Integrated Power Plug Connector for Surge Filtering and Circuit Status
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Solution Overview
Problem
Existing power cable plug connectors fail to integrate terminal contacts, surge protection devices, and circuit analysis devices within a single housing assembly, leading to increased electrical connections, longer wiring lengths, and higher costs, which can result in voltage drop and damage to connected electronic devices.
Innovation Solution
A power cable plug connector with a housing assembly that compartmentalizes terminal contacts, a surge protection device, and a circuit analysis device, allowing for efficient electrical connections and reduced wiring length, thereby protecting electronic devices from transient overvoltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If terminal contacts, surge protection devices, and circuit analysis devices are separated into different housings, then each device can be independently manufactured and maintained, but the number of electrical connections increases and wiring length increases leading to voltage drop
Solution Approach 1:
The patent combines terminal contacts, surge protection devices, and circuit analysis devices into a single integrated housing assembly. This merging eliminates the need for multiple separate electrical connections and reduces overall wiring length, thereby preventing voltage drop and improving reliability while maintaining manufacturing feasibility through modular internal design
2Reliability
If terminal contacts, surge protection devices, and circuit analysis devices are integrated into a single housing assembly, then wiring length is reduced and voltage drop is minimized, but the device complexity increases
Solution Approach 1:
The integrated housing assembly is divided into distinct internal compartments, each housing a specific functional component (terminal contacts, surge protection devices, circuit analysis devices). This segmentation allows for organized internal wiring and simplified assembly procedures, reducing the perceived complexity while maintaining the benefits of integration
3Adaptability or versatility
If more electrical connections and wiring are used to connect separate devices, then each component can be optimized independently, but the cost increases and the potential for voltage drop increases
Solution Approach 1:
By integrating multiple devices into a single housing assembly with a common terminal block and shared wiring infrastructure, the patent reduces the total number of electrical connections required. This merging approach lowers manufacturing costs by reducing wire usage and assembly steps while maintaining the ability to optimize each component's performance through targeted internal design
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 integrated design reduces the number of electrical connections and wiring length, lowering the risk of voltage drop and enhancing the protection of connected electronic devices from harmful transients, while also reducing overall costs.
Implementation Method 1
a surge protection configured device to filter potentially destructive transients
Data Source
AI summary
A power cable plug connector device is disclosed having a housing assembly and an internal assembly, the internal assembly includes a terminal configuration and an electronics configuration. The terminal configuration includes at least one metal contact configured to engage a power source and conduct an incoming power signal. The electronics configuration is electrically connected to the terminal configuration and includes a transient suppressor to conduct the incoming power signal and to filter a transient power signal of the incoming power signal when the incoming power signal exceeds a predetermined transient signal threshold. The electronic configuration further includes a circuit analyzer electrically connected to a LED display to provide a real-time circuit status based on one or more detected circuit measurements. The internal assembly electrically connects and supports the power wire electrically adapted to be connected to a system circuit and transmits a non-transient power signal to the system circuit.