Shallow GFCI Receptacle Latching Layout for Standard Junction Boxes
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Solution Overview
Problem
Conventional circuit interrupting devices, such as GFCIs, occupy substantial space due to their design, making it challenging to fit them within standard junction boxes and leaving limited space for other features or components in electrical receptacles.
Innovation Solution
The design incorporates a compact latching mechanism utilizing a solenoid, carriage, lifting shelf, slide mechanism, and reset plunger to efficiently manage the movement of contacts within a GFCI receptacle, allowing for a more compact form factor while maintaining functionality, including a symmetrical placement of sensing cores to minimize interference and optimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional GFCI devices are used with traditional protection circuitry and mechanisms, then ground fault protection functionality is achieved, but the device occupies substantial physical space within the receptacle housing
Solution Approach 1:
The patent replaces traditional mechanical sensing mechanisms with magnetic field sensing. The sensing cores detect ground faults through magnetic field changes induced by current imbalances, eliminating the need for bulky mechanical trip mechanisms and reducing overall device volume while maintaining protection functionality.
Solution Approach 2:
The patent changes the detection parameter from mechanical movement to magnetic field strength. By measuring magnetic field changes caused by current imbalances, the system achieves ground fault detection without requiring the physical space needed for traditional mechanical sensing and actuation components.
2Reliability
If traditional latching mechanisms are used to hold contacts in closed position, then reliable electrical connection is maintained, but the device depth increases making it difficult to fit in standard junction boxes
Solution Approach 1:
The patent nests the latching mechanism components within each other, with the armature, solenoid, and contacts arranged in a compact stacked configuration. This nesting allows the latching function to be achieved within a reduced depth while maintaining reliable electrical connection.
Solution Approach 2:
The patent reorients the latching mechanism to operate primarily in the horizontal plane rather than extending deeply in the vertical dimension. The sensing cores and latching components are arranged laterally, allowing the device to fit within standard junction box depth constraints while maintaining functional reliability.
3Reliability
If more space is allocated for protection circuitry and mechanisms, then comprehensive safety features are implemented, but less space remains for other elements and features in the receptacle
Solution Approach 1:
The patent designs the sensing cores to serve multiple functions: they detect ground faults, provide magnetic shielding, and structurally support the circuit board. This multi-functionality eliminates the need for separate components, reducing overall device footprint and leaving more space in the receptacle for additional features.
Solution Approach 2:
The patent merges the sensing, latching, and contact functions into a compact integrated assembly. By combining these functions into a single space-efficient unit, the device achieves comprehensive safety features while minimizing the space occupied in the receptacle housing.
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
This solution enables the creation of shallower receptacles with additional space for features, enhancing the compactness and functionality of circuit interrupting devices without compromising their protective capabilities.
Implementation Method 1
a solenoid having a central axis perpendicular to the first plane
Implementation Method 2
The slide mechanism includes a cam surface to transform a downward force to a translational force applied to the coupled lifting shelf
Data Source
AI summary
An electrical outlet receptacle including a circuit board defining a first plane and a solenoid having a central axis perpendicular to the first plane. The electrical outlet receptacle further including a reset plunger with a portion extending through the first end of the solenoid and axially movable therein, and an armature movable axially along the portion of the reset plunger extending through the solenoid. Wherein the armature includes a slanted projection configured to contact a cam surface of a slide mechanism and provide the downward force on the cam surface.