Plug-on Element Mechanical Edge Connection
Solution Overview
Problem
The existing plug-on parts for connectors require expensive and investment-intensive laser welding for connecting longitudinal edges, which is costly and prone to heat-related distortions, making mass production challenging.
Innovation Solution
The connection of longitudinal edges is achieved through simple mechanical connections such as latching elements, shearing lugs, shearing tabs, and recesses, eliminating the need for laser welding and ensuring high locking stability without heat influence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to connect the longitudinal edges of the material strip, then the connection strength and reliability are improved, but the manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent replaces the laser welding process (thermal/energy-based system) with a mechanical connection system consisting of deformation elements and corresponding recesses. The longitudinal edges are mechanically interlocked through forming protrusions that engage with recesses, eliminating the need for complex laser welding equipment while achieving reliable connections.
Solution Approach 2:
The patent changes the connection method from thermal bonding (laser welding) to mechanical bonding (deformation and interlocking). By altering the physical state and connection mechanism parameters, the solution achieves reliable joining without requiring high-temperature processes or complex welding equipment.
2Strength
If laser welding is used to connect the longitudinal edges of the material strip, then the connection strength is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent substitutes expensive laser welding equipment with simple mechanical forming and interlocking mechanisms. The connection is achieved through deformation of material edges to create engaging protrusions and recesses, which can be manufactured using conventional, cost-effective processes rather than expensive welding equipment.
Solution Approach 2:
The patent employs simple, inexpensive mechanical connection elements (protrusions and recesses) that can be integrated into the material strip during forming, replacing the need for expensive, specialized welding equipment. This approach uses basic mechanical components rather than high-cost thermal processing equipment.
3Reliability
If laser welding is used to connect the longitudinal edges of the material strip, then the connection reliability is improved, but heat-related distortions occur
Solution Approach 1:
The patent replaces thermal laser welding with a mechanical deformation and interlocking system. By using cold-forming processes to create protrusions and recesses that mechanically engage, the solution avoids heat input entirely, preventing thermal distortion and maintaining high fitting accuracy of the connector components.
Solution Approach 2:
The patent changes the connection process from thermal (laser welding) to mechanical (deformation and interlocking). This parameter change eliminates heat-related effects, preventing thermal distortion and maintaining the dimensional accuracy and fitting precision of the connector components.
Data Source
Figure 1~6d
Figure 1a~1e
Figure 2~5
AI summary
The plug-on element (10) has a sleeve-like base (11) which is formed by deforming one of two longitudinal edges and two transverse edges of material strip and connecting the longitudinal edges. The locking elements are arranged at longitudinal edges of top surfaces (14a,14d) of the material strip, and provided with locking portions. The longitudinal edges of material strip are connected to sleeve-like base by locking elements.