Plug Assembly Compression Locking Eliminates Welding
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Solution Overview
Problem
Conventional plug assemblies require complex manufacturing processes, including separate production of pin holders and electric wires, followed by welding and assembly, which can lead to malfunctions and increased costs due to the need for disassembly and reassembly for repairs.
Innovation Solution
A one-touch assembled plug assembly with a pin holder featuring locking slots and conductive terminals with protrusions for easy engagement, eliminating the need for welding by integrating electric wires and covering tubes through compression locking, allowing for simple assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to couple electric wires to contact pins, then reliable electrical connection is achieved, but manufacturing complexity and cost increase due to required disassembly for repairs
Solution Approach 1:
The invention divides the electrical connection system into modular components: a pin holder with contact pins, conductive terminals with locking parts, and wire units. These segments can be assembled and disassembled independently without welding, resolving the contradiction between reliable connection and assembly complexity.
Solution Approach 2:
The invention replaces the welding process (thermal/mechanical bonding) with a mechanical locking system consisting of locking parts, locking slots, and elastic protrusions. This substitution eliminates the need for welding while maintaining connection reliability and enabling easy disassembly for repairs.
2Reliability
If conventional welding process is used, then electrical connection is secured, but productivity decreases due to complicated assembly process
Solution Approach 1:
By segmenting the assembly into pre-fabricated modules (pin holder, conductive terminals, wire units), the invention enables parallel production and simplifies final assembly, significantly improving productivity while maintaining connection reliability through the locking mechanism.
Solution Approach 2:
The conductive terminals are pre-assembled with wire units using the locking mechanism before final installation into the pin holder. This preliminary action simplifies the overall assembly process, increases productivity, and ensures reliable connections are established before final assembly.
3Ease of manufacture
If separate production of pin holder and electric wires is performed, then manufacturing flexibility is improved, but assembly complexity increases due to multiple coupling steps
Solution Approach 1:
The invention merges the connection function into an integrated locking mechanism that simultaneously secures the wire unit and establishes electrical contact through the conductive terminal. This merging simplifies the assembly structure while preserving manufacturing flexibility through modular components.
4Reliability
If welding is required for assembly, then strong electrical connection is achieved, but ease of repair deteriorates due to need for disassembly and welding equipment
Solution Approach 1:
The modular segmented design allows individual components (wire units, conductive terminals, pin holder) to be independently replaced during repair without requiring welding equipment or complex disassembly procedures, dramatically improving ease of repair while maintaining connection reliability.
Solution Approach 2:
Replacing welding with a mechanical locking system enables simple manual assembly and disassembly for repairs, eliminating the need for welding equipment and specialized skills, thereby greatly improving ease of repair while maintaining reliable electrical connections.
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 reduces production costs, increases productivity, and simplifies the assembly process while preventing short circuits and facilitating easy repair by eliminating the need for welding and ensuring reliable electrical connections.
Implementation Method 1
a first locking part gripping an electric wire through compression
Implementation Method 2
a second locking part having a diameter larger than a diameter of the first locking part and gripping a covering tube covering the electric wire
Data Source
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AI summary
A plug assembly with an improved structure is disclosed. In the plug assembly, the assembling structure between a pin holder constituting a plug and a terminal assembled with the pin holder and allowing electricity to flow through the plug assembly is improved and realizes a reduction in manufacturing cost of the plug assembly and an increase in productivity of the plug assembly. The plug assembly includes a pin holder having locking slots, insert holes, and contact pins; a conductive terminal coupled to the pin holder and having an insert end, protrusions, a contact terminal, a first locking part, and a second locking part; and a wire unit having an electric wire gripped by the first locking part through compression so as to apply electricity to the conductive terminal and a covering tube covering the electric wire and gripped by the second locking part through compression.