Tongue-and-Groove Plug Enclosure for Weatherproof RV Cord Connections

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Solution Overview

Problem

RV electrical cord connectors are prone to degradation and failure due to exposure to harsh environmental conditions, leading to potential electrical hazards and safety concerns, especially when used with extension cords.

Innovation Solution

A weatherproof enclosure device for RV electrical cord connectors, constructed from high-quality, UV-stabilized plastics, featuring a two-piece design with reciprocal tongue and groove coupling, ventilation, and translucent material for visibility, designed to protect against moisture and corrosion while ensuring reliable performance and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If connectors are exposed to harsh environmental conditions for extended use, then power transmission function is maintained, but degradation and failure occur due to moisture intrusion and corrosion

Engineering Contradiction:

Improveservice life of connectorsVSAvoidelectrical connection reliability

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The connector system is divided into separate components: an indoor connector housing, an outdoor connector housing, and a protective enclosure. This segmentation allows each component to be optimized for its specific environment and enables replacement without replacing the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A protective enclosure acts as an intermediary between the connectors and the harsh outdoor environment. This enclosure provides a controlled interface that protects the electrical connections from moisture and corrosion while maintaining electrical functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If connectors are protected from environmental exposure, then reliability is improved, but accessibility and ease of connection are reduced

Engineering Contradiction:

Improveconnector protection from elementsVSAvoidconnector accessibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The protective enclosure is designed to be dynamic rather than fixed - it can be quickly opened and closed to allow connection and disconnection of cords. The latch mechanism enables rapid access while maintaining protection during operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connectors are extracted from the main connector body and placed in separate, accessible locations. This allows the protective enclosure to be opened only when needed for connection/disconnection while leaving the main system protected and operational.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If enclosed structure is added to protect connectors, then protection from water and corrosion is improved, but device complexity increases

Engineering Contradiction:

Improveprotection from water and corrosionVSAvoidenclosure structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The protective enclosure uses a simple shell structure rather than complex multi-layer protection. This thin-film approach provides adequate environmental protection while minimizing structural complexity and material usage.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

Instead of trying to make the connectors themselves weatherproof through complex sealing mechanisms, the solution inverts the approach by placing the connectors inside a simple protective enclosure that creates the protected environment.

Inventive Principle:

Principle #13The other way round (Inversion)

4Temperature

If ventilation is added to enclosure for heat dissipation, then temperature control is improved, but water intrusion risk increases

Engineering Contradiction:

Improveheat dissipation from connectorsVSAvoidwater intrusion through vents

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The ventilation openings are designed with specific local qualities - they are positioned and sized to allow heat dissipation while minimizing water intrusion risk. The vents have directional characteristics that favor air flow over water entry.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The ventilation design converts the potential harm of open vents (water intrusion) into a benefit (heat dissipation) by positioning and sizing the vents to allow air flow while creating surface tension barriers that prevent water entry during normal operation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS20250279609A1Extension cord plug enclosure

Publication Date: 2025.09.04 PROTECT-A-PLUG D B A

AI summary

An enclosure for an extension cord connector having a first container member forming a first receptacle and a second container member forming a second receptacle. The adjoining edges of the first and second receptacle form a continuous edge with reciprocal tongue and groove coupling, the first container member forming a mirror image of the second container member. In operation, a connector of a power cord and extension cord are placed in the first receptacle formed by said first container member and the extension cord placed in the second receptacle secured together by coupling the tongue shape continuous edge of the second container member to the groove shape continuous edge of the first container member.