Socket Conductive Component Dual-Arm Stress Distribution
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Solution Overview
Problem
Conventional socket structures experience stress and instability due to frequent plugging and unplugging, leading to cracked or separated welding joints, increased resistance, and risks of internal component damage and fire.
Innovation Solution
A socket structure with a conductive component featuring two arms connected by a connecting part, providing additional support through deformation and two fixing ends, which resist stress and maintain stability by distributing force and maintaining functionality even if one arm fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductive component is welded to the circuit board through a single fixing end, then the manufacturing process is simple, but the welding joints are easily cracked or separated due to stress from frequent plugging and unplugging
Solution Approach 1:
The conductive component is divided into two separate arms (first arm and second arm) that are misaligned relative to each other. Each arm is welded to the circuit board at a different position, creating multiple independent welding joints. This segmentation distributes the stress from plugging and unplugging operations across multiple joints rather than concentrating it at a single joint, thereby preventing crack propagation and joint separation while maintaining manufacturing simplicity.
Solution Approach 2:
The two arms of the conductive component are arranged in a misaligned configuration, extending in different directions from the insulating base. This spatial arrangement in multiple dimensions allows the welding joints to be positioned at different locations on the circuit board, creating a more robust structural distribution that resists stress from various directions during frequent plugging and unplugging operations.
2Device complexity
If the conductive component uses a single fixing end, then the device structure is simple, but it lacks sufficient strength to resist stress from frequent plugging and unplugging
Solution Approach 1:
The conductive component is segmented into two arms that are misaligned and positioned at different locations. This segmentation increases the overall structural strength by distributing mechanical stress from plugging and unplugging operations across multiple support points on the circuit board, preventing any single joint from bearing excessive load.
Solution Approach 2:
The conductive component is pre-formed with a specific geometry including the insulating base and two misaligned arms before assembly. This preliminary structuring ensures that the component has inherent mechanical strength and proper stress distribution characteristics built-in, allowing it to resist frequent plugging and unplugging forces without requiring additional reinforcement during assembly.
3Reliability
If welding joints are cracked continuously, then the electrical connection resistance increases, but the structural integrity deteriorates leading to potential fire hazards
Solution Approach 1:
By dividing the conductive component into two misaligned arms with separate welding joints, the design ensures that if one joint experiences stress or potential cracking, the other joint remains intact and maintains electrical continuity. This segmentation provides redundancy in the electrical connection path, preventing complete connection failure and the associated hazards of increased resistance, overheating, and fire risk.
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 design enhances the socket structure's stability and reliability by reducing stress on welding joints, preventing damage and fire risks, and ensuring long-term operational safety.
Implementation Method 1
When the socket structure and a corresponding plug are plugged and unplugged frequently, the two arms and the connecting part of the conductive component are capable of resisting the force applied to the conductive component by deformation
Data Source
AI summary
A socket structure is provided and includes a circuit board, an insulating base, a pin and a conductive component. The insulating base is disposed on the circuit board and includes a first side and a second side opposite to each other. The pin is disposed between the first side and the second side. The conductive component is connected between the circuit board and the insulating base and includes a first arm, a second arm and a connecting part. The first arm and the second arm are connected to each other through the connecting part. The first arm is fixed on the second side of the insulating base and connected to the pin and includes a first fixing end connected to the circuit board. The second arm includes a second fixing end connected to the circuit board.