Active Cover Plate Resilient Prongs for GFCI Terminals
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Solution Overview
Problem
GFCI outlets have unique configurations with recessed screw terminals and wider bodies, making it challenging for active cover plates to establish reliable electrical connections due to the limited space and varying setback distances, which can lead to installation issues and potential electrical hazards.
Innovation Solution
The design of active cover plates with adjustable prongs and resilient contacts that compress to fit through narrow gaps and expand to reach recessed screw terminals, utilizing auxiliary springs for reliable contact and rebounding to maintain electrical connection, and incorporating dual or movable contacts for compatibility with different GFCI outlet configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cover plate uses fixed rigid prongs, then the structure is simple, but it cannot accommodate varying setback distances of screw terminals on different GFCI outlets
Solution Approach 1:
The patent applies the dynamics principle by making the prongs flexible rather than rigid. The resilient prongs can bend and flex to accommodate different setback distances of screw terminals on various GFCI outlet configurations, allowing a single cover plate design to work with multiple outlet types without requiring complex adjustable mechanisms.
Solution Approach 2:
The patent changes the physical parameter of the prongs from rigid to resilient/flexible. This parameter change allows the prongs to deform elastically when contacting screw terminals at different positions, providing adaptability to various GFCI outlet geometries while maintaining a simple overall structure.
2Reliability
If the prongs are made resilient and compressible, then reliable electrical contact is achieved, but the installation space requirement increases
Solution Approach 1:
The patent applies partial action by having only the prong portion that needs to compress being resilient, while the rest of the cover plate remains rigid. The resilient section is localized to where contact with the screw terminal occurs, allowing compression for reliable electrical contact without requiring the entire cover plate to be flexible or occupy excessive space.
Solution Approach 2:
The prong structure is segmented into rigid and resilient portions. The rigid base provides structural support while the resilient tip section compresses to make reliable electrical contact with the screw terminal. This segmentation allows the cover plate to maintain structural integrity while achieving reliable contact in limited spaces.
3Reliability
If the prongs are made longer to reach recessed screw terminals, then electrical contact is achieved, but the risk of interfering with GFCI internal components increases
Solution Approach 1:
The patent uses flexible thin resilient prongs that can bend and conform to the space available. These flexible prongs can reach recessed screw terminals by flexing rather than by being excessively long, reducing the risk of interfering with internal GFCI components while maintaining reliable electrical contact.
Solution Approach 2:
The dynamic flexibility of the resilient prongs allows them to navigate the limited space between the cover plate and GFCI outlet body. The prongs can bend and flex during installation and operation, reaching recessed terminals without the need for overly long rigid structures that would risk damaging internal components.
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
Ensures secure and reliable electrical connections to GFCI outlets, maintaining functionality even during GFCI tripping and enhancing compatibility with a wide range of GFCI outlet geometries, thereby improving safety and installation ease.
Implementation Method 1
a resilient contact configured to deflect laterally upon insertion between the electrical receptacle and the electrical box to touch the screw terminal
Implementation Method 2
an auxiliary spring configured to urge the resilient contact to return to its undeflected state
Data Source
AI summary
A variety of active cover plate configurations with prongs configured to contact side screw terminals of electrical receptacles or switches are described.