High Current Connector Ring Spring Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-current plug connectors fail to maintain reliable electrical contact under high loads and mechanical vibrations without significant wear, particularly in space-constrained applications such as electric or hybrid vehicle systems.
Innovation Solution
The use of an annular helical spring contact element within a U-shaped groove in an electrically conductive mounting rail, which forms parallel main legs for mating connector reception, providing enhanced contact pressure and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional contact elements are used in high-current connectors, then the space requirement can be reduced, but reliable electrical contact under high loads and mechanical vibrations cannot be achieved
Solution Approach 1:
The contact element is designed as a spring mechanism that dynamically adapts its contact pressure in response to mechanical vibrations and load variations. The spring constantly exerts force to maintain optimal contact pressure between the contact surfaces, ensuring reliable electrical contact under varying operating conditions while occupying minimal space.
Solution Approach 2:
The contact element utilizes elastic deformation of the spring material to change its physical state and maintain constant contact force. The spring's elastic properties allow it to compress and expand, automatically adjusting to maintain reliable electrical contact despite vibrations and thermal expansion, all within a compact design.
2Device complexity
If conventional contact elements are used in high-current connectors, then the device complexity can be reduced, but significant wear at contact points occurs under high loads
Solution Approach 1:
The spring-based contact element dynamically maintains optimal contact pressure, distributing mechanical stress evenly across the contact surface. This dynamic adaptation prevents localized stress concentrations that would otherwise cause rapid wear, extending the connector's service life without requiring complex additional components.
Solution Approach 2:
The spring mechanism acts as a cushioning element that absorbs and dissipates mechanical shocks and vibrations before they can cause damage to the contact surfaces. By anticipating and mitigating impact forces, the spring protects the contact points from wear and damage throughout the connector's operational life.
3Reliability
If higher contact pressure is applied to ensure reliable electrical contact, then electrical transmission reliability improves, but mechanical wear at contact points increases
Solution Approach 1:
The spring contact element dynamically adjusts its pressure application, maintaining consistently optimal contact force without the need for excessive static preloading. The spring's elastic recovery ensures that contact pressure is maintained at the precise level needed for reliable electrical conduction while avoiding the excessive forces that would accelerate wear.
Solution Approach 2:
The spring mechanism is self-regulating, automatically maintaining the optimal contact pressure needed for reliable electrical contact without external control. The elastic properties of the spring inherently limit the maximum force applied, ensuring that contact pressure remains sufficient for good electrical connection while naturally preventing forces high enough to cause excessive wear.
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 configuration ensures reliable high-current transmission even under high mechanical vibrations without significant wear, maintaining effective electrical contact in low-space applications.
Implementation Method 1
the contact element, which is arranged and designed in the housing in such a way that it establishes electrical contact with a contact surface and contact pressure between the housing and the mating connector inserted therein, has at least one annular helical spring
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a high current connector for transmitting electric currents, comprising a housing made of electrically conductive material, which is designed for mechanical and electrical connection to a cable and has an open side for the insertion of a matching plug connector (4) made of an electrically conductive material, and comprising a contact element (5) which is disposed and formed in the housing in such a way that it produces an electrical contact with a contact surface and contact pressure between the housing and the matching plug connector (4) inserted therein, wherein the contact element (5) has at least one annular helical spring (5).