Power Plug Protector Bimetal Contact Deformation Prevention
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Solution Overview
Problem
Conventional power plugs fail to maintain the overcurrent protection function when a prong is inadvertently deformed due to external force, causing the bimetal electrical contact to shift and lose its protective functionality.
Innovation Solution
A power plug protector assembly with a bimetal contacting plate securely fixed inside the casing, where only the positive electrode prong is mounted inside, and the negative and ground prongs are outside, along with a circuit recovery button and spring mechanism to ensure the bimetal contact separates from the prong when heated, preventing deformation and maintaining protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all prongs are inserted partially in the casing, then the structure is compact and easy to manufacture, but the bimetal electrical contact will shift when a prong is deformed by external force, causing loss of overcurrent protection function
Solution Approach 1:
The invention divides the prong mounting structure into two segments: the positive electrode prong is mounted inside the casing while the negative electrode and ground prongs are mounted outside the casing. This segmentation allows the bimetal electrical contact to be protected within the casing while the external prongs can withstand external forces without affecting the internal protection mechanism.
Solution Approach 2:
The invention extracts the negative electrode prong and ground prong from the internal casing structure and mounts them externally. This extraction prevents these prongs from interfering with the bimetal electrical contact's positioning and function, while the positive electrode prong remains inside to maintain the protection mechanism.
2Reliability
If the bimetal electrical contact is mounted inside the casing, then it is protected from external damage, but it cannot effectively separate from the prong when heated due to space constraints
Solution Approach 1:
The invention incorporates a spring mechanism that provides dynamic movement capability to the bimetal electrical contact. When the bimetal contact heats up and expands, the spring allows it to move and separate from the positive electrode prong, effectively breaking the circuit. The spring ensures the contact can dynamically respond to thermal changes while remaining protected within the casing.
3Ease of operation
If the prong terminal is bent by excessive external force, then the power plug can be forcibly connected or disconnected, but the casing will be pulled and broken and the bimetal electrical contact will shift
Solution Approach 1:
The invention extracts the negative electrode prong and ground prong from the internal casing structure and mounts them externally on the casing surface. This allows these prongs to absorb external bending forces without transmitting stress to the casing or the internal bimetal electrical contact, preventing casing damage and contact displacement during forced plugging or unplugging operations.
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 deformation of the bimetal contact and maintains overcurrent protection, even with repeated pulling and plugging operations, ensuring the power plug and connected devices are not damaged by excessive current.
Implementation Method 1
the bimetal contacting plate deforms and bends to make the free end separated from the positive electrode prong terminal when suffering sufficient heat
Data Source
AI summary
A power plug assembly has: a protective casing having a cavity defined in the protective casing; a positive electrode prong terminal mounted in the cavity of the protective casing and extending out of the protective casing; a protecting assembly mounted in the cavity and having a bimetal contacting plate mounted in the protective casing and having a fixing end mounted securely in the cavity; and a free end being opposite to the fixing end and contacting the positive electrode prong terminal, wherein the bimetal contacting plate deforms and bends to make the free end separated from the positive electrode prong terminal when suffering sufficient heat; a negative electrode prong terminal mounted outside the protective casing; and a ground prong terminal mounted outside the protective casing. The negative electrode prong terminal and the ground prong terminal outside the protective casing would not negatively affect the bimetal contacting plate.