Electrical Plug With Segmented Housing And Fuse Clips
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Solution Overview
Problem
Existing electrical plugs used in light sets face issues such as cable disconnection, inadequate contact with fuses leading to overheating, and insufficient quality control indicators, resulting in assembly errors and reliability problems.
Innovation Solution
The electrical plug design features a sliding inner housing with corrugations to secure cables and fuse clips for improved contact, along with a visible assembly indicator to ensure proper assembly during manufacturing, enhancing both reliability and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing electrical plugs are used, then the structure is simple, but the cable can pull out of the plug leading to failure
Solution Approach 1:
The plug is divided into an outer housing and an inner housing that can be assembled separately. The inner housing contains the cable retention features (corrugations) while the outer housing provides the external structure. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity.
Solution Approach 2:
Corrugations (curved/ridged features) are added to the inner housing to engage with the cable jacket. These curved features provide mechanical retention through friction and geometric interlocking, preventing cable pull-out without requiring complex fastening mechanisms.
2Reliability
If existing electrical plugs are used, then the manufacturing process is simple, but sufficient contact with fuses is not created leading to higher temperature and increased risk
Solution Approach 1:
The fuse clips are designed to automatically engage with the fuses when the inner housing is inserted into the outer housing. The spring-loaded clips self-adjust to make reliable electrical contact with the fuse terminals without requiring precise manual alignment or additional fastening steps, ensuring good thermal and electrical contact while maintaining ease of assembly.
3Reliability
If existing electrical plugs are used, then the construction automation is partial, but sufficient quality control indicators are not included increasing misassembly risk
Solution Approach 1:
The protrusion on the inner housing serves as a visual indicator (quality control feature) that becomes visible through an opening in the outer housing when properly assembled. This simple geometric feature provides immediate visual confirmation of correct assembly without adding complex sensors, indicators, or control systems.
Data Source
AI summary
An electrical plug includes an inner housing slidably received within an outer housing. The inner housing includes corrugations at an end of the inner housing to prevent an electrical cable from pulling out of the plug. The inner housing also includes a protrusion that is structured to be received in an aperture of the outer housing to couple the inner housing and the outer housing and provide a visual indicator of proper assembly. The electrical plug further includes fuse clips that increase the contact area between terminals and fuses of the plug, which improves reliability.