Electrical Socket Front Plate Gap Elimination

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Solution Overview

Problem

Electrical socket boxes often leave gaps between the switch and the wall opening due to mismatched shapes, posing safety and aesthetic issues, particularly when a circular socket box is larger than the switch or when a square/rectangular switch is fitted into a round/circular socket box.

Innovation Solution

A circular socket box with an inwardly projecting annular lip and a frame-shaped rectangular front plate that covers the entire perimeter, featuring complementary fixing elements such as recesses and clips/projections to ensure a snug fit and complete coverage of the wall opening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a circular socket box is used, then ease of installation and wire connection are improved, but gaps appear between the switch and wall opening

Engineering Contradiction:

Improveease of installationVSAvoidgaps between switch and wall opening

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A front plate is introduced as an intermediary component between the circular socket box and the rectangular switch. The front plate has a rectangular opening that accommodates the switch while its outer perimeter covers the circular socket box, eliminating gaps. This mediator resolves the shape mismatch between circular socket box and rectangular switch/wall opening.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If a square or rectangular switch is fitted into a round socket box, then electrical functionality is achieved, but gaps remain that are dangerous and unsightly

Engineering Contradiction:

Improveelectrical functionalityVSAvoidgaps between switch and socket box

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The front plate is segmented into distinct functional zones: a rectangular opening region for the switch and an outer perimeter region for covering the circular socket box. This segmentation allows the single component to serve multiple purposes - accommodating the rectangular switch while covering the circular socket box perimeter, thereby eliminating gaps.

Inventive Principle:

Principle #1Segmentation

3Volume of stationary object

If the socket box diameter is larger than the switch height, then the socket box can accommodate wiring, but gaps appear at the boundaries

Engineering Contradiction:

Improvesocket box capacityVSAvoidgaps at boundaries

Core Design Contradiction:

Volume of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The front plate extends in the radial dimension outward from the switch opening, creating an annular coverage region. This dimensional extension allows the front plate to cover the circular socket box perimeter that extends beyond the rectangular switch boundaries, eliminating gaps without reducing the socket box's internal volume for wiring.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP2780994B1Electrical socket apparatus

Publication Date: 2016.02.03 ELECTRO EXPO

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AI summary

Electrical socket apparatus comprises a frame-shaped square front plate and a circular socket box which, in use, is set in a similarly shaped opening formed in the wall or other surface. The front plate includes fixing elements" positioned to engage complementary fixing elements present on or in an inwardly extending lip around the periphery of the open end of the socket box. The front plate is dimensioned to cover, in use, the entire periphery of the open end of the socket box. In use, the front plate is trapped between a switch and the wall surface within which the socket box is located.