Power Plug Insertion Plate Sleeve Thermal Protection
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Solution Overview
Problem
Current power plugs with leakage current protection devices face safety issues due to increased electrical resistance and potential fires caused by deteriorated connections and high temperatures, which can deform the plastic body or lead to fires.
Innovation Solution
Incorporating an insulating and temperature-resistant insertion plate sleeve made of materials like engineering plastics, ceramics, or fiber glass near the connection points to prevent temperature-related deformations and ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the insertion plates are connected directly to the plastic body without protective structure, then the structure is simple and manufacturing cost is low, but the plastic body can deform or melt due to high temperature from increased electrical resistance
Solution Approach 1:
The patent divides the protective structure into segments: the plastic body and the metal protection piece are separated components. The protection piece is a distinct element that can be independently manufactured and assembled, allowing the system to protect against heat while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
The metal protection piece acts as an intermediary between the insertion plates and the plastic body. It serves as a thermal barrier that mediates the heat transfer, protecting the plastic body from direct exposure to high temperatures generated by the insertion plates during electrical resistance heating.
2Temperature
If insulating material is used for the entire plug body, then temperature resistance is improved, but manufacturing cost increases significantly
Solution Approach 1:
Instead of making the entire plug body from expensive high-temperature resistant insulating material, the patent applies local quality enhancement by adding metal protection pieces only at the critical locations where insertion plates connect to the body. This localized approach provides necessary temperature resistance where needed while keeping the majority of the plug body made from cheaper materials.
Solution Approach 2:
The patent employs composite material construction by combining different materials with complementary properties: the plastic body provides insulation and structural form, while the metal protection pieces provide localized high-temperature resistance. This composite approach achieves superior overall performance at lower cost than using expensive high-temperature materials throughout.
3Reliability
If the connection between insertion plates and power receptacle deteriorates over time, then electrical resistance increases causing heat generation, but no protective mechanism exists to prevent fire or deformation
Solution Approach 1:
The metal protection pieces are installed in advance as preventive measures against future heat damage. They are positioned beforehand to cushion and protect the plastic body from the harmful effects of heat that may arise from connection deterioration and increased electrical resistance during the product's service life.
Solution Approach 2:
The patent converts the harmful heat generated by increased electrical resistance into a beneficial protective effect. The metal protection pieces absorb and dissipate the heat that would otherwise damage the plastic body, transforming a potentially dangerous thermal condition into a controlled situation where the heat is managed by the protective metal structures.
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 solution effectively prevents safety risks from high temperatures, maintains reliable operation, and is cost-effective compared to using insulating materials for the entire plug body, while maintaining a simple structure and easy implementation.
Implementation Method 1
an insertion plate sleeve disposed on the base, wherein the input insertion plates pass through the insertion plate sleeve to protrude from the base, and wherein the insertion plate sleeve is made of an insulating and temperature resistant material
Data Source
AI summary
A power plug with leakage current protection device, which includes a body formed of an upper cover and a base, a core assembly disposed in the body, a cable assembly attached to the body, a plurality of input insertion plates and output moving contact arms which are assembled with the core assembly, and an insertion plate sleeve disposed on the base, where the input insertion plates pass through the insertion plate sleeve to protrude from the base. The insertion plate sleeve is made of an insulating and temperature resistant material. The power plug has a simple overall structure and can be assembled easily and reliably. It can prevent the safety risk caused by high temperature of the input insertion plates without increasing the size of the plug. It also has low cost, and can be suitably employed in various types of power plugs.