality of electrically conductive spring contacts, respectively. A second connector housing arranged on the other side of the wall opening contains a recess receiving the collar portion, and a plurality of second bores extending collinearly opposite the first bores, respectively. An electrically conductive comb member includes a plurality of integral pin portions that extend from a common spine portion through the second bores and into the first bores for electrical engagement with the spring contacts, respectively, thereby to connect conductors arranged on opposite sides of the wall.