Plug Wiring Structure with S-Shaped Deformed Lines
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Solution Overview
Problem
Conventional electric line wiring structures in plugs are prone to delamination or line breakage due to tensile loads applied when the plug is pulled out, leading to unstable electric connections and potential conductivity issues.
Innovation Solution
The electric line wiring structure features a plug with terminals protruding on the front and electric lines connected to the rear, where the electric lines are deformed perpendicular to the wiring path and held by an electric line holding section, dispersing tensile loads across multiple holding sections along the wiring path to prevent direct stress on connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electric line is directly connected to the terminal base portion, then the electric connection is simple and easy to manufacture, but the connection portion is prone to delamination or line breakage when tensile load is applied
Solution Approach 1:
The patent introduces an electric line holding section that divides the electric line into multiple segments along the wiring path. The holding section creates multiple contact points between the electric line and the terminal, transforming a single direct connection into multiple segmented connections. This segmentation distributes the tensile load across multiple points, preventing delamination and line breakage while maintaining manufacturing simplicity through integrated molding of the holding section.
2Reliability
If the electric line is held in a deformed state perpendicular to the wiring path, then tensile load is dispersed and connection stability is improved, but the wiring path becomes more complex
Solution Approach 1:
The patent merges the electric line holding function with the terminal structure by integrating the holding section into the terminal body. The holding section is formed as an integral part of the terminal, combining the functions of electrical connection and mechanical strain relief in a single component. This merging approach improves connection stability through deformed electric line configuration while avoiding additional complexity, as the holding section is molded together with the terminal in one manufacturing process.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The present invention has an object of providing an electric line wiring structure of a plug which provides stable electric connection between a terminal and an electric line for a long time and guarantees a prescribed conductivity. In such a plug 10, the electric lines 14 are wired to an electric line wiring section 17 formed in the plug main body 11. Deformed portions 14c, 14d and 14e, obtained as a result of deforming the electric lines 14 to have U-shapes in a direction perpendicular to left and right wiring paths C1 which are set in the electric line wiring section 17, are hooked along electric wire holding sections 17a, 17b and 17c located on the wiring paths C1. Thus, the electric lines 14 are wired in an S-shaped winding state.