Door switch connector module and home appliance including the same
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Solution Overview
Problem
The existing door switch systems in home appliances, such as refrigerators, face complications due to complex wiring and increased assembly and installation time and cost, primarily because they rely on wire-to-wire connectors between reed sensors and mainboards.
Innovation Solution
A door switch connector module that includes a plug assembly within the appliance's inner case and a door switch assembly outside, coupled via a through hole, eliminating the need for separate wire-to-wire connectors by using a tab terminal and receptacle terminal configuration for simplified installation and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire-to-wire connectors are used to connect reed sensor to mainboard, then electrical connection is achieved, but wiring complexity increases and assembly time increases
Solution Approach 1:
The patent combines the reed sensor, tab terminal, and housing into an integrated door switch assembly. The tab terminal is directly formed as part of the housing structure, eliminating the need for separate wire-to-wire connectors. This merging of components simplifies the wiring system while maintaining reliable electrical connection between the reed sensor and mainboard.
Solution Approach 2:
The housing serves multiple functions: it protects the reed sensor, provides structural support, and integrates the tab terminal for electrical connection. The tab terminal itself serves dual purposes as both a structural element of the housing and an electrical conductor. This multi-functionality reduces the number of separate components needed.
2Reliability
If wire-to-wire connectors are used to connect reed sensor to mainboard, then electrical connection is achieved, but assembly time increases
Solution Approach 1:
The reed sensor, tab terminal, and housing are merged into a single integrated door switch assembly. This pre-assembly of components means that during final installation, the entire assembly is installed as one unit rather than requiring separate assembly steps for mounting the housing, installing the reed sensor, and connecting wires. This significantly reduces assembly time while maintaining reliable electrical connection.
Solution Approach 2:
The tab terminal is pre-formed as an integral part of the housing structure during manufacturing. The reed sensor is pre-mounted within the housing. These preliminary actions are completed during production, so that during final assembly and installation, no additional wiring or component mounting steps are required, thereby reducing assembly time.
3Reliability
If separate connectors and wires are used, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the housing and tab terminal into a single molded component. This integration eliminates the need to manufacture separate connectors and wires, reducing the number of parts that need to be produced, inventoried, and assembled. The single-molding process for creating the housing with integrated tab terminal reduces manufacturing complexity and cost while ensuring reliable electrical connection.
Solution Approach 2:
The housing is designed to serve as both a protective enclosure and an electrical connector through the integrated tab terminal. This multi-functionality eliminates the need for separate connector components, reducing part count and manufacturing cost. The reed sensor assembly similarly serves both sensing and electrical connection functions.
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
This solution simplifies the installation process, reduces costs, and minimizes wiring complexity by allowing direct insertion and connection of the door switch assembly into the plug assembly, thereby enhancing productivity and reducing assembly time and costs.
Implementation Method 1
The reed sensor includes two lead pieces formed of a magnetic body in a sealed glass tube, and detects opening and closing of a door as the two lead pieces come into contact or are separated depending on a distance from a magnet
Data Source
AI summary
A door switch connector module includes a plug assembly disposed in an inner case of an installation target and a door switch assembly disposed outside the inner case and coupled to the plug assembly. The plug assembly has a receptacle terminal. The door switch assembly includes a main housing, a reed sensor disposed in the main housing, a tab terminal, and a cover housing coupled to the main housing and closing the main housing. The main housing has a guide boss extending in a coupling direction. The tab terminal contacts a lead of the reed sensor and extends to an outside of the main housing in parallel with the guide boss.