LCDI Power Plug Insertion Assembly for Faster Reliable Wiring

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Solution Overview

Problem

Conventional power plugs with leakage current detection interrupters (LCDI) are time-consuming to assemble due to methods like soldering or crimping of conductor wires.

Innovation Solution

A power plug design featuring a shell with input insertion prongs, a movement assembly, a male end assembly, and output conductors, utilizing an insertion-type connection for efficient assembly, with optional affixing components like notches or clamps for secure connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering or crimping methods are used to connect conductor wires to the plug head, then reliable electrical connection is achieved, but assembly time increases significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The plug head is divided into separate modular components (male end assembly, female end assembly, movement assembly) that can be pre-assembled and tested independently, then quickly connected together without requiring time-consuming soldering or crimping operations at the final assembly stage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Electrical connections are pre-established within modular assemblies during manufacturing. The male end assembly, female end assembly, and movement assembly are prepared with internal connections already made, so that final assembly only requires plugging together pre-configured modules with reliable connections already in place

Inventive Principle:

Principle #10Preliminary action

2Reliability

If traditional connection methods are used, then secure electrical connection is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveconnection securityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The complex electrical connection system is segmented into multiple simple modular assemblies, each performing a specific function. This reduces the complexity of individual manufacturing steps while maintaining overall connection security through the modular architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The movement assembly serves multiple functions: it provides the interrupter mechanism for safety, enables the on/off switching action, and facilitates the connection between input and output conductors. This multi-functionality reduces the total number of components needed and simplifies the manufacturing process

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12119593B2Power plug with leakage current detection interrupter

Publication Date: 2024.10.15 LI CHENGLI

AI summary

A power plug with LCDI includes a shell, multiple input insertion prongs partially exposed to an exterior of the shell, a movement assembly disposed in the shell and coupled to the multiple input insertion prongs, a male end assembly and a female end assembly both disposed in the shell, and multiple output conductors. A first end of the male end assembly is connected to the movement assembly and electrically coupled to the multiple input insertion prongs via the movement assembly; a second end of the male end assembly is inserted into a first end of the female end assembly; a second end of the female end assembly is electrically coupled to the multiple output conductors; and the movement assembly is configured to establish or cut off an electrical connection between the multiple input insertion prongs and the multiple output conductors. This power plug improves efficiency of assembly.