Plug Wire Restraint Structure to Prevent Terminal Stretch Damage
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Solution Overview
Problem
Small-sized plugs with rubberized housings face terminal damage due to stretching over time, leading to increased contact resistance and potential fire hazards.
Innovation Solution
An insulating housing formed by ultrasonic welding of two housings, with a wire passing hole featuring limiting parts to restrict movement of connecting wires, allowing terminals to move in a second direction while preventing stretching in a first direction, thus reducing terminal damage and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rubberized housing is used to meet tensile requirements, then the tensile capacity is improved, but the terminals will be stretched and damaged over time
Solution Approach 1:
The housing is divided into a rigid outer housing and a separate connector component. The rigid housing provides tensile strength while the connector is designed with movement freedom in the second direction, separating the tensile function from the terminal fixation function.
Solution Approach 2:
The connector has different movement constraints in different directions: it is constrained in the first direction (preventing terminal stretching) but free to move in the second direction (absorbing tensile stress). This directional differentiation of constraints resolves the contradiction between tensile capacity and terminal protection.
2Strength
If the terminals are fixed in the connector to meet tensile requirements, then the tensile capacity is improved, but the contact resistance increases and fire risk occurs
Solution Approach 1:
The connector is designed to be dynamic rather than completely fixed. It can move in the second direction to absorb tensile forces, while the limiting part prevents excessive movement in the first direction. This dynamic design protects terminals from stretching while maintaining electrical contact.
Solution Approach 2:
The limiting part is pre-configured in the wire passing hole to prevent the connecting wire from moving in the first direction before damage can occur. This preliminary constraint prevents terminal stretching and the subsequent harmful effects of increased contact resistance and fire risk.
3Stability of the object's composition
If the connecting wire is completely fixed to prevent movement, then the terminal stability is improved, but the adaptability and movement freedom in the second direction is reduced
Solution Approach 1:
The constraint system is asymmetric: the limiting part restricts movement in the first direction (perpendicular to the wire axis) while allowing movement in the second direction (along the wire axis). This asymmetric constraint provides both stability and adaptability.
Solution Approach 2:
Different parts of the connector have different constraint characteristics. The limiting part in the wire passing hole provides localized constraint in the first direction, while the overall connector structure allows movement in the second direction, achieving local stability with global adaptability.
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 solution effectively reduces the risk of terminal damage and extends the service life of the plug by restricting movement in a first direction and allowing movement in a second direction, enhancing safety and reliability.
Implementation Method 1
The insulating housing is formed by ultrasonic welding of the first housing and the second housing
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention discloses a plug and a lamp. The plug includes an insulating housing, a connector and a connecting wire; the insulating housing is formed by ultrasonic welding of a first housing and a second housing; An installation cavity and a wire passing hole communicating with the installation cavity are formed; the connector is inserted in the installation cavity and protrudes outward, and the connector is provided with a terminal; the connecting wire is connected to the terminal and is drawn out through the wire passing hole, and the hole wall of the wire passing hole is provided with a limiting part, and the limiting part is against the outer wall of the connecting wire, so as to restrict the moving of the connecting wire along the first direction. The invention improves the structure of the plug, effectively reduces the risk of terminal damage in the plug connector, improves the safety of the plug, and prolongs the service life of the plug .