Industrial Connector Contact Insert With Integrated Potential Distribution
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Solution Overview
Problem
Existing contact inserts for industrial connectors are limited in their ability to efficiently distribute electrical potential across multiple conductor connection elements, often requiring additional components like distribution terminals or bridges.
Innovation Solution
The contact insert incorporates a potential distribution element, such as a busbar, that electrically conductively connects a contact element to multiple conductor connection elements, allowing for the distribution of electrical potential without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional contact inserts use individual conductor connection elements for each contact element, then the connection structure is simple, but the ability to distribute electrical potential across multiple conductor connection elements is limited and requires additional components
Solution Approach 1:
The patent combines multiple conductor connection elements with a common potential distribution element (busbar) into a single integrated unit. The busbar serves as a common electrical connection that distributes potential to multiple contact elements, eliminating the need for separate distribution terminals or bridges and reducing overall device complexity while maintaining versatility
2Adaptability or versatility
If additional distribution terminals or bridges are added to distribute electrical potential, then the adaptability to distribute electrical potential is improved, but the device complexity and number of components increases
Solution Approach 1:
The busbar serves multiple functions simultaneously: it acts as a potential distribution element connecting multiple conductor connection elements, provides mechanical support for the contact elements, and ensures electrical continuity across the connector. This multi-functionality eliminates the need for separate distribution terminals or bridges, reducing the total number of components
3Power
If the contact insert is designed for large current distribution, then the power handling capability is improved, but the structural complexity increases
Solution Approach 1:
The busbar integrates multiple conductor connection elements with a common potential distribution path, creating a streamlined structure that handles large currents efficiently. By merging the potential distribution function into the busbar itself rather than adding separate components, the structural complexity is minimized while maintaining high power handling capability
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 enables secure and efficient electrical connections, allowing for the distribution of large currents while reducing the need for additional components, thereby increasing the versatility and efficiency of the contact insert.
Implementation Method 1
a potential distribution element via which a contact element of the plurality of contact elements is electrically conductively connected to at least two conductor connection elements of the plurality of conductor connection elements
Data Source
AI summary
A contact insert for an industrial connector includes: an approximately cuboid-shaped insulating body; a plurality of conductor connection elements; and a plurality of contact elements. The contact insert has a connection side and an opposite contact side. On the connection side, a plurality of conductor insertion openings leading to individual conductor connection elements of the plurality of conductor connection elements are formed in the insulating body. The plurality of contact elements are accessible from the contact side for contacting corresponding mating contact elements of a mating contact insert. The contact insert has a potential distribution element via which a contact element of the plurality of contact elements is electrically conductively connected to at least two conductor connection elements of the plurality of conductor connection elements. n conductor insertion openings and n conductor connection elements are provided on the connection side.