Hybrid Plug Connector Carrier for On-Site Crimp Assembly
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Solution Overview
Problem
Existing plug connectors with Y-shaped shield elements do not allow for on-site assembly of crimp contacts, limiting ergonomic manufacturing and durable conductivity with low contact resistance in hybrid designs.
Innovation Solution
A multi-part contact carrier design with a Y-shaped shield element and crimp contacts, enabling on-site assembly and separation of signal and power contacts, allowing for the use of crimp contacts in a Y-coded plug connector with a central power contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug contacts are permanently installed in the contact carrier at the factory by overmolding with plastic, then shielding and structural integrity are improved, but on-site assembly and flexibility are lost
Solution Approach 1:
The contact carrier is divided into multiple separable parts: a first contact carrier part with signal contact receptacles and a Y-shaped shield element, and a second contact carrier part with power contact receptacles. This segmentation allows the components to be assembled on-site while maintaining shielding integrity through the Y-shaped shield element that separates signal and power contacts.
2Reliability
If a shield housing is used for hybrid plug connectors, then shielding effectiveness is improved, but device complexity increases
Solution Approach 1:
The Y-shaped shield element is extracted from a complete shield housing structure and integrated directly into the contact carrier. This extraction maintains the essential shielding function by separating signal and power contacts while reducing overall device complexity by eliminating the need for a separate shield housing.
3Ease of manufacture
If crimp contacts are used instead of solder contacts, then ease of manufacture and durable conductivity are improved, but on-site assembly capability is limited in existing designs
Solution Approach 1:
The contact carrier is designed with dynamic assembly capability, allowing crimp contacts to be installed on-site in the field. The multi-part design with separable first and second contact carrier parts enables flexible assembly operations while maintaining the durability and low contact resistance benefits of crimp connections.
Data Source
AI summary
In order to receive eight electrical crimp contacts, namely four electrical signal contacts and four electrical power contacts, and a Y-shaped shielding element in a hybrid electrical plug connector, according to the invention a contact carrier is designed in multiple parts, in particular three parts, wherein the signal contact receivers are located in the first contact carrier part. The central contact can be positioned on the first or second contact carrier part. When fastening these two contact carrier parts to one another, the central contact can thus be fixed between the two contact carrier parts. Furthermore, the Y-shaped shielding element is held on a holder of the first contact carrier part. This assembly is jointly inserted into the sleeve-shaped third contact carrier part so that the central contact is positioned with its plug-in region substantially centrally in the plug-in face of the plug connector.