High-Current Connector Contacts for Adjustable Disconnect Force
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Solution Overview
Problem
Existing high-current connector systems lack the ability to easily adjust the total disconnect force, which is crucial for safety in high-current applications, and require modifications that compromise modularity and compatibility with standard components.
Innovation Solution
A high-current connector system with additional plug and mating contacts that generate a predetermined total separation force by designing each contact pair to have a single separation force that is at least 1.5 times its insertion force, allowing for modular and compatible retrofitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the total disconnect force is increased for safety in high-current applications, then the safety and reliability are improved, but the device complexity increases and the ease of operation deteriorates
Solution Approach 1:
The connector system is divided into multiple contact pairs, each contributing a specific separation force. By segmenting the total separation force into individual contact pair contributions, the system achieves high total separation force while maintaining standardized, easily replaceable contact pairs that preserve ease of operation.
Solution Approach 2:
The invention changes the parameter of separation force by designing contact pairs with asymmetric force characteristics where the separation force is at least 1.5 times the insertion force. This parameter change ensures high reliability for high-current applications while maintaining manageable operational characteristics through standardized contact pair designs.
2Reliability
If the total disconnect force is adjusted to a predetermined value, then the reliability and safety are improved, but the device complexity increases
Solution Approach 1:
The invention achieves predetermined disconnect force by changing the parameters of individual contact pairs (separation force at least 1.5 times insertion force) rather than modifying the entire connector system. This allows reliable force adjustment through standardized parameter specifications that maintain system simplicity.
Solution Approach 2:
The contact pairs are designed with universal characteristics that allow them to be used in different configurations while maintaining their force characteristics. The standardized contact pair design with asymmetric force properties can be applied universally across different high-current connector applications, reducing overall device complexity.
3Reliability
If existing high-current connector systems are retrofitted to adjust disconnect force, then the reliability is improved, but the ease of manufacture and modularity deteriorate
Solution Approach 1:
The connector system is segmented into independent contact pairs that can be individually designed and manufactured with specific force characteristics. This segmentation allows contact pairs to be manufactured separately and assembled into existing connector housings, preserving modularity while achieving reliable disconnect force adjustment.
Solution Approach 2:
Rather than modifying the physical structure of existing connectors, the invention changes the parameters of the contact pairs (separation-to-insertion force ratio of at least 1.5:1). This parameter-based approach allows retrofitting existing connector systems without compromising their modular design or manufacturing simplicity.
Data Source
Figure 1a~1d
Figure 2a~2c
Figure 3a~3b
AI summary
The object of the invention is to enable the adjustment of the total disconnection force of a high-current connector system to a predetermined value using simple means and to make the corresponding retrofitting of existing high-current connector systems as straightforward as possible. To this end, it is proposed to equip a connector (1) and a mating connector (2) of the connector system each with at least one further plug contact (100) and at least one further mating contact (200), respectively. The at least one further plug contact (100) and the at least one further mating contact (200) are pluggable together and, in the plugged state, can be disconnected again by applying a single disconnection force, and are thus jointly configured to generate a predetermined amount of the aforementioned total disconnection force of the connector system. This allows for individual adjustment, e.g.,The end user can easily adjust the desired overall disconnection force by selecting suitable additional plug contacts and mating contacts, and adapt it, for example, to the actual current used, so that connections that transmit particularly high electrical currents are especially difficult to disconnect, particularly for safety reasons.