Bridging Contact Insert for Compact Industrial Connector Wiring
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Solution Overview
Problem
Existing contact inserts for industrial electrical connectors require sufficient space for bridging individual conductors, which poses a hazard if the mechanical connection fails, allowing live conductors to touch the connector housing.
Innovation Solution
A compact contact insert with a bridging element that includes a connection region for the multi-core cable and multiple contact regions for electrical connection, designed with a metal bar and crimp barrel or push-in connection technology for secure and space-efficient bridging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are bridged within the electrical connector housing, then sufficient space is required and a correspondingly sized housing must be selected, but this harbors a high hazard potential if the mechanical connection fails
Solution Approach 1:
The bridging function is extracted from the housing and integrated into the contact insert itself. The contact insert now contains the bridging element that directly connects conductors within its own structure, eliminating the need for separate housing-based bridging arrangements and reducing hazard potential while maintaining safety.
Solution Approach 2:
The contact insert acts as an intermediary component that provides a controlled and isolated environment for conductor bridging. By containing the bridging mechanism within the contact insert rather than the housing, it mediates between the conductors and the housing, preventing direct contact between live conductors and the housing even if mechanical connections fail.
2Volume of moving object
If a compact contact insert with integrated bridging element is used, then space efficiency is improved and hazard potential is reduced, but assembly complexity may increase
Solution Approach 1:
Multiple functions are merged into a single contact insert component: the bridging function, the connection function for conductors, and the isolation function are all integrated into one element. This consolidation reduces the overall number of parts and space required while managing complexity through functional integration rather than multiplication of separate components.
Solution Approach 2:
The contact insert is designed as a multi-functional element that simultaneously provides conductor connection, current bridging, and electrical isolation. This universal design approach allows a single component to perform multiple tasks that would traditionally require separate elements, improving compactness without proportionally increasing complexity.
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 solution provides a safe, compact, and convenient connection for dividing currents in industrial electrical connectors, reducing the hazard of live conductors touching the housing and enabling a more rapid assembly process.
Implementation Method 1
The bridging element (2) has a connection region (AB) arranged on the connection side (A) and moreover has at least two contact regions (KB) arranged on the contact side (K). The contact regions (KB) are designed for in each case electrical contacting of a mating contact element (KE) of a mating electrical connector or socket (or with the contact elements (KE) themselves).
Implementation Method 2
The connection region of the bridging element may be designed as a crimp barrel.
Implementation Method 3
the connection region is designed with a clamping spring as a so-called push-in connection
Implementation Method 4
The contact region of the bridging element is designed as a socket
Data Source
AI summary
A contact insert for an industrial electrical connector is provided. The contact insert has a connection side for the connection of individual conductors of a multi-core cable and a contact side for electrical connection to a mating electrical connector or to a socket. The contact insert includes a bridging element, which has a connection region associated with the connection side, for electrical connection to a conductor of the multi-core cable, and at least two contact regions associated with the contact side, for each electrically contacting a mating contact element of a mating electrical connector or of a socket.