Modular Connector With Movable Contact Carrier

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing connector parts face challenges in accommodating manufacturing tolerances and ensuring easy plugging and electrical contact, particularly in environments with varying device dimensions, where conventional solutions often require complex mechanisms or fixed contact lengths.

Innovation Solution

A connector part design featuring modular contact inserts with a movable contact carrier that can be adjusted relative to the module housing, allowing leading contact inserts to engage first, facilitating staggered contact and easier alignment with mating parts, while maintaining stability through a spring-loaded mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional fixed contact elements are used, then manufacturing precision is maintained, but adaptability to different device dimensions and manufacturing tolerances deteriorates

Engineering Contradiction:

Improveadaptability to manufacturing tolerancesVSAvoidcontact position precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The contact element is designed with a movable contact carrier that can adjust its position dynamically during the plugging process. The spring-loaded mechanism allows the contact carrier to move relative to the module housing, enabling the connector to adapt to manufacturing tolerances and varying device dimensions while maintaining reliable electrical contact.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The position of the contact element is made variable through the spring-loaded contact carrier. The spring force allows the contact carrier to displace and adjust the contact position, changing the spatial parameter of the contact element to accommodate manufacturing tolerances and ensure proper engagement with mating connectors.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If all contact elements engage simultaneously, then connection speed is improved, but alignment difficulty and plugging force increase

Engineering Contradiction:

Improveease of pluggingVSAvoidinsertion force

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The contact elements are designed with different lengths to create a staggered engagement sequence. Longer contact elements engage first, establishing preliminary contact and guiding the alignment between connectors before shorter contact elements engage. This preliminary action reduces misalignment forces and makes plugging easier.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Different contact elements have different lengths, creating local variations in the contact structure. This local quality difference ensures that contact is made in a specific sequence, with longer elements engaging first to guide alignment, reducing the overall force required for proper connector engagement.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If modular contact inserts are used, then adaptability and flexibility are improved, but device complexity increases

Engineering Contradiction:

Improveflexibility of connector configurationVSAvoidcomplexity of contact insert structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The connector is divided into modular contact inserts that can be independently configured. Each contact insert contains a module housing with a spring-loaded contact carrier, allowing flexible combination of different contact elements while using a standardized modular design that reduces overall system complexity through repetition of proven components.

Inventive Principle:

Principle #1Segmentation

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 enhances the flexibility and ease of use by allowing individual adjustment of contact positions, simplifies the plugging process, and reduces the force required for insertion, while ensuring consistent and staggered contact engagement.

Implementation Method 1

the contact carrier is spring-loaded to the module housing along the plug-in direction

Methodology Applied

Scientific EffectSpring mechanism: Spring

Data Source

PatentEP3446371B1An electrical connector with modular contacts inserted into a holding frame

Publication Date: 2023.05.31 PHOENIX CONTACT GMBH & CO KG

Figure 1~2
Figure 3
Figure 4~5

AI summary

The invention relates to a plug-in connector part (20) for a plug-in connection to an associated mating plug-in connector part (11), comprising a holding frame (3) and a plurality of modular contact inserts (4, 4A, 4B) inserted into the holding frame (3), which in each case have a plug-in portion (43) that can be connected to the mating plug-in connector part (11) in a plug-in direction (S) provided with a contact element (40) arranged thereon for making contact with the mating plug-in connector part (11). According to the invention, at least one of the contact inserts (4B) has a module housing (44) inserted into the holding frame (3), and a contact support (45) arranged on the module housing (44) that is movable along the plug-in direction (S) relative to the module housing (44) forming the plug-in portion (43) of the contact insert (4B). In this way, a plug-in connector part is provided, which can be produced in an economical way, can be used in a flexible way at the same time, and which allows a leading contacting of at least one contact insert in relation to a second one.