Electrical Module Curved Slope Collar Design
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Solution Overview
Problem
Standardized electrical plugs and sockets are too large for domestic use, lack suitable locking mechanisms for axial motion, and do not provide adequate protection against bending loads or high voltage and current requirements, making them unsuitable for modular electrical systems in residential settings.
Innovation Solution
A compact electrical module design featuring a curved slope to prevent jamming, tactile and audible locking mechanisms for secure engagement, and a shutter mechanism to prevent accidental disengagement, along with a design that accommodates bending forces by creating a gap between modules, ensuring safe and secure connections under various loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standardized plugs and sockets (IEC C19/C20) are used for modular electrical systems, then high voltage and current capacity (250V/16A) is achieved, but the system size becomes too large to be space-efficient for domestic use
Solution Approach 1:
The electrical connection system is divided into separate plug and socket modules that can be independently sized and configured. Each module contains only the essential connection components needed for its function, allowing the overall system to be compact while maintaining high current capacity through optimized internal conductor arrangements.
Solution Approach 2:
The plug connector is designed to be received within and nested inside the socket module housing. This nested arrangement allows the plug and socket to occupy overlapping spatial volumes, reducing the overall system footprint while maintaining the necessary current-carrying capacity through proper conductor sizing and arrangement.
2Volume of moving object
If industrial flat 3 pole connectors are used, then space efficiency is improved, but the connector cannot transfer bending loads and is unsuitable for modular systems
Solution Approach 1:
A curved slope is introduced to the collar-socket interface to prevent the 'jammed-drawer effect' that occurs when longitudinal axes are misaligned. This curved geometry allows for self-alignment and smooth engagement while maintaining the ability to transfer bending loads through the curved load path.
Solution Approach 2:
The collar and socket are designed with pre-formed curved surfaces that guide alignment during the engagement process. This preliminary geometric guidance ensures proper alignment before final connection, enabling the connector to handle bending loads effectively from the outset of engagement.
3Reliability
If industrial connectors with rotating locking mechanisms are used, then secure connection is achieved, but axial motion for connecting modules is hindered
Solution Approach 1:
Instead of using a rotating locking mechanism that requires angular motion, the invention employs an axial locking approach where the collar and socket engage through straight-line insertion. The locking action occurs axially through the interlocking of collar and socket features during linear engagement, reversing the conventional approach of rotational locking.
Solution Approach 2:
The collar and socket are designed with self-aligning curved surfaces that automatically guide the connection into proper alignment during axial insertion. This self-service alignment mechanism eliminates the need for manual rotation or complex positioning, allowing secure connection through simple axial motion alone.
4Device complexity
If conventional connectors without shutters are used, then device complexity is reduced, but protection against accidental disengagement and safety are compromised
Solution Approach 1:
The shutter mechanism is integrated into the existing collar and socket structure, combining the protective function with the connection mechanism. The shutter is formed as part of the socket assembly, using the same materials and manufacturing processes as the housing, thereby adding safety functionality without significantly increasing overall device complexity.
Data Source
Figure 1~2
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Figure 7~8
AI summary
An electrical module (10) comprises a first wall (12) with a plug interface (20), wherein the plug interface comprises a plurality of plug pins (22) and a collar (24) surrounding the plug pins, the collar having an envelope surface. A second wall (14) is provided with a socket interface (30), wherein the socket interface comprises a socket tip (34) exhibiting a plurality of socket holes (32) adapted to receive plug pins of an adjacent electrical module. The socket tip (34) is surrounded by a socket cavity (38) provided in the second wall and adapted to receive a collar of an adjacent electrical module. The plug interface is adapted to be connected to a socket interface of a corresponding electrical module and the socket interface is adapted to be connected to a plug interface of a corresponding electrical module. By providing a curved slope (24b) on the envelop surface of the collar (24), advantageous connection properties are achieved.