Locking Cord Connector Assembly with Ratcheting Mechanism
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Solution Overview
Problem
Conventional securing devices for electrical cords and extension cords often fail to maintain a secure connection, leading to disconnection issues and potential water infiltration, which can cause electrical shocks or fires.
Innovation Solution
A locking cord connector assembly featuring a male and female housing with ratcheting mechanisms, including tabs and teeth, that securely thread together to prevent disconnection and includes optional sealing gaskets for a water-tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional securing devices are used to hold cords together, then the connection is initially secure, but the connection becomes susceptible to disconnection over time
Solution Approach 1:
The patent employs a dynamic ratcheting mechanism where a tab on the male housing engages with teeth on the female housing, allowing the connection to be made easily but preventing reverse movement. This dynamic system transitions from a static conventional connector to an active locking mechanism that maintains reliability throughout the connection duration.
Solution Approach 2:
The patent replaces conventional mechanical securing methods (such as simple friction-fit connectors or external ties) with a threaded engagement system combined with a ratcheting tab mechanism. This substitution provides superior connection stability that maintains reliability over extended periods.
2Ease of manufacture
If conventional housings are used without sealing, then the device is simpler to manufacture, but water infiltration causes electrical hazards
Solution Approach 1:
The patent incorporates sealing gaskets made of flexible material between the male and female housings. These flexible seals conform to the mating surfaces and prevent water infiltration while adding minimal manufacturing complexity. The gaskets are integrated into the housing structure, providing protection against electrical hazards without significantly complicating the manufacturing process.
3Reliability
If a ratcheting mechanism with tab and teeth is implemented, then disconnection is prevented, but the device complexity increases
Solution Approach 1:
The patent merges the tab and teeth ratcheting mechanism directly into the housing structures themselves, rather than adding separate components. The tab is formed as an integral part of the male housing, and the teeth are molded into the female housing, combining the locking function with the basic connector structure to minimize overall device complexity while maintaining high connection security.
Solution Approach 2:
The threaded engagement system serves multiple functions: it provides the primary mechanical connection between housings, enables the ratcheting tab to engage and lock, and allows for controlled assembly and disassembly. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity.
4Strength
If threads are added to housings for secure engagement, then connection strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs standard thread parameters (such as UNC or UNF thread forms) that are well-established in manufacturing. By using conventional thread pitch, diameter, and profile standards, the design achieves strong engagement while maintaining compatibility with standard manufacturing capabilities, thereby limiting the increase in manufacturing precision requirements.
Data Source
AI summary
A locking cord connector assembly may include a male housing and a female housing. The male housing defines a male interior chamber configured to house one of a plug or outlet portion of an extension cord. The male housing includes male threads outwardly extending from an outer surface, and at least one tab. The female housing defines a female interior chamber configured to house the other of the plug or outlet portion of an extension cord. The female housing includes female threads inwardly extending from an interior surface. The at least one tab cooperates with a portion of the female housing to provide a ratcheting mechanism configured to maintain a secure connection between the male and female housings.