Corrugated Flat Conductors for Multiple Socket Overheating
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Solution Overview
Problem
Existing multiple socket electrical boxes face issues with overheating at connection points and require specific tools for production, leading to increased costs and management complexity due to different conductor types for phase, neutral, and earth distribution.
Innovation Solution
A multiple socket electrical box design featuring corrugated connection zones with perpendicular edges for tight plug positioning, periodic undulations for increased rigidity and elasticity, and insulating positioning means to align conductors, allowing for efficient assembly and earth connection compatibility across various standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional bending or clinching operations are used to assemble flat conductors, then production cost is reduced, but specific tools are required and production complexity increases
Solution Approach 1:
The flat conductor is segmented into multiple parallel strips that are assembled together through corrugations. This segmentation allows the conductor to be formed from simpler strip components rather than requiring complex bending or clinching operations on solid conductors, eliminating the need for specialized production tools.
Solution Approach 2:
The corrugated structure introduces curvature and undulations to the flat conductor strips. These corrugations create connection zones with specific geometric profiles that enable tight positioning of male plugs without requiring additional tools or complex assembly operations, while maintaining electrical conductivity.
2Ease of manufacture
If metal sections are bent to create conductors, then production cost is low, but electrical connection quality is average and overheating occurs
Solution Approach 1:
The corrugated structure with its curved undulations creates multiple contact points and increased surface area for electrical connections. This geometric modification improves heat dissipation and reduces localized overheating while maintaining simple manufacturing processes.
Solution Approach 2:
The connection zones of the corrugations are specifically designed with particular geometric characteristics (two edges spaced at a distance less than the male plug diameter) to optimize electrical contact and positioning. This local optimization of geometry at connection points improves electrical reliability without affecting the overall simple construction.
3Adaptability or versatility
If different conductor types are used for phase, neutral, and earth distribution, then connection compatibility is achieved, but management and storage complexity increases
Solution Approach 1:
The corrugated flat conductor design provides a universal connection structure that can accommodate different plug types and earth connection formats (pinching in Germany, card in France, etc.). The same basic conductor geometry serves multiple functions and is compatible with various national standards, eliminating the need for different conductor types.
Solution Approach 2:
The invention uses identical corrugated flat conductor structures for phase, neutral, and earth distribution. This homogenization of conductor design across all electrical functions simplifies production, storage, and management while maintaining compatibility with different connection standards through the universal corrugation geometry.
4Ease of operation
If connection zones have sufficient spacing, then male plug insertion is easy, but tight positioning cannot be achieved
Solution Approach 1:
The connection zones of the corrugations are designed with specific local geometry where two edges are spaced at a distance substantially less than the diameter of the male plug. This localized geometric constraint provides tight positioning for the plug while the overall corrugated structure still allows for easy insertion through its flexible, undulating form.
Data Source
Figure 1~2
Figure 3~4
AI summary
The box has flat conductors (10) including connection units receiving male plugs of an external socket (100), where each conductor comprises grooves (14) defining connection zones (14A) for receiving the male plugs of the external socket. Each groove comprises a flaring zone connected to one of the connection zones. The flaring zone includes two edges spaced from each other in a manner to authorize positioning of the other connection zone. Two edges of the connection zones are perpendicular to a longitudinal axis of the flat conductors.