Electrical Socket Base Crimped Bushing Design
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Solution Overview
Problem
Existing electrical socket outlet base parts with thermoplastic materials face plastic deformation under high pretensioning forces from screw torque, leading to a loose base-carrying ring connection due to limited bearing surfaces and excessive stress.
Innovation Solution
A second contact section on the flanged bushing allows the support ring to bear directly against it, creating an inseparable connection between the base and support ring, distributing axial forces and reducing plastic deformation risk through a flared collar and internal thread for the screw.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flanged bushing with a single contact section on the base is used, then the structure is simple, but the bearing surface is limited and plastic deformation occurs under high pretensioning forces
Solution Approach 1:
The contact surface is segmented into two distinct contact sections: a first contact section that rests on the base and a second contact section that the support ring bears directly against. This segmentation allows the axial forces to be distributed across two separate bearing surfaces, preventing excessive stress concentration and plastic deformation in thermoplastic base materials while maintaining structural simplicity.
2Strength
If the bearing surface between base and flanged bushing is increased, then plastic deformation is reduced, but the device complexity increases
Solution Approach 1:
Instead of increasing the size of a single bearing surface, the invention divides the load-bearing function into two separate contact sections. The first contact section on the base and the second contact section for the support ring each provide adequate bearing area, collectively distributing the axial forces without requiring an overly complex or enlarged single contact surface.
3Force
If high torque is applied to the screw for secure fastening, then the pretensioning force increases, but plastic deformation of the thermoplastic base occurs
Solution Approach 1:
The axial forces generated by screw torque are segmented and distributed across two contact sections. The first contact section transfers force to the base while the second contact section provides direct bearing for the support ring, allowing high pretensioning forces to be applied without concentrating excessive stress on the thermoplastic base material and preventing plastic deformation.
Solution Approach 2:
The second contact section acts as an intermediary bearing surface between the support ring and the base structure. This intermediary contact point allows the axial forces to be distributed more effectively, reducing the direct stress on the thermoplastic base material while maintaining the necessary pretensioning force for secure fastening.
Data Source
Figure 1a~1b
Figure 2a~2b
AI summary
The present invention relates to a base for an electrical installation device, e.g., an electrical socket, comprising a base (1) and a support ring (2). The support ring (2) is attached to the base (1) by means of two crimped bushings (5) arranged on the circumference of the support ring. The crimped bushings (5) extend through openings (10) in the support ring (2), and the support ring (2) is fixed to the base (1) by means of a crimped collar (11) formed on the crimped bushings (5) at their ends facing away from the base (1) and a first contact section (8) of the crimped bushing (5). The first contact section (8) rests against the base (1) on its underside facing away from the crimped collar (11). A second attachment section (14) is designed on the crimping bushing (5) such that the support ring (2) with its lower side facing away from the crimping collar (11) lies directly against the second attachment section (14).