Existing Product Disassembly
The size of the component will affect the design. To know how much space the components required, travel adapters, extension leads, thermal breakers and USB adapters, which have covered BSi regulations, were disassembled.
Sketches
The aim of the design was to have multiple sockets on one adapter. It will be able to work with multiple devices at the same time and will be easy to carry around. Cable wrapping methods, universal sockets layout and universal plugs designs have been developed according to the internal space for required components and technical specifications.
Minimalism is the most popular style currently. Especially for electronic products, as minimal design fits with most of the other styles. It is also the most acceptable finishing for most of the customers. As the general shape is round, the edges are kept without adding too many fillets; the sharp edges on the curvy shape keep the neat feeling. The design has been following the principle to provide a clean and simple feeling to suit most of the styles for different customers.
Prototypes
Scaled models were made so that the size could be felt. The photos compare the blue foam models with the most common products that people usually bring when traveling; a travel adapter and an extension cord. The size of the blue foam model is much smaller, which is nicer as one item and more handy for carrying it when traveling. The models were also used to test different cable wrapping methods. The UK plugs were used to test if the space is enough for all the sockets to be used. Some models were 3D printed to help look at the internal space and to feel the more accurate prototype for ergonomic testings. The red model is in the finial scale. It is used to test the length of the cable that is needed for maximum loops, which is 3 loops. The length of the cable for 3 loops is 110cm, which allows the plug to reach the outlets in some awkward positions. The model can also easily fit in the front pocket and side pocket of the backpack. It also has flat surfaces even when the cable is wrapped on the body, which makes it easy to store anywhere.
CAD has been made for manufacture. Each parts were made for injection moulding with minimal undercuts to reduce the cost. The parts were printed out and painted as an appearance prototype.
Internal Components
CAD models were built in Solidworks to make sure the fittings of all parts and components. The current size would not be able to fit the USB port in. The body will need to enlarge to wire the USB components. Having USB ports can be a selling point when it comes to advertisement. However, it is not worth to increase the size for the USB ports; there are two main reasons shows why I decided not to increase the size. Firstly, there are ports available for USB on other devices, such as laptops, power banks and USB adapters, it is not a necessity. Secondly, types of USB port will have a chance to change in the further. Type-A might not be used as common as now in a few years later. On the other hand, the standards for the plug would have very little chances to be changed in the following ten years. The product would not have problems to sell in the next ten, twenty years. If the Type-A USB is no longer be used in the future, the ports on the product will be useless but they are adding the volume of the whole item at the same time.
This would be a direction to improve the current product to have USB ports without increasing the size.