Integrated Voltage Converter Socket Housing Design
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Solution Overview
Problem
Conventional mains units for voltage conversion are cumbersome, prone to faults, and costly due to separate housings and cable connections, leading to complications in installation and safety compliance, and result in parasitic energy consumption.
Innovation Solution
Integration of voltage conversion means into a plug-in socket housing, allowing for a compact, hermetically sealed design that matches standard plug dimensions, eliminating the need for external mains units and simplifying installation and safety compliance by incorporating a switch and filter, while enabling zero consumption and automatic voltage adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If voltage conversion means are integrated into the socket housing, then device complexity and installation cost are reduced, but the socket housing must accommodate additional components within predetermined dimensions
Solution Approach 1:
The voltage conversion means are nested within the socket housing, with the transformer core and windings contained inside the housing that is substantially predetermined by the dimensions of the corresponding standard plug. This nesting approach allows the voltage conversion functionality to be integrated without increasing the external dimensions of the socket housing.
Solution Approach 2:
The socket housing and voltage conversion means are merged into a single integrated unit. The housing serves dual purposes: as the structural enclosure for the socket and as the containment structure for the voltage conversion components, eliminating the need for separate housings and reducing overall device complexity.
2Loss of energy
If voltage conversion means are integrated into the socket housing, then parasitic energy consumption is minimized, but heat dissipation becomes more challenging within the compact housing
Solution Approach 1:
The heat generated by the voltage conversion means during operation is converted into a beneficial heating effect for the terminal device, particularly during cold startup. The housing and internal components act as a heat source that warms the device during initial operation, transforming the previously harmful heat loss into a useful function.
3Ease of operation
If the socket housing dimensions are predetermined by standard plug dimensions, then ease of operation and compatibility are improved, but the space available for voltage conversion components is limited
Solution Approach 1:
The socket housing is designed to be universal, accommodating both the electrical connection function and the voltage conversion function within the same structure predetermined by standard plug dimensions. This multi-functionality allows the housing to serve as both the interface for the standard plug and the enclosure for the voltage conversion means.
4Reliability
If voltage conversion means are integrated into the socket housing, then reliability is improved by eliminating external connections, but manufacturing precision requirements increase
Solution Approach 1:
The voltage conversion means and socket housing are merged into a single integrated assembly, eliminating the need for external cable connections and separate housing assemblies. This integration reduces the number of connection points and potential failure modes, thereby improving reliability.
Solution Approach 2:
The integrated socket housing with voltage conversion means is designed as a modular unit that can be manufactured separately and then installed as a complete assembly into the terminal device. This segmentation allows for specialized manufacturing processes to achieve the required precision while maintaining overall system reliability.
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
This solution reduces the risk of faults, lowers production costs, and minimizes parasitic energy consumption by integrating voltage conversion within the socket, ensuring compliance with safety standards and allowing for flexible voltage adaptation without altering the external dimensions of the terminal device.
Implementation Method 1
means integrated in the socket housing for voltage conversion of a primary voltage into at least one secondary voltage for the electrical terminal device
Data Source
AI summary
A plug-in socket for coupling to a corresponding standard plug and for connection of an electrical terminal device to a primary voltage. The plug-in socket improves the use of mains units with voltage converters. The plug-in socket comprises a socket housing, a first electrical contact arranged in the socket housing for coupling to a corresponding standard plug electrical contact, a voltage converter integrated in the socket housing and converting a primary voltage into at least one secondary voltage for the electrical terminal device, a second electrical contact arranged on the socket housing for electrical contacting of the secondary voltage, wherein the voltage converter is integrated in the socket housing so that the external dimensions of the socket housing are substantially predetermined by the dimensions of the corresponding standard plug.