Plug Inner Frame Segmented Wire Seats and Fuse Recess
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Solution Overview
Problem
Conventional plug inner frames are bulky, aesthetically unpleasing, and require complex wire-coupling processes due to their design, leading to heavy final products and potential issues during injection molding.
Innovation Solution
A plug inner frame design featuring a frame body with a fuse-receiving seat, conductive plates, and wire-receiving seats with specific structural elements like ribs, protrusions, and a cap with partitioning plates to facilitate easier wire management and prevent short circuits during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second wire-receiving seat is formed on the raised portion with sufficient thickness, then the electrical connection between the fuse and second blade is ensured, but the plug structure becomes bulky and heavy
Solution Approach 1:
The wire-receiving seats are segmented into different types: the first wire-receiving seat has a U-shaped cross section formed by bending the sheet for clamping wires, while the second wire-receiving seat has a different configuration. This segmentation allows each seat to be optimized for its specific function, reducing overall material usage while maintaining electrical connection reliability.
Solution Approach 2:
The patent utilizes the raised portion's thickness in a strategic manner by forming the second wire-receiving seat to extend through the raised portion, utilizing its thickness for electrical conduction rather than adding more material. This dimensional utilization ensures electrical connection while minimizing bulk.
2Ease of operation
If wire-receiving seats with U-shaped cross sections are used, then wire clamping function is provided, but the tool required to roll them is difficult to operate in small spaces and liable to break
Solution Approach 1:
The wire-receiving seats are formed as integral parts of the plug body through sheet bending, segmenting the wire clamping function from the need for complex rolling tools. Each seat is independently formed with the appropriate cross-sectional shape directly during plug manufacturing, eliminating the need for separate rolling operations in confined spaces.
Solution Approach 2:
The sheet material itself is bent to form the U-shaped cross section of the wire-receiving seats, allowing the material to create its own clamping structure without requiring external rolling tools. This self-forming approach eliminates the complex and fragile rolling tools while maintaining effective wire clamping.
3Reliability
If a cap with partitioning walls is added to isolate wires, then short circuit prevention is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The partitioning function is merged with the plug body structure itself rather than being a separate cap assembly. The raised portion and its configuration provide both structural support and electrical isolation, combining multiple functions into a single integrated structure that reduces overall complexity.
Solution Approach 2:
The cap with partitioning walls is extracted from the design, and the short circuit prevention function is achieved through the raised portion's configuration and the positioning of wire-receiving seats. This extraction eliminates the complex cap assembly while maintaining the essential isolation function through simpler structural means.
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
A plug inner frame (4) includes a frame body (41) having opposite first and second sides (40, 43). The first side (40) includes a recessed portion (421) that receives a fuse and that forms a raised portion (422) on the second side (43). A lower area (423A) is formed on the second side (43) and located at a side of the raised portion (422). First and second conductive plates (424, 425) are mounted in the recessed portion (421) and extend from the first side (40) through the second side (43). First and second blades (45, 44) are mounted to the frame body (41). The second blade (44) is electrically connected to the second conductive plate (425). Spaced first and second wire-receiving seats (451, 441) are formed in the lower area (423A) and electrically connected to the first blade (45) and the first conductive plate (424), respectively. The second wire-receiving seat (441) is intermediate the first-wire receiving seat (451) and the second blade (44). Each wire-receiving seat (451, 441) includes an opening (452, 442) facing away from the frame body (41).