Wall-Mounted Electrical Connector Assembly with Twist Lock
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Solution Overview
Problem
The manufacturing processes for heavy-duty electrical connectors used in high-amperage applications, such as in vehicles and appliances, are inefficient during installation and wiring connections, particularly in wall-mounted electrical-connector-engaging assemblies.
Innovation Solution
A wall-mounted electrical-connector-engaging assembly featuring a wall-surface adapter with slidably-engaging electrical connection points and a twist lock mechanism, along with a backcap for secure engagement and wire management, improves installation efficiency by providing a secure and easy-to-use connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used in wall-mounted assemblies, then secure electrical connection is achieved, but installation time and manufacturing complexity increase
Solution Approach 1:
The electrical connector is divided into two separate components: a plug portion that attaches to the power cord and a receptacle portion that mounts to the wall. This segmentation allows independent preparation and assembly of components, enabling faster installation while maintaining secure electrical connection through the mating interface between plug and receptacle blades and contacts.
Solution Approach 2:
The plug portion is pre-assembled onto the power cord with the housing and blade assembly before final installation. This preliminary action allows the connector to be prepared in advance, reducing on-site installation time while ensuring proper alignment and secure attachment to the cord.
2Reliability
If traditional electrical connectors are used in wall-mounted assemblies, then secure electrical connection is achieved, but device complexity and installation difficulty increase
Solution Approach 1:
By separating the connector into plug and receptacle portions with distinct functions, the system reduces installation complexity. The plug portion simply attaches to the cord end while the receptacle portion mounts to the wall, eliminating the need for complex assembly procedures and reducing installation difficulty while maintaining reliable electrical connection.
Solution Approach 2:
The plug portion housing includes integrated features that automatically align and secure the blade assembly to the power cord without requiring additional fasteners or complex assembly steps. The housing structure itself provides the connection mechanism, simplifying the installation process while ensuring secure electrical connection.
3Adaptability or versatility
If frequent connection and disconnection is required in high-amperage applications, then versatility and usability are improved, but reliability and risk of accidental withdrawal increase
Solution Approach 1:
The connector employs a dynamic locking mechanism where the plug and receptacle portions can be easily engaged and disengaged through simple axial motion, yet automatically lock into a secure position during connection. This dynamic behavior allows frequent connection/disconnection operations while preventing accidental withdrawal through the interlocking blade and contact design.
Solution Approach 2:
The plug and receptacle portions feature asymmetric blade and contact configurations that ensure proper orientation during insertion. The asymmetric design provides mechanical keying that guides correct alignment and creates a secure mating interface that resists accidental withdrawal while allowing intentional connection and disconnection operations.
Data Source
AI summary
A wall-mounted electrical-connector-engaging assembly for axial engagement with an electrical connector, the assembly including (a) a wall-surface adapter having front and back faces and attached to a wall over an opening in the wall and (b) a backcap. The adapter back face has a plurality of wire-connection points for installation of a corresponding plurality of wires, and the adapter front face has a plurality of slidably-engaging electrical connection points for engagement in at least an axial direction with the electrical connector. The backcap surrounds the plurality of wire-connection points and adjacent portions of the corresponding plurality of wires connected thereto, and includes a twist lock for installation on the wall-surface adapter.