Modular Socket Assembly for Expandable Outlets and Stable Contacts
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Solution Overview
Problem
Existing extension cords with multiple sockets require different molds for manufacturing, leading to increased costs and unstable electrical connections.
Innovation Solution
A modularized socket structure comprising a main socket module, expansion socket modules, a sub-socket module, and an expansion conductive plate set, allowing for the expansion of socket numbers according to requirements, while enhancing electrical connection stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different molds with different numbers of sockets are used to manufacture extension cords, then the number of sockets can be varied to meet different requirements, but the manufacturing cost increases and the electrical connection becomes unstable
Solution Approach 1:
The extension cord is divided into multiple independent socket modules (main socket module, expansion socket modules, and sub-socket modules) that can be manufactured separately using a single mold design. Each module contains complete electrical connection components, allowing them to be produced independently and then assembled together to create extension cords with different numbers of sockets, eliminating the need for multiple specialized molds.
Solution Approach 2:
The socket modules are designed to nest together through hierarchical assembly: main socket modules can contain or be connected to expansion socket modules, which in turn can connect to sub-socket modules. This nested structure allows flexible configuration of socket numbers while maintaining stable electrical connections through standardized conductive plate interfaces that ensure reliable contact between nested modules.
2Adaptability or versatility
If different molds with different numbers of sockets are used to manufacture extension cords, then various socket configurations can be produced, but the electrical connection stability deteriorates
Solution Approach 1:
By segmenting the extension cord into standardized socket modules with uniform conductive plate interfaces, each module maintains consistent electrical connection quality. The segmentation allows different configurations to be assembled from the same reliable module design, ensuring that electrical connection stability is preserved regardless of the total number of sockets in the final product.
Solution Approach 2:
The invention changes the parameter of socket configuration by assembling different numbers of identical standardized modules rather than changing the mold design itself. This approach maintains constant electrical connection parameters (contact area, material properties, structural integrity) across all configurations, ensuring stable electrical connections while achieving versatility in socket numbers.
3Ease of manufacture
If a single mold is used to manufacture all socket modules, then manufacturing cost is reduced, but the ability to create different socket numbers is limited
Solution Approach 1:
The extension cord system is segmented into standardized, interchangeable socket modules that can all be manufactured using the same mold. This segmentation enables a single mold design to produce multiple socket configurations by simply varying the number of modules assembled, not the mold itself. The modular architecture transforms a manufacturing limitation into a design advantage.
Solution Approach 2:
The standardized socket module design serves multiple functions: it can be used as a standalone main socket module, as an expandable unit, or as a sub-module in larger configurations. This universal module design allows a single mold to produce components that can be assembled into extension cords with any number of sockets, achieving versatility without requiring specialized molds for each configuration.
Data Source
AI summary
An improved modularized socket structure comprises: a main socket module, first, second and third polar main jacks are formed on a main conductive component of the module; at least one expansion socket module, first, second and third polar expansion jacks are formed on an expansion conductive component of the module; a sub-socket module, first, second and third polar sub-jacks are formed on a sub-conductive component of the module; and an expansion conductive plate set comprising first, second and third conductive plates, the first conductive plate has first extension portions inserted into first polar main jack, first polar expansion jack and first polar sub-jack, the second conductive plate has second extension portions inserted into second polar main jack, second polar expansion jack and second polar sub-jack, and the third conductive plate has third extension portions inserted into third polar main jack, third polar expansion jack and third polar sub-jack.