High-current connector with segmented contact cage and spring preload

The contact system is segmented into multiple contact tongues (at least two) that are arranged parallel to each other. Each contact tongue provides an independent contact path, distributing the electrical and thermal current across multiple surfaces rather than relying on a single punctiform or linear contact. This segmentation increases the total contact surface area while maintaining the concealed connection advantage of spring contacts.

The contact tongues are extended in the radial direction perpendicular to the axial plugging direction, transitioning from traditional axial linear contacts to radial planar contacts. This dimensional change allows for significantly larger contact surfaces (each tongue having a contact area of at least 10 mm²) while maintaining compact assembly, thereby improving electrical and thermal conductivity without compromising the concealed connection feature.

The contact system employs dynamic spring elements that provide continuous elastic force to maintain contact pressure between the contact tongues and the plug pin/socket. The spring force (at least 10 N per contact tongue) is generated elastically rather than requiring high static plugging forces, allowing large contact surfaces to be achieved with manageable assembly forces. The springs accommodate minor misalignments and maintain optimal contact pressure throughout operation.

Spring elements act as intermediary components between the plug pin and plug socket, mediating the force transmission. Instead of requiring direct high-force mechanical engagement between large contact surfaces, the spring elements convert axial plugging motion into radial contact pressure, enabling large contact areas to be achieved with reduced plugging forces through elastic energy storage and release.

The spring elements provide self-adjusting contact pressure that automatically compensates for thermal expansion and vibrational movements. As the contact system warms up or experiences vibration, the spring force increases to maintain constant contact pressure between the contact tongues and the plug pin/socket. This self-service mechanism ensures stable electrical conductivity and prevents relative movement without requiring external adjustment mechanisms.

The spring elements pre-load the contact system with elastic force before operational loads are applied. This beforehand cushioning effect creates a force reserve that counteracts thermal expansion forces and vibrational impacts, preventing relative movement between contact surfaces. The spring elements absorb and dissipate energy from thermal and vibrational disturbances, maintaining stable contact pressure and preventing loosening under high-temperature and high-vibration conditions.