High Current Connector Axial Fixation via Housing Extension
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Solution Overview
Problem
Existing high current connectors face challenges in broadening their application and improving manufacturing and assembly processes, particularly in achieving reliable and cost-effective axial fixation without additional undercuts and ensuring high current transmission efficiency.
Innovation Solution
A high current connector design featuring a housing that extends beyond the external current conducting element with a radially inwardly projecting section for axial fixation, utilizing a rectangular contact element with lamellar spring elements tilted relative to support frames and lugs for enhanced mechanical stability and contact force, eliminating the need for undercuts and enabling efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional housing design is used without extension beyond the external current conducting element, then the connector structure is simpler, but the contact element cannot be reliably fixed axially without additional undercuts
Solution Approach 1:
The housing is extended in the axial direction beyond the external current conducting element, creating a new spatial dimension for fixation. This axial extension provides a surface for the contact element to rest against, enabling reliable axial fixation without requiring radial undercuts or additional complex structural features.
2Reliability
If additional undercuts are added to the external current conducting element for axial fixation, then the contact element can be securely fixed, but the manufacturing complexity and cost increase
Solution Approach 1:
The fixation function is extracted from the external current conducting element and transferred to the housing structure. By extending the housing axially to provide a resting surface, the need for complex undercut features in the external current conducting element is eliminated, simplifying its manufacturing while maintaining reliable contact element fixation.
3Power
If the contact element has a rectangular cross-section with lamellar spring elements, then the connector achieves high current transmission capability and mechanical stability, but the manufacturing precision requirements increase
Solution Approach 1:
The lamellar spring elements are tilted relative to the support frames, creating a dynamic structure that can deform elastically during assembly and operation. This dynamic design allows the spring elements to automatically adjust to minor dimensional variations, reducing the impact of manufacturing precision limitations while maintaining high current transmission capability and mechanical stability.
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 reduces production costs and assembly effort while providing a twist-resistant, mechanically stable connector capable of transmitting high electric currents, with a rectangular configuration facilitating economical production and integration into rectangular housings, and ensuring reliable contact through a large number of contact points.
Implementation Method 1
the contact element having a plurality of spring elements for establishing an electrical multi-point contact between the internal current conducting element and the external current conducting element
Data Source
AI summary
A high current connector for transmitting electrical currents with at least one contact element establishing an electric contact between an internal current guiding element and an external current guiding element, having a plurality of spring elements establishing an electric multipoint contact between the internal current guiding element and the external current guiding element. The contact element arranged in a housing together with the external guiding element so that said spring elements establish an electric contact with the external current guiding element on the radial outer side of the contact element and an internal guiding element can be inserted into the housing so that the spring elements establish a contact with the internal current guiding element on a radial inner side of the contact element. The housing overlaps the external current guiding element in the axial direction, having a radially inwardly rising housing section.