Metallic Plug Connector Module Grounding via Segmented Housing
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Solution Overview
Problem
Existing modular connector solutions are limited in their ability to establish reliable electrical grounding for large conductor cross sections due to the design of holding frames, which are typically only suited for up to 10 mm^2, and lack secure ground connections.
Innovation Solution
An electrical connector module with a metal housing and two-part design, featuring different types of fastening means that allow for secure mechanical fixation and electrical conductivity, ensuring reliable grounding even with larger conductors, and utilizing conductive materials for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting frames with limited ground connection design are used, then the connector module can be assembled with standard components, but the electrical ground connection is insufficient for large conductor cross-sections
Solution Approach 1:
The ground connection is divided into multiple parallel contact points between the housing and mounting frame, distributing the electrical current across several pathways. This segmentation allows the system to handle larger conductor cross-sections by providing multiple ground paths simultaneously, resolving the contradiction between reliable ground connection and adaptability to large conductors.
Solution Approach 2:
The housing serves dual functions: it provides mechanical support for the contact element and simultaneously acts as a ground connection pathway to the mounting frame. This multi-functionality allows the same structure to accommodate both small and large conductor cross-sections while maintaining reliable electrical ground connection, thus resolving the adaptability-reliability contradiction.
2Reliability
If the housing is made of metal to ensure electrical conductivity, then ground connection is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The electrical housing and ground connection pathway are merged into a single integrated component. The metal housing simultaneously provides mechanical protection, structural support, and electrical conductivity for ground connection. This merging eliminates the need for separate ground wires or additional conductive components, reducing manufacturing complexity while maintaining reliable electrical conductivity.
Solution Approach 2:
The housing is designed to perform multiple functions: mechanical support, insulation (in non-metallic versions), and electrical ground conduction (in metallic versions). By making the housing itself the ground pathway, the design eliminates additional components and simplifies manufacturing, resolving the contradiction between reliability and ease of manufacture.
3Stability of the object's composition
If mounting elements are provided on the housing for secure fixation, then mechanical stability is improved, but the device complexity increases
Solution Approach 1:
The mounting elements are integrated directly into the housing structure rather than being separate components. The housing itself incorporates the mounting features, combining the functions of structural support and mechanical fixation. This integration reduces the number of separate parts and simplifies the overall device complexity while maintaining stable mechanical fixation.
Solution Approach 2:
The mounting elements are strategically positioned and designed with asymmetric features that provide secure fixation in critical directions while minimizing complexity in other areas. This asymmetric design allows for stable mechanical attachment without requiring complex mounting structures in all directions, resolving the contradiction between stability and device complexity.
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 reliable electrical contact and secure grounding for larger conductor cross sections, ensuring effective electrical connectivity and mechanical stability, while allowing for flexible assembly and cost-effective production.
Implementation Method 1
The housing (2) is made from a metallic material. The contact element (3) is in direct contact with the housing (2) so that a ground can be transferred via the housing (2) to a mounting frame (8).
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a plug connector module (1) for use in a retaining frame (8) of a modular plug connector. The plug connector module (1) is provided to make electrical contact with the retaining frame (8). A housing that forms the plug connector module (1) is therefore metallic and can be connected to the retaining frame (8) in a mechanical and electrically conductive manner by means of a first type of fastening means (5) and a second type of fastening means (7).