Snap-Together Electrical Receptacle With L-Shaped Tabs
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Solution Overview
Problem
Conventional electrical receptacles face challenges in assembly, as two-piece housings with fasteners are cumbersome and time-consuming, while snap-fit designs lack rigidity, making them prone to being twisted or pulled apart, potentially causing electrical shock or damage.
Innovation Solution
A receptacle design featuring a face member coupled to a base with L-shaped tabs, a centrally located post with barbs, and snaps from the base ends engaging apertures in the mounting bridge, providing a secure and quick assembly with enhanced stability against separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners or screws are used to couple the two-piece housing, then the housing is rigidly secured and difficult to separate, but the assembly process becomes cumbersome and time-consuming
Solution Approach 1:
The housing is divided into modular components (front cover, back cover, mounting bridge) that can be independently manufactured and assembled. The face member is separated from the base, allowing pre-assembly of the base-monturing bridge-snap combination, which reduces overall assembly time while maintaining structural integrity through designed engagement features.
Solution Approach 2:
Different regions of the housing have different coupling mechanisms optimized for their specific functions. The mounting bridge uses L-shaped tabs with barbs for rigid structural connection, while the face member uses simpler post engagement for easier assembly. This localized optimization allows each part to be secured appropriately without requiring fasteners throughout the entire housing.
2Ease of operation
If snap-fit design is used to couple the front cover to the back cover, then the housing is quick and easy to assemble, but the housing lacks rigidity and can be easily twisted or pulled apart
Solution Approach 1:
The housing employs a composite structure combining multiple materials and coupling mechanisms. The mounting bridge appears to be made of a rigid material (possibly metal or rigid plastic) that provides structural strength, while the snap-fit face member uses a more flexible material allowing easy assembly. This composite approach combines the ease of snap-fit assembly with the rigidity of a stronger mounting structure.
Solution Approach 2:
The L-shaped tabs feature curved engagement surfaces and barbed edges that provide both easy snap-in assembly and strong mechanical interlocking. The curved geometry allows the tabs to deflect during assembly for easy insertion, then lock into place with the barbs preventing withdrawal, thus achieving both ease of assembly and structural rigidity.
3Reliability
If multiple fasteners are used in each housing, then the housing is securely assembled, but the assembly process becomes tedious and time-consuming
Solution Approach 1:
Traditional fasteners (screws, rivets) are completely removed from the design and replaced with integrated snap-fit and L-shaped tab mechanisms. This extraction of fastening elements simplifies the assembly process to a single snap-action operation while maintaining secure connection through the engineered engagement features of the L-shaped tabs with barbs and the snap protrusions.
Data Source
AI summary
A receptacle includes a housing with a face member coupled to a base. A mounting bridge with first and second sides is connected to the base by a bottom member extending along a back surface of the base. The mounting bridge includes at least one substantially L-shaped tab formed on the first side of the bridge engaging a front surface of the base remote from the back surface. An upright post located towards the center of the bridge has a circular opening and a plurality of barbs disposed along its outer edges. Snaps protrude from the first and second ends of the base to engage apertures in the first and second sides of the mounting bridge.