High-Current Contact Device Injection-Molded Circuit Carrier
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Solution Overview
Problem
Existing high-current contact devices for motor vehicles and charging stations face challenges in design flexibility, assembly complexity, and cost-effectiveness, particularly in accommodating different geometric designs and ensuring reliable sealing and temperature monitoring.
Innovation Solution
A high-current contact device featuring a one-piece, injection-molded circuit carrier with offset portions and a reinforcing rib, incorporating a sealing sleeve for fluid-tight sealing and a thermally conductive temperature sensor, which allows for flexible geometric adaptation, reduced component count, and efficient assembly, while enabling easy data interface access and monitoring of operating parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components are used to support data contacts and interfaces, then structural flexibility and adaptability are improved, but device complexity and assembly outlay increase
Solution Approach 1:
The patent merges the carrier structure, data contact support, and data interface mounting into a single integrated circuit carrier component. This one-piece construction eliminates the need for multiple separate support structures while maintaining the ability to accommodate different geometric designs of contact elements, thereby reducing device complexity without sacrificing adaptability.
Solution Approach 2:
The circuit carrier is designed as a universal component that performs multiple functions: it mechanically supports data contacts, provides electrical connections via conductor tracks, mounts data interfaces, and adapts to various contact element geometries. This multi-functional design reduces the overall component count while maintaining design flexibility.
2Adaptability or versatility
If contact elements with different lengths are used, then functional versatility is improved, but geometric consistency and assembly precision worsen
Solution Approach 1:
The carrier features locally adapted support structures for data contacts at different positions. The offset arrangement of carrier portions provides customized support geometry for each data contact location, allowing accommodation of contact elements with different lengths while maintaining precise geometric alignment through position-specific design features.
3Reliability
If data interface is accessed through the contact housing, then sealing reliability is improved, but ease of operation and data access worsen
Solution Approach 1:
The data interface is extracted from the housing interior and mounted on the exterior surface of the contact housing. This extraction allows the data interface to be easily accessible for connection and disconnection operations while the contact housing maintains its seal integrity for the high-current contact elements, separating the data access function from the sealed contact environment.
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
The solution enables quick, cost-effective assembly and reliable operation by accommodating various geometric designs, preventing mechanical damage and corrosion, and allowing for efficient monitoring of temperature and current, thus enhancing the device's durability and performance.
Implementation Method 1
The circuit carrier is designed as an injection-moulded circuit carrier, wherein a carrier of the circuit carrier mechanically supports the first data contact and the data interface
Implementation Method 2
a thermally conductive temperature sensor, which allows for flexible geometric adaptation, reduced component count, and efficient assembly, while enabling easy data interface access and monitoring of operating parameters
Implementation Method 3
incorporating a sealing sleeve for fluid-tight sealing and a thermally conductive temperature sensor, which allows for flexible geometric adaptation, reduced component count, and efficient assembly
Data Source
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AI summary
The invention relates to a high-current contact device (10) and to a method for producing such a high-current contact device (10), wherein the high-current contact device (10) has at least one first contact element (25) designed for transmission of electrical energy, a circuit carrier (30), at least one first data contact (40) for transmission of a data signal and at least one data interface (60), wherein the first contact element (25) reaches through the circuit carrier (30) along a mating axis (110) at a feedthrough (175), wherein a conductor track (145) of the circuit carrier (30) electrically connects the first data contact (40) to the data interface (60), wherein the circuit carrier (30) is designed as an injection-moulded circuit carrier, wherein a carrier (115) of the circuit carrier (30) mechanically supports the first data contact (40), the first contact element (25) and the data interface (60).