Outlet Safety Plug Structure for Warp-Resistant Child Protection
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Solution Overview
Problem
Existing safety plug covers do not effectively protect USB, Ethernet, Telephone, and Coaxial outlets from child access and damage, as they lack structural integrity and consistent wall thickness, leading to potential choking hazards and warping issues.
Innovation Solution
The development of safety plugs with one or more rows of cavities and specific patterns that provide structure and stiffness, featuring interfacing elements on ridges between cavities to prevent warping and ensure consistent wall thickness, designed for various types of outlets including USB, Ethernet, Telephone, and Coaxial.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional thin cover plates are used for electrical outlets, then they provide basic coverage, but they lack structural integrity and can break into small parts creating choking hazards
Solution Approach 1:
The cover plate is divided into multiple sections with recessed cavities that create internal structural support. The cavities are separated by ridges that act as structural reinforcement, preventing the plate from breaking into small hazardous parts while maintaining coverage functionality.
Solution Approach 2:
The cover plate features varying wall thicknesses with thicker regions at critical stress points (ridges between cavities) and thinner regions where coverage is needed. This local variation in quality provides structural integrity where required while maintaining overall lightness and coverage capability.
2Ease of manufacture
If cover plates with varying wall thickness are used, then they are easier to manufacture, but they warp during molding due to inconsistent thickness
Solution Approach 1:
The plate is segmented into multiple cavities and ridges that distribute stress evenly during molding. The ridges act as internal support structures that prevent warping while allowing varying wall thicknesses in different regions for manufacturing efficiency.
Solution Approach 2:
The design incorporates specific cavity depths and ridge heights that optimize the molding process. By carefully controlling the parameters of cavity dimensions and ridge thickness, the plate achieves consistent wall thickness in critical areas while maintaining manufacturing ease in other regions.
3Strength
If thin cover plates are used, then they provide basic outlet coverage, but they lack stiffness and can break easily
Solution Approach 1:
The plate is divided into multiple recessed cavities separated by ridges. This segmentation creates internal structural support that significantly increases resistance to breaking while maintaining a relatively simple overall design that is easy to manufacture and install.
Solution Approach 2:
The cavities are formed with curved surfaces rather than sharp angles, distributing stress more evenly throughout the structure. This curvature increases structural integrity and resistance to breaking while adding minimal complexity to the manufacturing process.
4Stability of the object's composition
If consistent wall thickness is maintained throughout the plate, then warping is prevented, but manufacturing becomes more difficult and costly
Solution Approach 1:
The plate is segmented into cavities and ridges that create zones of different thickness. The ridges provide consistent thickness at critical structural points to prevent warping, while other areas can have varying thicknesses that are easier to manufacture.
Solution Approach 2:
The design applies consistent wall thickness locally at critical areas (ridges and cavity walls) where structural stability is needed to prevent warping, while allowing varying thickness in non-critical areas to simplify manufacturing and reduce material usage.
Data Source
AI summary
A system and method directed for one or more safety plugs whereby safety plugs may either be individual plates that will insert into unused Telephone, Ethernet, and USB outlets, the safety plug may also be an individual coaxial plate that will cover a coaxial stud thus preventing any damage.