Active Cover Plates With Resilient Prongs For GFCI Outlets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical cover plates for GFCI outlets face challenges in securely connecting to the wider and deeper screw terminals of GFCI outlets due to their unique geometry, which can lead to installation issues and reduced compatibility with various outlet configurations.
Innovation Solution
The design of active cover plates with adjustable prongs and resilient contacts that can compress to fit through narrow gaps and expand to securely contact screw terminals, ensuring compatibility with a range of GFCI outlet configurations by using insulating elements and auxiliary springs to facilitate installation and maintain electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cover plate uses fixed rigid prongs, then the structure is simple and easy to manufacture, but it cannot adapt to the wider and deeper screw terminals of GFCI outlets, leading to installation failures
Solution Approach 1:
The patent applies the dynamics principle by making the prongs flexible and resilient rather than rigid. The resilient contacts can deflect and flex to accommodate the wider and deeper screw terminals of GFCI outlets, then return to their original position to maintain secure electrical connection. This dynamic adaptation resolves the contradiction between adaptability and structural simplicity.
Solution Approach 2:
The patent changes the physical parameters of the prongs by using resilient materials and designing them with deflection capabilities. The prongs can change their shape and position parameters to fit different outlet configurations, transforming from fixed rigid structures to adjustable flexible ones that maintain electrical connectivity across various GFCI outlet geometries.
2Adaptability or versatility
If the prongs are made flexible to reach deeper terminals, then adaptability improves, but the electrical connection reliability may deteriorate due to potential loose contact
Solution Approach 1:
The resilient contacts utilize elastic deformation to reach deeper terminals while maintaining reliable contact. The material properties and structural design ensure that the deflection remains within elastic limits, allowing the prongs to flex during installation and then return to a stable position that secures dependable electrical connection without permanent deformation or loose contact.
Solution Approach 2:
The patent incorporates resilient elements that act as cushioning mechanisms before contact is made. These elements absorb mechanical stresses and misalignments during installation, protecting the electrical connection from damage and ensuring reliable contact is established even when reaching deeper terminals with varying outlet geometries.
3Reliability
If the prong width is increased to ensure contact, then connection reliability improves, but the ability to pass through narrow gaps between outlet and box deteriorates
Solution Approach 1:
The patent employs dynamic prong design where the width can effectively change during installation. The resilient contacts are designed to compress and flex to a reduced width to pass through narrow gaps between the outlet and electrical box, then expand to their full width to ensure secure contact with the screw terminals. This dynamic size adaptation resolves the contradiction between contact security and gap penetration capability.
Solution Approach 2:
The patent addresses the width contradiction by introducing temporal and spatial dimensionality changes. The prongs undergo dimensional transformation during the installation process, changing their effective width over time and space - narrow during insertion through gaps, then expanded for contact. This multi-dimensional approach allows the same structure to satisfy both contradictory requirements at different stages.
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 allows for secure and reliable installation of active cover plates over GFCI outlets, ensuring consistent electrical connectivity and compatibility with different outlet geometries, thereby enhancing safety and usability.
Implementation Method 1
a resilient contact configured to deflect laterally upon insertion between the outlet and the box to reduce a width of the resilient contact. After inserting, the resilient contact rebounds to a second width greater than the reduced width to touch a screw terminal
Data Source
AI summary
A variety of active cover plate configurations with prongs configured to contact side screw terminals of electrical receptacles are described.