Coiled Extension Cord with Thermoplastic Elastomer Jacket
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Solution Overview
Problem
Conventional extension cords have limited coiled diameter and are prone to kinking, lack cut resistance, and offer moderate abrasion resistance and durability, which restricts their ability to efficiently extend and retract without requiring excessive storage space.
Innovation Solution
A coiled extension cord with a harder outer jacket made from a blend of thermoplastic and thermoset materials, having a coiled diameter of at least 3.5 times the cord diameter, featuring a memory that allows it to extend up to 25-30 times its retracted length, achieved by winding around a mandrel and baking the material to create memory characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coiled diameter is increased to reduce kinking and improve durability, then the extension force and space efficiency are improved, but the storage space required increases
Solution Approach 1:
The patent changes the physical parameters of the cord by using a larger coiled diameter (at least 3.5 times the cord diameter) and modifying the jacket material properties (blend of thermoplastic and thermoset materials with specific durometer hardness). These parameter changes enable the cord to achieve anti-kinking and cut-resistant properties while maintaining manageable storage characteristics.
Solution Approach 2:
The outer jacket is constructed from a composite material blend of thermoplastic and thermoset materials, including thermoplastic elastomers, cross-linked polyethylene, polypropylene, polyvinyl chloride, and ethylene vinyl acetate. This composite structure provides enhanced durability, cut resistance, and abrasion resistance while maintaining the necessary flexibility for coiling and storage.
2Strength
If a harder outer jacket is used to improve cut resistance and durability, then the abrasion resistance and strength are improved, but the flexibility and ease of coiling deteriorate
Solution Approach 1:
The outer jacket utilizes a composite material system combining thermoplastic and thermoset materials. The thermoplastic components provide flexibility and ease of coiling, while the thermoset components contribute to cut resistance, abrasion resistance, and overall durability. This composite approach allows the jacket to simultaneously achieve hardness for protection and softness for coiling operation.
Solution Approach 2:
The patent specifies a durometer hardness of approximately 50 D or more for the outer jacket, which represents an optimized parameter balance. This hardness level provides sufficient cut and abrasion resistance while maintaining enough flexibility to allow the cord to be coiled and stored without excessive difficulty.
3Length of moving object
If the coiled diameter is increased to at least 3.5 times the cord diameter, then the memory and extension capability are improved, but the cord length that can be stored in a given space decreases
Solution Approach 1:
The patent establishes a specific geometric parameter relationship where the coiled diameter is at least 3.5 times the cord diameter. This parameter optimization creates sufficient memory in the coiled cord to allow extension up to 25-30 times the retracted length while maintaining a compact storage form factor that fits within reasonable storage spaces.
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 provides an anti-kinking, cut-resistant, and highly durable extension cord with reduced storage needs, offering improved extension force and space efficiency while maintaining suitable insulating properties.
Implementation Method 1
The primary insulation and jacket of the extension cord has a hardness of approximately 50 D or more (and preferably 55 D or more) and is comprised of a blend of thermoplastic and/or thermoset materials of thermoplastic elastomers (which include polyester, polyurethane, olefin rubber) cross linked polyethylene, polypropylene, polyvinyl chlorine and ethylene vinyl acetate
Implementation Method 2
The coiled portion of the extension cord has a memory that allows the cord to extend out up to approximately 25 to 30 time its retracted length, and then retract back to its retracted position
Implementation Method 3
Memory is imparted to the coiled extension cord by first making the cord (or cable), then winding the cord around a mandrel or other device, backing the cord at a sufficient temperature and length of time to create the memory, and then reversing the winding of the cord
Data Source
AI summary
An electrical power cable extension cord with a coiled section between the first and the second ends and at least one metal core conductor contained within the electrical power cable extension cord for transmitting electrical current to supply electrical power to a power device. The coiled section has a coiled diameter of approximately five times or more greater than the diameter of the electrical power cable extension cord.