Combination Outlet Assembly With Plug Latch for Multi-Plug PDUs
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Solution Overview
Problem
Conventional combination outlets for power distribution units (PDUs) are impractical, complicated, and expensive to manufacture, and often result in inefficient inventory management and customization issues due to the need for multiple outlets to accommodate different plug connector types, leading to increased costs and potential obsolescence.
Innovation Solution
A single-piece, molded housing with dual outlets that can interchangeably accommodate different plug connectors, featuring a cantilevered latch and biasing element to secure plugs, and ganging features for modular installation, reducing manufacturing complexity and costs while enhancing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate outlets are used to accommodate different plug connector types, then adaptability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The outlet assembly is designed with a single housing containing multiple outlet cores that can accommodate different plug connector types (NEMA 5-15, NEMA 6-15, NEMA 14-15, NEMA 14-20) through a unified structure. This universal design allows one outlet assembly to replace what would traditionally require multiple separate outlet units, thereby reducing device complexity while maintaining adaptability across different plug types.
Solution Approach 2:
Multiple outlet cores are integrated within a single molded housing structure, combining what would traditionally be separate outlet units into one unified component. The housing merges multiple functional elements (different outlet configurations, latch mechanisms, biasing elements) into a single manufacturable unit, reducing the overall number of parts and simplifying both manufacturing and installation processes.
2Adaptability or versatility
If multiple separate outlets are used to accommodate different plug connector types, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
Multiple outlet cores are integrated within a single molded housing structure, combining what would traditionally be separate outlet units into one unified component. The housing merges multiple functional elements (different outlet configurations, latch mechanisms, biasing elements) into a single manufacturable unit, reducing the overall number of parts and simplifying both manufacturing and installation processes.
Solution Approach 2:
The outlet assembly is designed with a single housing containing multiple outlet cores that can accommodate different plug connector types (NEMA 5-15, NEMA 6-15, NEMA 14-15, NEMA 14-20) through a unified structure. This universal design allows one outlet assembly to replace what would traditionally require multiple separate outlet units, thereby reducing device complexity while maintaining adaptability across different plug types.
3Reliability
If conventional combination outlets are used, then plug retention is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The outlet assembly incorporates spring-loaded biasing elements that automatically engage with the plug connector upon insertion, providing self-latching retention without requiring complex manual operation. The spring mechanism self-adjusts to secure the plug firmly, and the deflectable latch portion automatically engages to prevent accidental disconnection, ensuring reliable plug retention through simple, automatic mechanical action.
Solution Approach 2:
The latch portion is designed to be deflectable, allowing it to move dynamically during plug insertion and retention. The spring-loaded mechanism provides continuous contact force that adapts to the plug's position, ensuring secure retention while allowing for easy removal when needed. This dynamic design simplifies the overall structure compared to rigid, multi-component latching systems.
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 a compact, economical, and reliable combination outlet assembly that can connect multiple plug types, minimizing manufacturing costs and inventory complexity while ensuring reliable plug retention and ease of installation.
Implementation Method 1
a biasing element is attached to the molded housing to bias the latch portion toward the outlet core
Data Source
AI summary
An electrical outlet assembly includes a molded housing having side walls, end walls extending between the side walls, a bottom wall interconnecting the side walls and the end walls, and an outlet core extending upwardly from the bottom wall into a space defined between the side and end walls. In one example, a first end wall of the end walls includes a latch portion that is deflectable relative to the space to selectively secure an electrical plug that is engaged with the outlet core. In another example, a biasing element is attached to the molded housing to bias the latch portion toward the outlet core.