Cast Contacting Element for Connector Housing Grounding
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Solution Overview
Problem
Existing connectors face challenges in creating a simple and automatable electrical connection between a grounding contact on a contact carrier and an electrically conductive housing part, particularly in demanding environments like industrial settings.
Innovation Solution
The connector employs a contacting element formed in situ on a pre-assembly assembly of the contact carrier, grounding contact, and housing part using casting technology, with materials like aluminum alloys or electrically conductive plastics, ensuring direct electrical contact between the housing part and grounding contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal spring formed by stamping and bending is used to connect the housing component to the grounding contact, then the electrical connection is established, but the manufacturing process becomes complex and difficult to automate
Solution Approach 1:
The contacting element integrates multiple functions into a single component: it provides electrical connection between the housing and grounding contact, structural support, and grounding continuity. This merging eliminates the need for separate metal spring components and simplifies the manufacturing process by allowing the contacting element to be formed in-situ through casting.
Solution Approach 2:
The invention replaces the traditional mechanical stamping and bending process with a casting process. The contacting element is formed by casting material into a mold that defines its final shape, including the contact surfaces and grounding path. This substitution enables automation and simplifies manufacturing while maintaining electrical connection functionality.
2Extent of automation
If conventional stamping and bending techniques are used to form the metal spring, then the electrical connection is achieved, but the process is not automatable
Solution Approach 1:
The casting process replaces manual or semi-automated stamping and bending operations with a fully automatable mold-based forming process. The contacting element is created by injecting or pouring molten material into a pre-configured mold that defines the exact geometry, contact surfaces, and grounding pathways, enabling consistent automated production.
Solution Approach 2:
The mold is pre-configured with all necessary features including contact surfaces, grounding paths, and structural geometry before the casting process begins. This preliminary preparation of the mold allows the contacting element to be formed in a single automated operation without subsequent manual shaping or assembly steps.
3Reliability
If the housing component is made of metal for demanding environments, then durability is improved, but integration into the grounding system becomes more complex
Solution Approach 1:
The contacting element merges the electrical connection function with the grounding integration function. By forming the contacting element directly within the housing structure through casting, the invention creates an inherent grounding path that integrates the metal housing into the grounding system without requiring separate grounding components or complex assembly procedures.
Solution Approach 2:
The contacting element can be formed from materials that combine electrical conductivity with mechanical strength, such as conductive plastics or metal matrix composites. This allows the element to serve both structural and electrical grounding functions simultaneously, simplifying the integration of the metal housing into the grounding system while maintaining durability for demanding environments.
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 method allows for a robust, low-resistance electrical connection that integrates the housing part into the grounding system, enhancing safety and reliability in demanding environments.
Implementation Method 1
the contacting element is formed in situ on a pre-assembly assembly formed by the contact carrier, the grounding contact and the housing part using casting technology
Implementation Method 2
the contacting element rests with its first contact section against the housing part and with its second contact section against the grounding contact arranged on the contact carrier, thus contacting the housing part and the grounding contact and thereby establishing an electrical connection
Data Source
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AI summary
The invention relates to an electrical connector (1) to be connected, by plugging, to a mating electrical connector (3), the electrical connector comprising a contact carrier (12) manufactured from an electrically insulating material, an electrical earthing contact (14) arranged on the contact carrier (12) for making electrical contact with the mating electrical connector (3), and an electrically conductive housing part (17) connected to the contact carrier (12). In addition, the electrical connector (1) has an electrically conductive contacting element (16), which is manufactured by means of a casting technique, has a first contacting portion (160) which bears against the housing part (17), making electrical contact with same, and a second contacting portion (161) which bears against the earthing contact (14), making electrical contact with same, and electrically connects the housing part (17) to the earthing contact (14).