Universal DC Socket Assembly for Stable Plug Contact
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Solution Overview
Problem
Current DC sockets have poor reliability and complex assembly processes, especially in humid environments, and lack structural consistency, failing to meet safety standards and requiring different assembly structures for various components.
Innovation Solution
A universal DC socket design featuring an insulating housing with a conductive resilient piece and post, along with an insulating seat, utilizing snap-fitting mechanisms and hot riveting for precise assembly, reducing parts and complexity, and ensuring standardized compatibility with various lamp end covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional DC sockets are assembled with designed end covers using pasting or welding, then the assembly process is complex, but the reliability of the plug connection is poor in humid environments
Solution Approach 1:
The DC socket is divided into two main segments: an insulating housing containing the conductive resilient piece, and an insulating seat containing the conductive post. This segmentation allows each component to be optimized independently and assembled through simple snap-fitting, reducing overall assembly complexity while maintaining connection reliability through dedicated functional zones
Solution Approach 2:
The insulating housing and insulating seat are merged through snap-fitting connection to form an integrated assembly. The conductive resilient piece and conductive post are combined within the sealed housing to create a reliable electrical connection that protects against humid environments, eliminating the need for separate pasting or welding operations
2Adaptability or versatility
If different DC sockets use different assembly structures, then adaptability to various components is improved, but structural consistency and ease of manufacture deteriorate
Solution Approach 1:
The DC socket design incorporates a universal interface through the standardized jack structure that can accommodate various lamp end covers. The insulating housing and seat assembly with integrated conductive elements provides a multi-functional platform that maintains structural consistency across different applications while adapting to various connection requirements through the resilient piece and positioning mechanisms
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 solution simplifies assembly, enhances electrical contact reliability, reduces production costs, and achieves product consistency by allowing standardized design of lamp end covers, improving assembly precision and meeting safety standards.
Implementation Method 1
a conductive resilient piece (30) and a conductive post (40)... the resilient clamping pieces being arranged at intervals and abutting against the inner wall of the insulating housing
Data Source
Figure 1~2
Figure 3
Figure 4a~5b
AI summary
The invention provides a DC socket that facilitates universal assembly, assembled from an insulating housing and an insulating seat, wherein a positioning hole is provided in the insulating housing, and a first limiting groove and a second limiting groove are formed in the insulating seat; the conductive resilient piece is positioned and installed on the inner wall of the insulating housing, and the rear end of the conductive resilient piece is provided with a first connecting piece; a conductive post is positioned and installed on the insulating seat, wherein the front end of the conductive post is provided with a post body, the rear end of the conductive post is provided with a second connecting piece, the post body passes through the insulating seat, and the second connecting piece is clamped with the second limiting groove; along with the assembly of the insulating seat to the insulating housing, the post body penetrates into the positioning hole, and the first connecting piece is accommodated in the first limiting groove, thereby restricting rotation of the conductive resilient piece relative to the conductive post. The DC socket is easy to assemble, the number of parts is reduced, the conductive post and the conductive resilient piece can be formed integrally, and the reliability and stability of electric contact is remarkably improved, so that the DC socket can become a universal standard component and ensure the consistency of products.