Integral Plug Connector Housing to Reduce Circuit Carrier Stress
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Solution Overview
Problem
The installation of multiple plug connectors in electrical devices is complicated by manufacturing tolerances, leading to mechanical stresses and potential impairment of the circuit carrier's long-term operation, especially when cumulative structural tolerances occur.
Innovation Solution
An electrical device with a device connection part that forms an integral part of the device housing, featuring a circuit carrier with multiple plug connectors and contact carriers made of insulating material, where plug contacts are secured within uninterrupted contact chambers and connected to conducting tracks, allowing for simplified assembly and reduced tolerance issues through injection-molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple plug connectors are installed in the device housing, then the device can provide multiple network interfaces and connect more field devices, but manufacturing tolerances and cumulative structural tolerances generate increased assembly complexity and mechanical stresses
Solution Approach 1:
The device housing and contact carriers are merged into a single integral component through co-injection molding. The contact carriers are directly formed as part of the housing structure, eliminating the need for separate installation steps and reducing assembly complexity while maintaining the ability to accommodate multiple plug connectors
Solution Approach 2:
The integral contact carriers are designed with universal mounting features and standardized contact chamber structures that can accommodate different types of plug connectors. This multi-functional design allows the same housing structure to support various network interface configurations without increasing assembly complexity
2Adaptability or versatility
If multiple plug connectors are installed in the device housing, then more network interfaces are available, but mechanical stresses and strain on the circuit carrier increase, potentially impairing long-term operation
Solution Approach 1:
The contact carriers are integrated directly into the housing structure through co-injection molding, creating a unified load-bearing structure. This merging distributes mechanical stresses across the entire housing-contact carrier assembly rather than concentrating them on the circuit carrier, thereby maintaining reliability while supporting multiple connectors
Solution Approach 2:
The co-injection molding process creates a composite structure with the housing material and contact carrier material forming an integrated assembly. This composite construction provides enhanced mechanical strength and stress distribution capabilities, reducing the strain on the circuit carrier while maintaining multiple network interfaces
Data Source
AI summary
An electrical device includes a device housing; at least one circuit carrier having electrical conducting tracks; and a plurality of plug connectors, each of which includes a contact carrier having a plurality of contact chambers extending all the way through and comprises a plurality electrical plug contacts. The plug contacts each have, at their plugging-side end, a plugging region for the plugging-side connection to the mating contacts of a mating plug plugged to the plug connector in question and each have, at their connection-side end, a connection region (23), at which the plug contacts are electrically connected to the conducting tracks of the circuit carrier. Each plug contact is at least partly received in one of the contact chambers of the contact carrier in question and is retained therein. The electrical device also has a device connection part, which forms a housing part of the device housing, the device connection part being integral with the contact carriers.