High-Power Plug Connector Compact Housing Design
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Solution Overview
Problem
Existing high-power plug connector systems for rail-bound vehicles require significant spatial resources, which is undesirable for ecological and economic reasons, and need modernization for efficient transmission and distribution of high electrical currents and voltages.
Innovation Solution
A space-saving cable connection housing with a dielectric substance for potting high-power contacts and a conductive rail, providing a compact, media-tight seal and enhanced thermal conductivity for heat dissipation, suitable for use as a Y-, T-, H-, or X-distributor, utilizing epoxy resin or silicone-containing components for flexibility and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-power plug connector systems are used, then high electrical currents and voltages can be transmitted, but significant spatial resources are required
Solution Approach 1:
The patent combines multiple functional elements into a single integrated housing structure. The housing simultaneously provides mechanical protection, electrical insulation, thermal management (via integrated heat sinks), and sealing functions. This merging of functions reduces the overall spatial footprint while maintaining the capability to transmit high electrical currents and voltages.
Solution Approach 2:
The patent employs a nested arrangement where contacts are positioned within insulating bodies, which are in turn housed within the protective housing. Heat sinks are integrated within the housing structure, and sealing elements are positioned within grooves in the housing. This nested configuration maximizes space utilization and reduces the overall volume required for the connector system.
2Volume of stationary object
If compact designs are implemented to reduce spatial requirements, then space is saved, but manufacturing complexity may increase
Solution Approach 1:
The patent divides the connector into modular components: a housing, insulating bodies, contacts, heat sinks, and sealing elements. Each component can be manufactured separately using standard processes, then assembled together. This segmentation reduces manufacturing complexity despite the compact integrated design, as each component is relatively simple to produce independently.
Solution Approach 2:
The housing serves multiple functions simultaneously: mechanical protection, electrical insulation, thermal management (integrated heat sinks), and sealing (integrated sealing elements). This multi-functionality reduces the total number of separate components needed, simplifying the assembly process and reducing manufacturing complexity while achieving a compact design.
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 a compact, safe, and cost-effective high-power plug connector system that effectively transmits high currents and voltages while dissipating heat, reducing spatial requirements and ensuring reliable operation in underfloor applications.
Implementation Method 1
an interior space formed in the cable connection housing is at least partially potted with a dielectric substance
Implementation Method 2
the dielectric substance has a high thermal conductivity coefficient
Data Source
AI summary
A high-power plug connection system is provided comprising a cable connection housing for connecting at least two electric high-power plug connectors in order to transmit and/or distribute high electric current strengths and/or high electric voltages, at least two insulating bodies for receiving a respective high-power contact and at least one electrically conductive rail, wherein the longitudinal axes of the high-power contacts are arranged essentially in one plane in an offset manner from each other, the high-power contacts being connected together in an electrically conductive manner by the electrically conductive rail, said high-power contacts being provided with at least one recess, into which the rail at least partly fits, and wherein an interior space formed in the cable connection housing is at least partially encapsulated with a dielectric substance.