Outlet Safety Device with Thermal Expansion Ejection
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Solution Overview
Problem
Poor electrical connections between plugs and outlets can lead to high resistance and heat generation, potentially causing fires, especially with high amperage appliances, as the contacts may lose resilience over time, resulting in inadequate contact and increased resistance.
Innovation Solution
An electrical outlet safety device with thin conductive blades that enhance contact between the plug and outlet, an amperage measuring device, and a thermal sensor to expel the plug from the outlet when excessive current or temperature is detected, using a fire-retardant material that expands to eject the plug and becomes insulating, providing visual and thermal safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thin conductive blades are inserted between plug and outlet contacts, then electrical contact quality is improved, but device complexity increases
Solution Approach 1:
The patent introduces thin conductive blades as an intermediary element inserted between the plug contacts and outlet contacts. These blades improve electrical contact quality by filling gaps and ensuring reliable connection, while the overall device complexity is managed by integrating multiple functions (contact improvement, heat conduction, amperage measurement, thermal sensing) into a single composite safety device structure.
2Reliability
If amperage measuring device and thermal sensor are added to detect excessive current and temperature, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple safety functions (amperage measurement, thermal sensing, contact improvement, and ejection mechanism) into a single integrated safety device. The thin conductive blades serve both as electrical contacts and thermal conduction paths to the thermal sensor. The control system integrates signals from both the amperage measuring device and thermal sensor to trigger the ejection mechanism, consolidating safety monitoring and response functions in one unified structure.
Solution Approach 2:
The safety device performs multiple functions simultaneously: the thin conductive blades improve electrical contact and conduct heat to the thermal sensor; the amperage measuring device monitors current levels; the thermal sensor detects temperature changes; and the ejection mechanism responds to both electrical and thermal hazards. This multi-functionality approach improves safety comprehensively while managing device complexity through functional integration.
3Reliability
If fire retardant material is used for the body, then safety is improved, but manufacturing complexity increases
Solution Approach 1:
The patent specifies that the device body be formed from compressed fire retardant material with particular properties: it must be electrically conductive when compressed (to allow current flow during normal operation) but become electrically insulating when expanded (to prevent fire and electrical shock after activation). The material also undergoes a volume expansion parameter change when exposed to heat, transforming from a dense compressed state to an expanded insulating foam state. This parameter change approach provides safety benefits while using commercially available specialized materials that can be manufactured through standard compression molding processes.
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
Effectively prevents fires by breaking the electrical contact and reducing heat generation through the automatic ejection of the plug from the outlet, offering a safe and unobtrusive solution for high resistance scenarios.
Implementation Method 1
The blades are captured between the prongs of the electrical plug and the corresponding internal terminals of the outlet or receptacle to provide better electrical contact and to conduct heat generated by poor contact or high resistance to the body of the safety device
Implementation Method 2
The material of which the body of the device is made is configured to expand rapidly, i.e., to produce a small explosion, when a predetermined temperature is reached
Implementation Method 3
The material of which the body of the device is made is configured to expand rapidly, i.e., to produce a small explosion, when a predetermined temperature is reached
Implementation Method 4
Compressive springs may be provided within the body of the device, so that the springs release to push the plug from the outlet when the body of the device expands
Implementation Method 5
The amperage measuring device is preset at a predetermined amperage to cause the body of the safety device to expel the electrical plug from the outlet
Implementation Method 6
The thermally conductive blades also transfer heat to a thermal sensor, which causes the body of the safety device to expel the plug in the event that an excessive temperature is reached
Implementation Method 7
The material of which the body of the device is made becomes an electrically insulating foam material as it expands
Data Source
AI summary
The electrical outlet safety device is placed between an electrical plug and the corresponding electrical outlet or receptacle to which the plug is connected. The safety device includes a thin body portion formed of a material adapted to expand rapidly if exposed to a predetermined temperature. A series of thin, electrically and thermally conductive blades extends from the body, with the blades being captured between the prongs of the plug and the internal contacts of the receptacle when installed therewith. If excessively high electrical resistance and correspondingly high temperature are produced in one or more of the electrical connections between the plug and the outlet, the blades of the safety device transmit the excessive temperature to the body, whereupon the body is transformed to an expansive electrically insulating foam that expels the plug from the receptacle. Springs may be included within the body to provide additional expansive force.