Modular Plug Circuit Breaker for Overheat and Overcurrent Protection
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Solution Overview
Problem
Existing electrical plugs suffer from poor compatibility, resource wastage due to non-interchangeable ground wire pins, frequent loosening leading to poor contact, and lack of effective overheat/overcurrent protection, resulting in potential burning and disruption of electrical appliances.
Innovation Solution
A plug with a temperature-controlled circuit breaker featuring overheat/overcurrent protection components, including bimetallic strips and PTC elements, ensures safe and stable connection through symmetrical positioning modules and quick replacement components, preventing overheating and overcurrent by automatically disconnecting the circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive is used to adhere lead end and shell together, then assembly is simplified, but the plug cannot be repaired and resources are wasted when damaged
Solution Approach 1:
The plug is divided into separable modules: the lead end assembly (containing pins and electrical components) and the shell assembly (containing the positioning module and external structure). These modules are connected through the positioning module with positioning openings and corresponding positioning structures, allowing them to be separated and reassembled. This segmentation enables the lead end to be replaced independently when damaged, eliminating the need to discard the entire plug and reducing resource waste.
2Adaptability or versatility
If ground wire pins are made in different specifications (cylindrical and flat sheet), then compatibility with different sockets is improved, but multiple plugs need to be carried and interchangeability is lost
Solution Approach 1:
The positioning module employs asymmetric positioning openings with specific geometric shapes (e.g., rectangular, triangular, or irregular cross-sections) that correspond to asymmetric positioning structures on the lead end. This asymmetric design creates a unique fit that prevents rotation and ensures correct orientation, while still allowing the same plug to interface with different socket types through the pins themselves, thus maintaining interchangeability across different specifications.
3Ease of manufacture
If pins are directly connected to power cord with PVC molding, then manufacturing is simple, but overload and short circuit protection mechanisms are insufficient
Solution Approach 1:
The positioning module incorporates protection components (such as fuse holders, circuit breaker mechanisms, or thermal protection elements) into the shell assembly before final assembly. These protective elements are pre-installed and positioned to automatically activate when abnormal conditions occur, providing preliminary protection against overload and short circuits before damage can propagate to the entire plug or connected devices.
4Ease of operation
If plug and socket are allowed to loosen after usage, then ease of insertion is maintained, but poor contact occurs and burning out is caused
Solution Approach 1:
The positioning module employs elastic positioning structures (such as spring-loaded clips, elastic deformable positioning elements, or resilient locking mechanisms) that exert a continuous counteracting force to maintain firm contact between the plug and socket. These elastic elements compensate for loosening forces that occur during use, ensuring stable electrical contact without requiring excessive insertion force, thus preventing poor contact and burning out while maintaining ease of insertion.
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 plug effectively prevents overheating and overcurrent issues, ensuring safe and reliable operation by automatically cutting off power when overheating occurs, reducing resource waste and enhancing compatibility and durability.
Implementation Method 1
an overheat/overcurrent protection component is connected in series between the lead end and the live wire pin, or an overheat/overcurrent protection component is connected in series between the lead end and the neutral wire pin
Implementation Method 2
A plug with temperature-controlled circuit breaker can include a positive temperature coefficient ("PTC") element bridging the connecting terminal and the bimetallic strip, or a PTC element bridging the second connecting terminal and the second bimetallic strip
Data Source
AI summary
A plug with a temperature-controlled circuit breaker can include a main body; a lead end; a live wire pin; and a neutral wire pin; wherein the lead end is fixed on a first end of the main body, wherein the live wire pin and the neutral wire pin are provided on a second end of the main body, and wherein an overheat/overcurrent protection component is connected in series between the lead end and the live wire pin, or an overheat/overcurrent protection component is connected in series between the lead end and the neutral wire pin.