Connector Structure With Pressing Leaf Spring Unlocking Mechanism
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Solution Overview
Problem
Conventional connector structures face issues with secure connection and material efficiency, leading to increased labor and manufacturing costs due to the need for special materials and complex assembly processes, which affect the reliability and versatility of conductive wire connections.
Innovation Solution
A connector structure featuring a case seat assembly with plug assemblies and a pressing leaf spring, where a conductive wire is engaged by a flexible connection member and a pressing leaf spring, allowing for easy insertion and extraction with an unlocking assembly, reducing material waste and enhancing operational simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the conductor connection holder, plug and connection member are integrally formed, then the structural strength is improved, but the material consumption increases and manufacturing cost rises
Solution Approach 1:
The connector is divided into separate components: conductor connection holder, plug, and connection member. These parts are assembled together rather than formed as one integral piece, reducing material consumption while maintaining structural strength through proper design of connection interfaces.
2Strength
If the connection member is welded between the conductor connection holder and the plug, then the connection strength is improved, but the labor cost increases
Solution Approach 1:
The connection member is designed to be press-fitted or snap-fitted into the conductor connection holder and plug, combining these components through interference fit or elastic deformation rather than welding. This eliminates welding operations, reducing labor cost while maintaining connection strength.
Solution Approach 2:
The connection member structure enables self-locating and self-fixing through its geometric design, where the connection is established through simple insertion and elastic retention without requiring external welding operations or additional fastening steps.
3Ease of manufacture
If a fixed length connection member is used, then the manufacturing simplicity is improved, but the connection reliability deteriorates when positions are misaligned
Solution Approach 1:
The connection member is designed with flexible or elastically deformable sections that allow it to adapt its shape and length during assembly. This dynamic characteristic enables the connection member to compensate for position misalignments between the conductor connection holder and plug, ensuring reliable connection while maintaining manufacturing simplicity.
4Adaptability or versatility
If the conductor connection holder can move relative to the plug, then the flexibility to compensate deflection is improved, but the connection stability deteriorates
Solution Approach 1:
The connection member incorporates elastic or flexible sections that enable controlled relative movement between the conductor connection holder and plug. This dynamic design allows the system to absorb angular deflections and position variations while maintaining stable electrical connection through the elastic retention force of the connection member.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed connector structure minimizes material usage, simplifies operation, and improves connection reliability by using a flexible connection and pressing leaf spring mechanism, allowing for versatile application across different specifications without increasing labor or manufacturing costs.
Implementation Method 1
a pressing leaf spring, where a conductive wire is engaged by a flexible connection member and a pressing leaf spring
Implementation Method 2
the flexible connection member can absorb and compensate the length difference between the stranded wires
Data Source
AI summary
A connector structure includes a case seat assembly and plug assemblies. Two ends of the case seat assembly are formed with channels. Each plug assembly has a conductive section and a wire connection member. The wire connection member is formed with a receiving space for receiving a pressing leaf spring. Each pressing leaf spring has an abutment end. A lateral protrusion section is disposed on the abutment end. Multiple unlocking assemblies are disposed beside the wire connection member. Each unlocking assembly has a push member formed with a push block. The lateral protrusion section is positioned in a sliding path of the push block along the channel, whereby the lateral protrusion section can be pushed to drive the abutment end to release a conductive wire.