Modular Pop-up Plug Separation Mechanism for Easy Reassembly
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Solution Overview
Problem
Existing plug separation mechanisms are inconvenient to reassemble after disassembly, as their parts are scattered, making it difficult for users to reassemble the plug to its original state.
Innovation Solution
A modularized plug separation mechanism is introduced, where the sleeve and inner cover form a housing to fix and restrict other components, allowing for integral removal and installation, facilitating automated production and integrated plug design. This mechanism includes an ejector pin, springs, and a button for easy assembly and disassembly, enabling one-handed plug removal without damaging the socket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plug separation mechanism parts are provided as discrete components, then the mechanism can be easily disassembled, but the parts scatter and become difficult to reassemble
Solution Approach 1:
The patent combines multiple discrete parts of the plug separation mechanism (ejector pin, spring, button, and housing components) into an integrated assembly that moves together. The ejector pin is positioned within a housing formed by the plug body and insertion sheet, with the spring and button arranged in a coordinated manner. This merging ensures that when the plug is disassembled, all mechanism parts remain associated with each other rather than scattering, making reassembly straightforward while still allowing easy disassembly for manufacturing purposes.
2Reliability
If a large clamping force is applied to secure the insertion sheet, then the connection reliability is improved, but the user needs two hands to pull the plug out
Solution Approach 1:
The patent segments the plug structure into distinct functional components: a stationary housing, a movable ejector pin, and a control button. The ejector pin is separated from the housing and can move independently to provide the ejection function. This segmentation allows the clamping mechanism to maintain strong connection force through the housing structure while the separate ejector pin and button provide easy one-handed operation for plug removal by pushing the button to release the clamping force.
3Adaptability or versatility
If the plug separation mechanism is designed with multiple discrete parts, then the mechanism functionality is improved, but the reassembly process becomes complex and time-consuming
Solution Approach 1:
The patent designs the plug separation mechanism with preliminary positioning features and pre-arranged component relationships. The ejector pin, spring, and button are positioned and oriented in advance during manufacturing, with the spring pre-compressed or pre-oriented to provide the necessary ejection force. The button is pre-positioned to engage with the ejector pin control mechanism. This preliminary arrangement ensures that when reassembly is needed, the parts can be quickly put together in the correct configuration without complex alignment procedures, significantly reducing reassembly time while maintaining full mechanism functionality.
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 modular design simplifies assembly and disassembly, allowing for easy one-handed plug removal, improving convenience for average users and those with disabilities, while enabling efficient automated production and reducing the risk of socket damage.
Implementation Method 1
a first spring for driving the ejector pin to extend out of the plug housing
Implementation Method 2
a second spring for driving the engaging head to be engaged with the engaging part
Data Source
AI summary
A pop-up plug having a modularized plug separation mechanism, includes a plug housing and a plug separation mechanism. The plug separation mechanism includes a sleeve, an ejector pin arranged in the sleeve in a penetrating manner, an ejector pin control mechanism and a first spring for driving the ejector pin to extend out of the plug housing from the side where the insertion sheet is located; the ejector pin control mechanism includes an engaging part arranged at the ejector pin, an engaging head matched with the engaging part to keep the ejector pin in a contracted state, a second spring for driving the engaging head to be engaged with the engaging part, and a button for driving the engaging head to be separated from the engaging part. The sleeve is provided with a holding part connected to an inner cover.