Connectors for electrical connection of electrical appliances to electrical networks
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Solution Overview
Problem
Existing rotating electrical connectors for appliances like hair dryers experience significant friction and heat generation due to cylindrical contact surfaces, leading to reliability issues and potential cable twisting, which are not optimal for frequent rotation and long-term use.
Innovation Solution
A connector design featuring a rotating body with concentric metal discs and an annular element, where the discs are crimped to secure the power cable wires and the annular element's jaws provide sliding electrical contacts, allowing free rotation while maintaining a stable connection through crimping and insulating materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cylindrical contact surfaces are used in rotating connectors, then reliable electrical connection is ensured, but significant friction and heat generation occur during rotation
Solution Approach 1:
The patent replaces the cylindrical contact surface with a conical contact surface. The conical geometry changes the distribution of contact pressure and friction forces during rotation, allowing the male and female connectors to maintain electrical contact while rotating with reduced friction compared to cylindrical contacts. The conical shape enables the contacts to engage and disengage more smoothly during rotational movement.
Solution Approach 2:
The patent modifies the geometric parameters of the contact surfaces by transitioning from cylindrical to conical shapes. This parameter change affects the contact mechanics, distributing the friction force over a different area and orientation, thereby reducing the overall friction resistance during rotation while maintaining electrical connectivity.
2Reliability
If cylindrical contact surfaces are used in rotating connectors, then electrical connection is maintained, but excessive heat is generated during frequent rotation
Solution Approach 1:
The conical contact surface geometry improves heat dissipation during rotation compared to cylindrical contacts. The angled surface allows for better thermal conduction paths and reduced contact pressure concentration, thereby lowering the temperature generated during frequent rotational operations while maintaining stable electrical connection.
3Ease of operation
If 360° rotation between male and female connectors is allowed, then cable twisting is prevented, but friction is distributed over the entire cylindrical surface causing wear
Solution Approach 1:
The conical contact surface enables 360° rotation between male and female connectors while reducing friction and wear compared to cylindrical contacts. The conical geometry allows smoother engagement and disengagement during rotation, distributing wear more evenly and reducing the frictional forces that would otherwise degrade the connection over time.
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 ensures low friction, reduced wear, and improved heat dissipation, providing a reliable and stable electrical connection that prevents cable kinking and maintains optimal operating temperature during frequent use.
Implementation Method 1
The discs are crimped to secure the power cable wires
Implementation Method 2
the annular element's jaws provide sliding electrical contacts, allowing free rotation while maintaining a stable connection
Data Source
AI summary
A connector for electrical connection of an appliance to a power cable may include: a rotating body associated with the cable; and an annular element configured to surround the body. When the annular element is coupled to the body, that coupling may determine the electrical connection between the annular element and body through electrical contacts, and the annular element and body may rotate relative to each other. The body may include first and second electrical contacts, which appear as discs of electrically conductive material. The discs may be superimposed and may be interspersed with a spacer of insulating material, also disc-shaped. The discs and disc-shaped spacer may be of equal radius. The annular element may include two jaws configured to close on the body, and third and fourth electrical contacts inside at least one of the two jaws configured to grip a respective disc using sliding electrical contact.