Snap-in Plug System for Power Cord Strain Relief
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of electrical power cords to devices like kitchen appliances is labor-intensive due to the need for manual or automated positioning of power cord strain relievers between housing portions, which increases assembly time and labor costs.
Innovation Solution
A snap-in plug system with resilient prongs and a lip design secures the strain reliever to the base of an electrical device by wedging it between projections, preventing it from being pulled back through the opening and ensuring the power cord is securely attached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw or fastener methods are used to attach power cord strain relievers, then the power cord is securely attached, but the assembly process becomes labor-intensive and time-consuming
Solution Approach 1:
The strain reliever is divided into multiple components: a cord grip portion, a flared portion with projections, and a separate plug assembly with resilient prongs. This segmentation allows each component to perform its specific function independently, enabling the plug to snap into place and secure the strain reliever without requiring complex fastening operations
Solution Approach 2:
The plug combines multiple functions into a single component: it provides structural support, engages with the strain reliever's projections through resilient prongs, and secures the power cord assembly simultaneously. This merging eliminates the need for separate fasteners and reduces assembly steps
2Manufacturing precision
If manual positioning of strain relievers is required, then proper positioning can be achieved, but labor costs and assembly time increase
Solution Approach 1:
The strain reliever is pre-formed with specific geometric features including a flared portion with projections that align with corresponding features in the plug. This preliminary preparation of the strain reliever geometry enables automatic positioning when the plug is inserted, eliminating the need for manual alignment during assembly
Solution Approach 2:
The plug acts as an intermediary component that mediates between the strain reliever and the device housing. The resilient prongs on the plug engage with the projections on the strain reliever, providing a mechanical interface that ensures proper positioning without requiring manual intervention
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
This solution simplifies the assembly process by reducing labor and time required for attaching power cords, enhancing the efficiency of the assembly line by securely fastening the strain reliever without the need for extensive manual or automated manipulation.
Implementation Method 1
a pair of resilient prongs extending upwardly from the base
Data Source
AI summary
An electrical device including an electrical power cord secured to a base of the electrical device by using a plug having a pair of resilient prongs. The plug is inserted into an opening in the base to secure a strain reliever on an end of the electrical power cord into the opening. The resilient prongs flex towards each other when the plug is inserted into the opening. The prongs return to their original positions after passing through the opening and seat the plug in the opening. When seated, the plug secures the strain reliever into the opening thereby securing the electrical power cord to the base.