Modular Wire Terminal Adapter for Hazardous Location Devices

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Solution Overview

Problem

Electrical wiring devices for hazardous locations face challenges in connecting multiple wires due to limited internal space and complex, expensive connector designs, which often require wrapping wires around screws, leading to insecure attachments and potential arcing issues.

Innovation Solution

A modular connector assembly that allows multiple wires to be securely attached to a single terminal using a cover member with apertures and clamping members, eliminating the need for additional jumping wires or connectors, and enabling easy retrofitting of existing devices with minimal modification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a single screw fastener is used to connect wires to the terminal connector, then the connector structure remains simple, but multiple wires cannot be securely attached to a single terminal

Engineering Contradiction:

Improvenumber of wires per terminalVSAvoidconnector structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The terminal connector is divided into multiple independent terminal elements, each capable of accepting wire connections. The cover member is segmented with individual apertures and clamping members for each wire, allowing independent connection of multiple wires to a single terminal location without requiring a completely new connector design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal elements are nested within the housing structure, and the cover member with clamping members is nested over the terminal elements. This nested arrangement allows multiple wires to be connected to a single terminal while maintaining a compact overall structure that fits within the existing housing dimensions.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of operation

If wires are wrapped or twisted around the screw shaft before tightening, then connection is possible in limited space, but secure attachment is difficult to ensure

Engineering Contradiction:

Improvewire connection processVSAvoidwire attachment security

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A clamping member is introduced as an intermediary element between the wire and the terminal element. The clamping member secures the wire through a separate fastening mechanism (such as a barrel connector or clamp) before the terminal screw is tightened, ensuring reliable wire attachment without requiring the wire to be wrapped around the screw shaft.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If additional terminals are added to allow multiple wires per connector, then wire connectivity improves, but the housing internal space becomes insufficient

Engineering Contradiction:

Improvewire connectivityVSAvoidhousing internal space

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The terminal element is designed to serve multiple functions: it provides the electrical connection point, supports the clamping member for wire securing, and accommodates multiple wires through the segmented cover structure. This multi-functionality allows multiple wires to be connected to a single terminal location without adding additional terminal elements that would consume housing space.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If specialty hazardous location connectors are designed for multiple wires, then wire attachment capability improves, but manufacturing cost increases significantly

Engineering Contradiction:

Improvemultiple wire attachmentVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The terminal elements and clamping members are prepared and positioned within the housing before the cover member is installed. This preliminary arrangement allows the use of standard, readily available components rather than requiring custom-molded integrated connectors, significantly reducing manufacturing cost while still achieving multiple wire attachment capability.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10020600B2Wire terminal assembly and adapter kit

Publication Date: 2018.07.10 HUBBELL INC

AI summary

An assembly is provided for a connector of an electrical wiring device having a base with a plurality of electrical terminals having a connecting screw. The assembly includes a plurality of terminal connector with a base extending from the first end and having a screw hole for coupling to one of the electrical terminals by a connecting screw. The leg has a screw hole receiving a coupling screw for electrically connecting a wire to the terminal connector and the terminal of the electrical wiring device. A clamping member receives the coupling screw for clamping the wire between the leg and clamping member. A cover encloses the terminal connectors and includes one or more apertures directing a wire through the cover to the terminal connector assembly to clamp the wire in place. Access openings are provided in a wall of the cover to access the coupling screws for clamping wires to the terminal connector assembly.