Thin-Walled Cylindrical Plug With Slot for Secure Electrical Connection
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Solution Overview
Problem
Existing electrical connectors with cylindrical plug walls face issues of lost frictional connection and secure hold when frequently plugged and unplugged, and require precise dimensioning and high material consumption for manufacturing.
Innovation Solution
A connector design featuring a thin-walled cylindrical plug with a single slot or embossings that allows elastic bending for secure contact, utilizing the deep-drawing process for cost-effective and material-efficient production, and incorporating indentations for enhanced contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple longitudinal slots are formed in the cylindrical plug wall to enable elastic spreading, then the connector wall can clamp the mating connector wall, but the manufacturing precision requirements increase and material consumption increases due to thick walls
Solution Approach 1:
The cylindrical plug wall is divided into multiple longitudinal segments by forming slots, enabling elastic spreading and clamping of the mating connector wall while maintaining manufacturing feasibility
Solution Approach 2:
The plug wall is designed with thin-walled construction that provides sufficient elasticity for spreading and clamping without requiring thick material, reducing both material consumption and manufacturing complexity
2Reliability
If multiple longitudinal slots are formed in the cylindrical plug wall, then elastic spreading is enabled, but material consumption increases
Solution Approach 1:
The plug wall utilizes thin-walled flexible construction that provides the necessary elasticity for spreading and clamping functions without requiring excessive material, thereby reducing material consumption
Solution Approach 2:
By dividing the plug wall into segments through slots, the design achieves elastic deformation capability with minimal material usage, as each segment can independently deform to provide clamping force
3Adaptability or versatility
If the plug wall is made thin to provide elasticity, then spring properties are sufficient for elastic bending, but the mechanical strength may be compromised
Solution Approach 1:
The thin-walled plug is designed to utilize elastic deformation of the cylindrical wall itself as a spring mechanism, where the thin walls provide sufficient elasticity for bending and spreading while maintaining adequate mechanical strength through optimized geometry
Solution Approach 2:
The plug wall is designed to dynamically deform elastically during insertion and withdrawal, utilizing the natural spring properties of thin-walled cylinders to provide both flexibility and mechanical strength through controlled deformation
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 achieves reliable mechanical and electrical contact with reduced material usage, allowing for simple and cost-effective manufacturing while maintaining mechanical stability and efficient assembly/disassembly.
Implementation Method 1
The plug wall is preferably thin enough in relation to the length in the plugging direction to be elastically bendable over a cylindrical mating plug wall of a mating plug or to be plugged into a cylindrical mating plug wall of a mating plug. The focus here is on the thin walls, which offer sufficient elasticity or spring properties of the plug wall designed as a cylinder.
Data Source
AI summary
The plug (1) has a thin cylindrical plug wall (5) for electrical connection of a counter plug wall (15) of a counter plug (2). A slot (10) is formed in the cylindrical plug wall, where the slot runs from an open plug side to the cylindrical plug wall. An embossing (11) is formed in the cylindrical plug wall in an assembled condition and protrudes in the direction of the counter plug wall. The cylindrical plug wall is elastically bendable, and is pluggable via the counter plug wall.