Integral Protective Conductor Connector for Electrical Plug Grounding

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Solution Overview

Problem

Existing electrical plugs with multiple separate housing exterior parts face challenges in achieving reliable and cost-effective grounding connections, as traditional methods require extensive assembly effort and can lead to increased electrical transition resistance over time due to corrosion and material flow issues, particularly in zinc die-cast configurations.

Innovation Solution

An electrical plug design featuring a protective conductor connector element that is integrally formed with the protective conductor contact, radially protruding to establish direct electrical connections between housing exterior parts, reducing the need for separate grounding strands and mechanical interfaces, and ensuring a secure, low-resistance ground connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional grounding methods with separate strands and mechanical connections are used, then grounding coverage can be achieved, but assembly effort increases and transition resistance increases over time

Engineering Contradiction:

Improvegrounding connection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective conductor connector element is integrally formed with the protective conductor contact, merging two previously separate components into one. This integral construction eliminates the need for separate grounding strands and mechanical fasteners, significantly reducing assembly complexity while maintaining reliable grounding coverage across multiple housing exterior parts.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If separate grounding connections are used for multiple housing exterior parts, then grounding coverage is achieved, but transition resistance increases over time due to corrosion and material flow

Engineering Contradiction:

Improvegrounding connection stabilityVSAvoidgrounding connection longevity

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

By integrating the protective conductor connector element with the protective conductor contact, the invention creates a unified grounding path that eliminates multiple mechanical interfaces. This reduces the number of potential corrosion and failure points, thereby improving the longevity and stability of the grounding connection over time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protective conductor connector element acts as an intermediary component that establishes direct electrical contact between the protective conductor contact and the metallic areas of multiple housing exterior parts. This intermediary structure provides a stable, low-resistance electrical path that is less susceptible to degradation from corrosion and material flow compared to traditional separate grounding methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If extensive protective conductor configurations are used for multiple housing exterior parts, then grounding coverage is improved, but costs and assembly effort increase

Engineering Contradiction:

Improvegrounding coverageVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The integral construction of the protective conductor connector element with the protective conductor contact reduces the total number of components that need to be manufactured and assembled. This consolidation simplifies the manufacturing process, reduces material costs, and eliminates the need for extensive protective conductor configurations while maintaining adequate grounding coverage.

Inventive Principle:

Principle #5Merging (Combining)

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 design simplifies assembly, reduces assembly effort, and maintains a low transition resistance ground connection, enhancing the longevity and reliability of the electrical plug by eliminating the need for delicate strand connections and minimizing oxidation-related issues.

Implementation Method 1

The protective conductor connector element is formed integrally with the protective conductor contact... directly abutting on, a metallic area of at least one of the housing exterior parts

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentEP3642909B1Electrical plug with a protective conductor contact and protective conductor connector element formed integrally therewith for grounding exterior parts

Publication Date: 2022.10.05 TE CONNECTIVITY IND GMBH

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Figure 5~6

AI summary

The invention relates to an electrical plug (1) with a plug housing (2), which comprises a first housing exterior part (3) metallic at least in certain areas and a separate second housing exterior part (4) metallic at least in certain areas, wherein the electrical plug (1) comprises a protective conductor contact (28), which is arranged in the plug housing (2), and comprises a protective conductor connector element (34), which is arranged in the plug housing (2) and is connected to the protective conductor contact (28) and at least one housing exterior part (3, 4) for establishing an electrically conducting connection, wherein the protective conductor connector element (34) is formed integrally with the protective conductor contact (28).