Right-Angled Plug Asymmetric Housing Reduces Terminal Stress
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Solution Overview
Problem
Right-angled electrical plugs experience terminal damage due to rotation within sockets when improperly removed or when electrical devices hang from outlets, leading to increased electrical resistance and potential terminal breakage, particularly in NEMA 5-15P standard plugs with two blade style terminals and a round pin terminal.
Innovation Solution
A right-angled electrical plug design with an extended housing that moves the pivot point further from the ground terminal, reducing stress on the terminal by increasing the lever arm length, thereby minimizing damage during improper removal or when devices hang from outlets, and conforming to NEMA 5-15P standards with a housing made of injection molded plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug is designed with standard housing length, then the plug conforms to standard dimensions, but the ground terminal is susceptible to rotation damage when the plug is improperly removed or devices hang from outlets
Solution Approach 1:
The housing is designed with asymmetric terminal positioning where the ground terminal is located closer to the portal than the hot and neutral terminals. This asymmetric arrangement creates a shorter lever arm for the ground terminal, reducing the rotational moment and stress on the ground terminal when the plug is improperly removed or devices hang from the outlet.
2Strength
If the ground terminal is positioned closer to the portal, then stress on the ground terminal is reduced during improper removal, but the housing becomes asymmetric and may affect manufacturing simplicity
Solution Approach 1:
The invention changes the positional parameter of the ground terminal within the housing, placing it closer to the portal than the hot and neutral terminals. This parameter change optimizes the lever arm length to reduce stress on the ground terminal while maintaining compatibility with standard injection molding processes for housing fabrication.
3Adaptability or versatility
If the plug follows standard NEMA 5-15P configuration, then compatibility with standard sockets is ensured, but the round ground terminal is more likely to bend or break due to rotation constraints
Solution Approach 1:
While maintaining standard NEMA 5-15P terminal types and socket compatibility, the invention introduces asymmetric positioning of terminals within the housing. The ground terminal is positioned closer to the portal, creating a shorter lever arm that reduces rotational stress and prevents bending or breaking, while the hot and neutral terminals maintain their standard positions for compatibility.
Data Source
AI summary
A right-angled electrical plug includes a first plug terminal and a second plug terminal longitudinally spaced apart from one another. First and second electrical wires are interconnected with the first and second plug terminals respectively. A housing configured to secure the first and second plug terminals has a generally planar surface from which the first and second plug terminals project and has a portal through which the first and second electrical wires exit the housing. The surface has a first lateral edge that is closer to the portal than a second lateral edge opposite the first lateral edge. A first distance between the first lateral edge and the first plug terminal is at least two times less, and is preferably is at least three time less, than a second distance between the second lateral edge and the second plug terminal. The right-angled electrical plug may conform to NEMA 5-15P standards.