Wire Connectors with Binding Terminals for Electrical Box Space
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Solution Overview
Problem
Existing electrical wiring devices require significant time and skill to connect wires using twist-on connectors, and the large amount of wire needed for installations can be difficult to pack into electrical boxes, making the process inefficient and space-constrained.
Innovation Solution
The wire connector design includes a housing with cavities and openings for wire termination, a plug member that mates with electrical devices, and a screw binding terminal for secure wire connection, allowing for quick and easy installation and increased space within the electrical box by aligning wires parallel to the device's longitudinal axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If twist-on wire connectors are used to connect plug wires to building wires, then reliable electrical connections are achieved, but installation time increases and skill requirement increases
Solution Approach 1:
The wire connector is divided into distinct functional segments: a push-wire connection component for rapid electrical connection and a binding terminal component for mechanical wire securing. This segmentation allows different connection methods to be applied to different wires simultaneously, reducing overall installation time while maintaining connection reliability.
Solution Approach 2:
The binding terminals are pre-positioned and accessible from the front of the device, allowing wire binding to be performed before or during the push-wire connection process. This preliminary preparation eliminates the need for sequential connection steps, reducing installation time without compromising connection reliability.
2Reliability
If twist-on wire connectors are used to connect plug wires to building wires, then reliable electrical connections are achieved, but the complexity of the installation process increases
Solution Approach 1:
The connector separates wire binding and electrical connection functions into distinct components. The binding terminals handle mechanical wire securing while the push-wire mechanism handles electrical connection, simplifying the overall installation process by allowing these operations to be performed independently and simultaneously.
Solution Approach 2:
The binding terminals serve as intermediary components that simplify the connection process. By providing dedicated binding points accessible from the front, they mediate between the wire insertion action and the final secure connection, reducing the skill level required for proper installation.
3Length of moving object
If a large amount of wire is inserted in the electrical box for twist-on connector installations, then sufficient wire length for connections is ensured, but the available space in the electrical box decreases
Solution Approach 1:
The binding terminals are positioned to allow wire binding in a different spatial dimension than traditional side-access connectors. By providing front-accessible binding points, wires can be routed and bound more efficiently, reducing the volume of wire that must be accommodated in the electrical box while maintaining sufficient connection length.
4Ease of operation
If binding terminals are made accessible from the front of the device, then wire binding becomes easier and installation time is reduced, but the device structure becomes more complex
Solution Approach 1:
The binding terminals are merged with the housing structure rather than being separate components. This integration allows front accessibility for easier wire binding while avoiding the complexity of separate mounting mechanisms, as the terminals become an inherent part of the housing design.
Data Source
AI summary
Configurations for wire connectors and for electrical wiring devices that mate with or connect to the wire connectors are disclosed. The wire connectors have a housing and one or more contact assemblies positioned within the housing. Each contact assembly can receive and secure one or more wires, where the wires can be secured to or released from a contact assembly using a fastener accessible through an aperture in the housing.