Flexible Terminal Retainer for Electrical Plug
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Solution Overview
Problem
Electrical plug terminals are prone to damage due to improper removal techniques and equipment orientation, leading to rotation within sockets, which increases electrical resistance and can cause terminal breakage, especially in plugs conforming to the NEMA 5-15P standard.
Innovation Solution
An electrical plug design featuring a flexible terminal retainer with a cantilever beam structure that secures the round ground terminal independently of the rectangular neutral and hot terminals, preventing rotation and reducing the risk of damage during improper removal or equipment hanging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the plug terminals are rigidly secured in the socket, then the structural stability is improved, but the terminals are more susceptible to damage from rotation during improper removal
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a rigid terminal retention system to a flexible one. The flexible terminal retainer allows the ground terminal to move independently when rotational forces are applied during improper removal, preventing damage while maintaining normal operational stability. This is achieved through the flexible structure that can deform under stress and return to its original position.
Solution Approach 2:
The patent changes the physical parameter of the terminal retainer from rigid to flexible. This parameter change allows the retainer to accommodate rotational movements without transmitting damaging forces to the terminals, while still providing sufficient retention during normal plug operation and insertion.
2Object-affected harmful factors
If the ground terminal is rigidly constrained, then rotation is prevented, but the terminal may break under stress from improper handling
Solution Approach 1:
The flexible terminal retainer dynamically responds to applied forces by deforming in a controlled manner. When rotational stress is applied during improper removal, the flexible structure allows movement that prevents the ground terminal from breaking, while still providing sufficient constraint during normal operation.
Solution Approach 2:
The flexible terminal retainer acts as a cushioning element that absorbs and dissipates the energy from improper removal attempts before it can reach the ground terminal. The flexibility provides a buffer zone that protects the terminal from direct stress and potential fracture.
3Reliability
If the terminal retainer is made flexible, then damage from rotation is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the material parameter of the terminal retainer to a flexible polymer or elastomeric material that can be manufactured using standard injection molding processes. This approach maintains ease of manufacture while achieving the desired flexibility and damage resistance properties.
Solution Approach 2:
The terminal retainer may utilize composite material structures combining different polymers or materials with complementary properties - one providing flexibility and another providing structural support and retention force. This composite approach allows optimization of both manufacturing ease and functional performance.
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 flexible structure allows the ground terminal to move independently, preventing rotation and reducing the likelihood of damage or breakage, while the neutral and hot terminals can rotate within their sockets, thus protecting the plug terminals from improper handling and equipment-induced stress.
Implementation Method 1
The flexible structure is in the form of a cantilever beam and wherein the first plug terminal is secured in a location proximate a free end of the cantilever beam
Data Source
AI summary
An electrical plug includes a first, second, and third plug terminal, and a terminal retainer configured to secure the first, second, and third plug terminals within the electrical plug. The first, second, and third plug terminal are attached to a first, second, and third electrical wire respectively. The terminal retainer defines a flexible structure in which the first plug terminal is secured, thereby allowing the first plug terminal to move independently of the second and third plug terminals. The flexible structure may be in the form of a cantilever beam, wherein the first plug terminal is secured in a location proximate a free end of the cantilever beam. The terminal retainer consists of a single piece of injection molded plastic. The electrical plug may be part of an electrical vehicle battery charger.