Foldable Plug Cam Mechanism Resolves Blade Stress
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Solution Overview
Problem
Existing foldable plug-in devices face manufacturing and assembly issues due to multiple components, and the constant force on the bending tab leads to deformation and reduced click feel over time.
Innovation Solution
A foldable plug-in device design using only two integral housing elements, eliminating the need for additional components, and employing a contact clip for circuit board connection without soldering, with a pivot and cam mechanism to maintain blade position and provide a satisfying click without exerting pressure on the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic positioner with bending tab is used to hold blades and provide closing force, then the blades can be held in open and closed positions, but the bending tab experiences significant stress and deforms over time, reducing the click feel
Solution Approach 1:
The blade holding mechanism is segmented into a pivot assembly with locking cam and bending cam, separated from the housing. This divides the force-bearing functions between the cam mechanism (which handles positioning) and the housing (which provides structural support), preventing stress concentration on a single bending tab element.
Solution Approach 2:
The pivot assembly acts as an intermediary between the blades and the housing. It transfers and distributes the forces generated during blade opening and closing across multiple components (locking cam, bending cam, pivot point) rather than concentrating them on a single bending tab, thereby reducing stress and deformation.
2Ease of operation
If a plastic positioner with holder and bending tab is used to assemble blades, then the blades can be positioned and forced closed, but multiple components require assembly and bonding, increasing manufacturing complexity
Solution Approach 1:
The pivot assembly integrates multiple functions into a single component: it holds the blades at the pivot point, provides the locking cam for positioning, provides the bending cam for closing force, and connects to the housing. This consolidation eliminates the need for separate plastic positioner, holder, and bending tab components, reducing assembly steps and bonding requirements.
Solution Approach 2:
The pivot assembly serves multiple functions simultaneously: it acts as a blade holder, a positioning mechanism (via locking cam), a force application mechanism (via bending cam), and a connection element to the housing. This multi-functionality reduces the total number of components needed while maintaining all necessary blade operations.
3Stability of the object's composition
If constant force is applied to blades by bending tab, then blades remain closed, but this continuous stress permanently deforms the bending tab over time, deteriorating the opening and closing force
Solution Approach 1:
The cam mechanism provides force application in a periodic rather than continuous manner. The bending cam applies closing force only when needed to maintain the closed position, while the locking cam maintains the open position without requiring continuous force on the same element. This periodic engagement reduces cumulative stress and deformation.
Solution Approach 2:
The cam profiles are designed with specific geometric parameters that change the force application characteristics. The locking cam and bending cam have optimized curvature and engagement points that allow the mechanism to maintain blade positions with minimal and distributed stress, preventing permanent deformation while maintaining stability.
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
Simplifies assembly, reduces stress on components, and maintains the click feel over time by eliminating constant force on the bending tab, ensuring reliable operation and durability.
Implementation Method 1
A close look at the pivot shows that it includes a locking cam and a bending cam
Data Source
AI summary
A structure of a plug-in device with a foldable plug for connecting a power supply to a power-receiving device is provided. The plug-in device includes an upper housing, a blade element, and a lower housing.