High-Current Connector Assembly With Integrated Contact Bridging
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Solution Overview
Problem
Existing high-current plug-in connectors face challenges in achieving a compact design suitable for transmitting high currents due to mechanical fastening difficulties with metal bridging elements, which are unsuitable for high-current applications.
Innovation Solution
A high-current plug-in connector design featuring an insulating body with a contact carrier, parallel plug-in contacts, and an electrically conductive connecting element with open ring contact receptacles, allowing for interlocking and force-fitting connection of plug-in contacts, along with a crimped cable connection and a contact holding plate for secure fastening and touch protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal bridging elements are used to connect plug-in contacts, then electrical connectivity is achieved, but mechanical fastening reliability is insufficient for high-current applications
Solution Approach 1:
The patent merges the electrical connection function and mechanical fastening function into a single integrated connecting element. The connecting element comprises contact receptacles that simultaneously provide electrical connectivity and mechanical retention for the plug-in contacts, eliminating the need for separate bridging elements and fastening structures. This integration resolves the contradiction by achieving both reliable electrical connection and secure mechanical fastening through one unified component.
Solution Approach 2:
The contact receptacles are designed with curved, U-shaped configurations that wrap around the plug-in contacts. This curvature enables the receptacles to embrace and securely retain the contacts through elastic deformation, providing reliable mechanical fastening while maintaining electrical connectivity. The curved geometry allows the connecting element to flexibly adapt to the contacts and provide robust retention forces.
2Stability of the object's composition
If plug-in contacts are securely fastened in the insulating body, then mechanical stability is improved, but plug-in and tensile forces increase
Solution Approach 1:
The connecting element is designed as an elastic, deformable component that dynamically adapts to the plug-in contacts during insertion and operation. The elastic material allows the contact receptacles to flexibly engage the contacts, providing secure retention through elastic recovery rather than rigid mechanical constraints. This dynamic behavior reduces peak insertion forces while maintaining stable contact fastening throughout operation.
Solution Approach 2:
The patent utilizes changes in the physical parameters of the connecting element, specifically its elastic properties and deformability. By selecting materials and designs that exhibit appropriate elastic deformation characteristics, the connecting element can absorb insertion energy and provide gradual, controlled retention forces. This parameter optimization allows secure contact fastening with reduced peak forces during plugging and unplugging operations.
3Volume of moving object
If a compact connector design is implemented, then space efficiency is improved, but mechanical fastening difficulty increases
Solution Approach 1:
The integration of electrical connection and mechanical fastening functions into a single connecting element significantly reduces the overall connector volume. By eliminating separate components for electrical bridging and mechanical retention, the design achieves compact dimensions while maintaining effective contact fastening. The multi-functional connecting element fits within the insulating body with minimal space requirements.
Solution Approach 2:
The connecting element is designed to perform multiple functions simultaneously: it provides electrical connectivity through its conductive structure, mechanical retention through its elastic receptacles, and self-alignment during assembly. The elastic deformation capability allows the element to self-adjust during insertion, facilitating ease of assembly despite the compact design. This self-service characteristic reduces manufacturing complexity while maintaining compact dimensions.
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
Enables the transmission of high currents (up to 70 A) while maintaining a compact and robust structure, ensuring reliable electrical connectivity and mechanical stability with reduced risk of flashovers at high voltages.
Implementation Method 1
The at least two plug-in contacts are electrically conductively connected to one another by way of the connecting element
Implementation Method 2
The contact receptacles are designed in particular in the form of elastically deformable open sleeves
Data Source
AI summary
A high-current connector includes an insulating body which has at least one contact carrier having at least one contact chamber, which has at least two through-openings on the plug-in side, and at least two electrically conductive plug-in contacts which are arranged parallel to one another in the contact chamber and each have a cable connection region at a first end and a plug-in region opposite at a second end, the plug-in regions of the plug-in contacts being guided through one of the through-openings each of the contact chamber. The high-current plug connector also has an electrically conductive connection element which is inserted into the contact chamber and which has at least two contact receptacles, into each of which one of the plug-in contacts is inserted interlockingly and frictionally by its plug-in region, and the at least two plug-in contacts are electrically conductively connected to one another by the connection element.