Thermal Welding Coupling Member for Plug Cord
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Solution Overview
Problem
Existing electrical plug-provided cords are prone to lead wire breakage when forcibly pulled out and are susceptible to moisture invasion due to gaps between the plug outer housing and outer cover, especially when used with outdoor electrical outlets.
Innovation Solution
An electrical plug-provided cord design featuring a cord with lead wires and an outer cover, where the plug outer housing is formed of synthetic resin and coupled to a heat-weldable coupling member that surrounds the cord tip, ensuring an airtight connection through thermal welding, using materials like poly(vinyl chloride) or hot melt adhesives to prevent breakage and moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plug outer housing and outer cover are formed of different materials and not integrally coupled, then manufacturing flexibility is improved, but moisture can invade the inside of the electrical plug through gaps between the plug outer housing and outer cover
Solution Approach 1:
A coupling member made of heat-weldable material is introduced as an intermediary component between the plug outer housing and the outer cover. This coupling member is thermally welded to both components, creating a sealed connection that prevents moisture invasion while allowing the plug outer housing and outer cover to remain made of different materials
Solution Approach 2:
The coupling member is formed of a heat-weldable material that is thermally weldable with the plug outer housing, creating a composite structure that combines the sealing properties of the heat-weldable material with the functional properties of the plug outer housing and outer cover materials
2Ease of operation
If the cord is strongly pulled out from an electrical outlet, then ease of removal is improved, but the parts of the lead wires connected with the plug blades are prone to breakage
Solution Approach 1:
The coupling member is positioned at the tip part of the cord to provide protective cushioning at the connection point. This coupling member reinforces the area where lead wires connect to plug blades, preventing breakage during strong pulling operations while still allowing normal removal
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 design effectively prevents lead wire breakage and moisture invasion into the electrical plug, maintaining a secure connection even under severe conditions such as outdoor use or bending, while ensuring a space-saving structure.
Implementation Method 1
a coupling member which surrounds the tip part of the cord in close contact therewith and is coupled to the plug outer housing by thermal welding
Data Source
AI summary
An electrical plug-provided cord has a cord including lead wires and an outer cover for covering the lead wires, an electrical plug including plug blades connected to the lead wires at a tip of the cord and a plug outer housing for covering a part of the cord and a part of the plug blades from base parts of the plug blades to the outer cover at a tip part of the cord, and a coupling member which surrounds the tip part of the cord in close contact and is coupled to the plug outer housing by thermal welding. The plug outer housing is formed of a synthetic resin. At least an interface of the coupling member with the plug outer housing is formed of a heat-weldable material which is thermally weldable with the plug outer housing.