Auxiliary Contact Elements Prevent Arcing in Electrical Connectors
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Solution Overview
Problem
Electrical connectors in automotive systems face significant electrical arcs when disconnecting main contact elements, leading to damage due to ongoing power transmission through arcs, especially in 'hot mating' scenarios where power is active.
Innovation Solution
The electrical connector assembly employs auxiliary contact elements that remain connected during the initial stages of mating and unmating to divert power, allowing the main contact elements to disconnect without arcing, and are designed to be sacrificial, avoiding damage to the main contact elements by bearing the electrical arc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If main contact elements are used to carry electrical power during hot mating, then power transmission is enabled, but electrical arcs occur causing damage to contact elements
Solution Approach 1:
The contact system is segmented into main contact elements and auxiliary contact elements. The auxiliary contact elements are designed to be longer and make contact first during mating, carrying the electrical load initially. This segmentation allows the main contact elements to avoid arcing damage while still enabling power transmission when fully mated.
Solution Approach 2:
The auxiliary contact elements are designed as sacrificial components that can be damaged by electrical arcs. These auxiliary contacts are replaceable and serve to protect the more valuable main contact elements from arc damage. When the auxiliary contacts wear out or get damaged, they can be replaced without replacing the entire connector assembly.
2Object-affected harmful factors
If auxiliary contact elements are designed to be sacrificial and longer than main contact elements, then main contact elements are protected from arcing, but device complexity increases
Solution Approach 1:
The auxiliary contact elements are integrated into the same connector housing as the main contact elements, sharing the same structural framework. Both types of contact elements are held in respective housings that mate together, combining the protective function with the existing connector structure rather than adding a completely separate system.
Solution Approach 2:
The auxiliary contact elements are positioned in a different spatial dimension relative to the main contact elements - specifically, they extend further in the mating direction. This dimensional difference in length allows the auxiliary contacts to engage first and carry the load initially, providing protection without requiring a completely separate structural arrangement.
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 design effectively prevents arcing between main contact elements during unmating and minimizes damage to the auxiliary contact elements, ensuring the main contact elements remain functional and undamaged, even in high-temperature conditions.
Implementation Method 1
the first auxiliary contact element and the second auxiliary contact element are configured to contact each other before the first main contact element and the second main contact element contact each other when the first connector and the second connector are mated, starting from an unmated condition
Implementation Method 2
The current will be shunted to the still connected longer auxiliary contact element when the main contact elements are just disconnected from each other. Heat, generated by the high electrical power shunted through the auxiliary contact elements, will increase the resistance in the positive temperature coefficient resistor.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Electrical connector assembly comprising: a first connector 1 having a first main contact element 3 and a first auxiliary contact element 4, said first auxiliary contact element 4 being electrically connected to said first main contact element 3, a second connector 2 having a second main contact element 6 and a second auxiliary contact element 7, said second auxiliary contact element 7 being electrically connected to said second main contact element 6, wherein the first connector 1 and the second connector 2 are mateable in a mating direction parallel to a longitudinal axis L of the electrical connector assembly, and wherein the first and second main contact elements (3, 6) are configured to disconnect from each other before the first and second auxiliary contact elements (4, 7) disconnect from each other during unmating the first and second connectors (1, 2), wherein in a fully mated condition the first and second main contact elements 3, 6 are in contact and the first and second auxiliary contact elements 4, 7 are disconnected from each other.