Low Profile Electrical Device Assembly with Parallel Wire Routing
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Solution Overview
Problem
GFCI devices with plug connectors result in a large and obtrusive design due to wires extending perpendicularly from the rear surface, necessitating a solution for a low-profile electrical receptacle and plug assembly with improved ground contact.
Innovation Solution
An electrical device assembly featuring a housing with a rear aperture for a plug connector, where wires extend parallel to the rear surface, and a grounding member connects the plug to a ground strap, providing a low-profile configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If wires are extended perpendicularly from the rear surface to connect the plug connector, then electrical connection is achieved, but the device profile becomes large and obtrusive
Solution Approach 1:
The patent reorients the wire extension from a perpendicular direction to a parallel direction relative to the rear surface. This dimensional change in wire routing allows the plug connector to be received in a rear aperture while wires extend parallel to the rear surface, achieving both low profile and proper electrical connection
2Adaptability or versatility
If a plug connector is added to the GFCI device, then wiring flexibility is improved, but the device complexity increases
Solution Approach 1:
The patent integrates the plug connector directly into the receptacle housing structure, merging two separate components (receptacle and plug connector) into a single unified device. This combination provides wiring flexibility while avoiding the complexity of separate assembly and installation of distinct components
3Reliability
If the grounding member connects the plug connector to the ground strap, then ground contact is improved, but the device profile increases
Solution Approach 1:
The grounding member is configured to extend parallel to the rear surface rather than perpendicular to it, connecting the plug connector to the ground strap while maintaining a low profile. This dimensional reorientation ensures reliable ground contact without increasing the device profile
Data Source
AI summary
An electrical device assembly includes an electrical device and a plug connector adapted to be received thereby. The electrical device includes a housing having a rear surface and an aperture in the rear surface. A ground strap is connected to the housing and is adapted to secure the electrical device to an electrical box. A plurality of contact blades are disposed in the electrical device and are accessible through the aperture. One of the contact blades is a ground contact blade. A conductive member extends between the ground contact blade and the ground strap. The plug connector includes a plurality of contact members adapted to engage the plurality of contact blades in the electrical device. A plurality of wires extend outwardly from the plurality of contact members such that the plurality of wires are substantially parallel to the rear surface of the electrical device when the plug connector is connected to the electrical device, thereby providing an electrical device assembly having a low profile.