Latched Combination Outlet Assembly for Multi-Plug PDU Reliability
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Solution Overview
Problem
Conventional combination outlets for industrial power distribution units (PDUs) are impractical, limited, complex, and expensive to manufacture, and they often suffer from reliability issues, making them unsuitable for flexible and cost-effective power distribution in data centers and other applications.
Innovation Solution
A compact, economical, and reliable combination outlet assembly with a single piece integrally formed housing, featuring dual outlets that can interchangeably accept different special purpose plug connectors, and a modular design that allows for easy scaling of PDUs to meet varying power needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional combination outlets are used in PDUs, then multiple plug types can be accommodated, but the device becomes complex and expensive to manufacture
Solution Approach 1:
The outlet core is designed with a universal configuration that can accommodate multiple types of plug connectors (C13, C14, C15, C16, etc.) through a single standardized interface. The standardized aperture and contact arrangement allow different plug types to be connected to the same outlet core without requiring multiple specialized outlets, thereby reducing device complexity while maintaining adaptability.
Solution Approach 2:
The outlet assembly is segmented into distinct functional components: the outlet core with standardized electrical contacts, the housing with aperture, and the latch mechanism. This segmentation allows each component to be optimized independently and facilitates manufacturing while maintaining compatibility with various plug types.
2Adaptability or versatility
If conventional combination outlets are used in PDUs, then multiple plug types can be accommodated, but manufacturing costs increase
Solution Approach 1:
By designing a universal outlet core that serves multiple plug types, the patent eliminates the need to manufacture and inventory multiple specialized outlet assemblies. This single standardized design reduces tooling costs, simplifies production processes, and lowers overall manufacturing expenses while maintaining compatibility with C13, C14, C15, C16 and other plug connector types.
Solution Approach 2:
The patent combines multiple outlet functions into a single integrated outlet core assembly. Instead of providing separate outlets for different plug types, the merged design allows one outlet core to serve multiple purposes, reducing the total number of components that need to be manufactured and assembled, thereby reducing manufacturing costs.
3Adaptability or versatility
If combination outlets are designed to accept different plug types, then versatility is improved, but reliability issues arise
Solution Approach 1:
The outlet core incorporates a self-aligning and self-latching mechanism that automatically ensures proper connection when a plug is inserted. The latch portion engages with the plug housing to secure the connection, while the standardized contact arrangement automatically aligns with corresponding plug contacts, ensuring reliable electrical connection without requiring manual adjustment or intervention.
Solution Approach 2:
The outlet core design includes built-in tolerance compensation and contact pressure regulation that anticipates variations in plug manufacturing. The resilient contact elements and precisely engineered aperture provide a cushioning effect that accommodates dimensional variations in different plug types while maintaining consistent electrical contact pressure, thereby ensuring reliable connections across all compatible plug connectors.
4Ease of operation
If conventional outlets are used without latching mechanisms, then ease of operation is improved, but connection reliability deteriorates
Solution Approach 1:
The latch mechanism is designed as a dynamic component that transitions between engaged and disengaged states based on plug insertion and removal actions. During normal operation, the latch remains engaged to secure the connection. When a user applies force to remove the plug, the latch automatically disengages, providing both secure connection during use and easy removal when needed, thus balancing reliability with ease of operation.
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 solution provides a flexible and cost-effective means of power distribution, reducing the size and material costs of PDUs while enhancing reliability and adaptability to changing power requirements, thereby addressing the limitations of conventional combination outlets.
Implementation Method 1
a biasing element is attached to the molded housing to bias the latch portion toward the outlet core
Data Source
AI summary
An electrical outlet assembly includes a molded housing having side walls, end walls extending between the side walls, a bottom wall interconnecting the side walls and the end walls, and an outlet core extending upwardly from the bottom wall into a space defined between the side and end walls. In one example, a first end wall of the end walls includes a latch portion that is deflectable relative to the space to selectively secure an electrical plug that is engaged with the outlet core. In another example, a biasing element is attached to the molded housing to bias the latch portion toward the outlet core.