Extension Cord Thermal Indicator Circuit
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Solution Overview
Problem
Extension cords used in construction and residential settings face safety issues due to overloading, cord degradation, and the inability to handle varying voltage requirements, leading to potential electrical faults, fires, and hazards, as well as difficulties in ensuring proper connection and securing power distribution.
Innovation Solution
An extension cord design featuring multiple electrically isolated circuits with integrated ground fault circuit interrupters and thermal indicators that allow for balanced power distribution and real-time temperature monitoring without interrupting electrical flow, along with a twist lock mechanism for secure connections and adjustable anchors for secure placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If extension cords are used to deliver electrical power to equipment far from outlets, then power distribution capability is improved, but safety hazards increase due to overloading and cord degradation
Solution Approach 1:
The extension cord is divided into multiple electrically isolated circuits (e.g., 120V and 240V circuits) that can independently carry different power loads. This segmentation allows the cord to safely handle diverse equipment requirements without overloading a single circuit, thereby improving both adaptability and safety.
Solution Approach 2:
The patent incorporates temperature sensors that continuously monitor the thermal state of the cord and provide feedback to a control system. When abnormal heating is detected, the system can alert users or automatically disconnect affected circuits, preventing thermal degradation and fire hazards while maintaining safe operation.
2Adaptability or versatility
If multiple devices with different voltage requirements are connected to a single cord, then power distribution versatility is improved, but the risk of electrical faults increases
Solution Approach 1:
The extension cord incorporates multiple electrically isolated circuits with different voltage ratings (e.g., 120V and 240V circuits). Each circuit is independently protected by its own GFCI and thermal monitoring, allowing safe connection of devices with different voltage requirements without cross-contaminating faults between circuits.
Solution Approach 2:
Different portions of the cord are assigned different electrical characteristics (voltage levels, current capacities) according to the specific needs of connected devices. Each circuit is locally optimized and protected with appropriate safety devices matched to its voltage and load requirements.
3Reliability
If traditional safety devices (fuses, GFCI) are integrated into the cord, then protection against catastrophic electrical events is improved, but the entire cord is disabled when a single device fails
Solution Approach 1:
The cord is divided into multiple electrically isolated circuits, each with its own GFCI and protection devices. When a fault occurs in one circuit, only that specific circuit is disconnected while other circuits remain operational, maintaining power supply to unaffected devices.
Solution Approach 2:
The extension cord is designed to serve multiple functions simultaneously - providing both 120V and 240V power, supporting multiple devices with different voltage requirements, and maintaining operational continuity even when individual circuits are protected or disconnected.
4Reliability
If the cord is monitored for temperature to detect overheating, then safety warning capability is improved, but the monitoring system complexity increases
Solution Approach 1:
The patent replaces complex electronic temperature monitoring systems with simpler thermal sensing elements that directly detect excessive heat and trigger warnings or disconnections. This mechanical/thermal approach reduces system complexity while maintaining effective overheating detection capability.
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
Enhances safety by preventing electrical shocks and fires, allowing for simultaneous use of devices with different voltage requirements on a single cord, and ensuring secure connections and stable power distribution, while providing visual and auditory warnings for overheating.
Implementation Method 1
At least one thermal indicator circuit is electrically connected between two of the conducting wires. The thermal indicator circuit is configured to actuate an alarm upon detecting a temperature at or above a threshold temperature
Implementation Method 2
Heating is another safety problem for both commercial and residential extension cords even when the cord is overloaded. Extension cords that have a flaw such as a loose connector, partially broken wire, or kink have a point of increased resistance that causes resistive heating
Data Source
AI summary
An extension cord comprising of a male electrical plug; at least two electrically conducting wires electrically connected to the male electrical plug, each electrically conducting wire having a length; and at least one thermal indicator circuit electrically connected between two of the conducting wires, the thermal indicator circuit configured to actuate an alarm upon detecting a temperature at or above a threshold temperature without interrupting electrical flow along the electrically conducting wires.