Integrated Grounding Insert for High-Current Connector Earthing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing grounding devices for electrical connectors face challenges in assembly complexity, material limitations, reduced space for pole patterns, and limited current carrying capacity due to non-positive connections and complex tooling requirements, which hinder reliable fault current discharge and increase the risk of heating and damage.
Innovation Solution
A grounding device with a plate-shaped base body made of conductive material, featuring passages for contact pins and radially extending contact elements, allowing for robust and reliable PE contacting, high current capacity, and optimized heat dissipation, produced using laser cutting or punching processes, with resilient contact elements for secure engagement with the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate contact assembly with spring arms is used to connect the PE contact to the housing, then electrical connection is established, but assembly complexity increases and automation becomes difficult
Solution Approach 1:
The grounding device integrates the base body, contact elements, and connection functionality into a single unit that is inserted as one piece into the insulating body. This merging of components eliminates the need for separate spring arms and complex assemblies, thereby reducing assembly complexity while maintaining reliable electrical connection through the integrated contact elements.
2Reliability
If gaps and perforations are created in the one-piece insulating body to accommodate the connection assembly, then contact with the metal housing is enabled, but manufacturing complexity and tooling costs increase
Solution Approach 1:
The grounding device extracts the connection functionality from the insulating body by providing its own integrated contact elements that extend through the insulating material. This eliminates the need to create complex gaps and perforations in the insulating body, as the contact elements are self-contained within the grounding device structure, thereby simplifying manufacturing and reducing tooling requirements.
3Reliability
If the connection assembly is inserted deep into the monolithic contact body, then contact surfaces can reach the metal housing, but assembly difficulty and tooling complexity increase
Solution Approach 1:
The grounding device segments the connection function into distinct contact elements that are positioned at optimal locations within the grounding device structure. These segmented contact elements engage with the housing at the appropriate depth without requiring deep insertion into the insulating body, thereby reducing assembly difficulty while ensuring reliable contact surface engagement.
4Ease of manufacture
If flame-retardant plastics with required flowability are used for the insulating body, then injection molding is enabled, but material selection is limited
Solution Approach 1:
The grounding device segments the functional requirements by providing the contact and connection elements as separate metallic components within the insulating body. This segmentation allows the insulating body to be manufactured using standard injection molding with flame-retardant plastics, while the metallic contact elements provide the required electrical functionality, thereby enabling broader material selection for the insulating body without compromising manufacturing capability.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An earthing device, particularly for a contact insert, comprising a substantially plate-shaped base body made of an electrically conductive material, wherein the base body has at least one passage for a contact, particularly a contact pin, and at least one contact element with a contact surface extending radially outwards. Furthermore, an earthing unit, a contact insert, and an electrical connector are specified. A method for manufacturing a contact insert is also described.