Guide Plate Plug Structure for Burr-Controlled Contact Pin Insertion
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Solution Overview
Problem
Existing connectors with stamped contact wires face issues of burrs breaking off or detaching during installation, leading to short circuits and debris formation due to inadequate guidance and positioning of the contact wires.
Innovation Solution
The guide plate features guide shafts with flat and inclined walls that guide contact wires, ensuring burrs are angled and remain attached, preventing breakage and debris formation, while maintaining high positioning accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional plug design without a guide plate is used, then the structure is simpler, but the insertion accuracy and alignment between plug and socket are poor
Solution Approach 1:
The plug is divided into functional segments: the guide plate as a separate alignment component, the contact elements section, and the insulation body. This segmentation allows the guide plate to specifically address alignment accuracy without complicating the entire plug structure.
Solution Approach 2:
The guide plate performs preliminary alignment action before the actual electrical contact is made. By providing guide ribs that engage with socket grooves in advance, the plug ensures proper positioning is established before insertion is complete, improving insertion accuracy.
2Strength
If the plug uses traditional insulation materials only, then the material selection is simpler, but the grip strength and safety are insufficient
Solution Approach 1:
The insulation body is constructed from composite materials combining rubber and thermoplastic elastomer (TPE). This composite material provides enhanced grip strength, flexibility, and safety compared to traditional single-material insulation, while maintaining ease of manufacturing through co-molding or overmolding processes.
3Ease of operation
If the plug lacks a guide plate, then the number of components is lower, but the insertion force required is higher and user comfort is reduced
Solution Approach 1:
By separating the guide function into a distinct guide plate component with guide ribs, the insertion action is facilitated without requiring the user to apply excessive force. The guide ribs engage with the socket grooves to provide mechanical guidance, making insertion easier.
Solution Approach 2:
The guide plate acts as an intermediary element between the user's insertion action and the electrical contacts. It mediates the insertion process by providing alignment and reducing friction, thereby improving ease of operation without significantly increasing overall device complexity.
Data Source
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AI summary
The invention relates to a plug, in particular an electrical plug, comprising an electrically insulating guide plate. The plug comprises a plurality of electrical contact wires, in particular contact pins, which are in particular stamped. The contact wire has an angular, in particular square, cross section and is guided through an opening in the guide plate and projects out of the guide plate. According to the invention, the opening comprises a guide shaft along a thickness extension of the guide plate. The guide shaft comprises at least one planar wall for guiding a flat side of the contact wire. The guide shaft also comprises, opposite the planar wall, at least one wall region extending obliquely thereto, which wall region is designed to touch a corner of the contact wire. More preferably, the guide shaft is designed to press the contact wire against the obliquely extending wall region, when the corner of said contact wire is guided through the opening, and to deform, in particular bend, a burr formed at the corner.