Boxless Electrical Receptacle with Embedded Conductors
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Solution Overview
Problem
The traditional process of wiring electrical receptacles is cumbersome, time-consuming, and hazardous, with exposed connecting screws posing a risk of electrical shock, and the process of replacing receptacles can cause wire breakage due to work hardening from twisting and forming copper conductors.
Innovation Solution
A self-contained boxless electrical receptacle system featuring a mounting bracket with embedded conductors, a self-contained electrical outlet with face-mounted counter-bored connecting screws, and a wireless control module, which simplifies the installation process and eliminates the need for control wiring for smart home applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional wiring methods with exposed connecting screws are used, then electrical receptacles can be connected to home wiring, but users are exposed to risk of electrical shock
Solution Approach 1:
The connecting screws are nested within counter-bored holes in the receptacle face, with the screw heads recessed below the surface level. This nesting approach allows the screws to remain functional for electrical connection while being physically protected and not exposed to users, thereby eliminating electrical shock risk while maintaining ease of installation
Solution Approach 2:
The counter-bored holes serve as an intermediary structure between the connecting screws and the external environment. This intermediate feature allows electrical connection to be made while simultaneously providing physical protection and isolation, preventing direct contact between users and exposed screws
2Ease of repair
If wire twisting and forming is performed during receptacle installation, then wires can be connected to receptacles, but work hardening causes wires to break during replacement
Solution Approach 1:
The mounting bracket is pre-configured with embedded conductors and connection terminals before the receptacle is installed. This preliminary preparation eliminates the need for on-site wire twisting and forming, preserving wire strength and integrity while enabling easy receptacle replacement later
Solution Approach 2:
The electrical connection system is segmented into separate functional components: the mounting bracket with embedded conductors, the receptacle with connecting screws, and the wiring infrastructure. This segmentation allows the receptacle to be replaced without manipulating or reworking the wire conductors themselves, maintaining wire integrity while enabling easy repair
3Productivity
If traditional wiring processes are used, then electrical receptacles can be installed, but the process is cumbersome and time-consuming
Solution Approach 1:
The mounting bracket and electrical connection system are merged into a single integrated component with pre-configured embedded conductors and connection terminals. This consolidation eliminates multiple separate wiring steps, reducing installation time and complexity while maintaining full electrical functionality
Solution Approach 2:
The mounting bracket serves multiple functions simultaneously: it provides mechanical mounting support for the receptacle, contains embedded conductors for electrical connection, and includes pre-configured connection terminals. This multi-functionality reduces the number of components and steps required, improving productivity without adding device complexity
Data Source
AI summary
A novel system for installing, wiring and controlling electrical outlets is disclosed. The system includes a mounting bracket, a self-contained receptacle, and an option control module. The mounting bracket has preconfigured embedded conductors to facilitate the mounting of electrical outlets thereto. The self-contained receptacle includes a self-contained electrical outlet having face-mounted counter bored connecting screws for electrically connecting the self-contained receptacle to the embedded conductors of the mounting bracket. The optional control module may wirelessly receive instructions for controlling an electrical output of the self-contained receptacle.