Modular High-Current Connector for Space-Saving Installation
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Solution Overview
Problem
Existing high-current connectors require significant space for installation due to the parallel alignment of cable outlets and plug-in directions, making them inefficient in terms of space usage.
Innovation Solution
A modular high-current connector design featuring a screw connection between housing parts, with a pin contact and insulating body that protrude from the first housing part, allowing for space-saving installation and extension as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cable outlet runs parallel to the plug-in direction, then the connector can be structurally simple, but a lot of space is required when installing the connector
Solution Approach 1:
The patent changes the spatial arrangement by orienting the cable outlet perpendicular to the plug-in direction instead of parallel. This dimensional change allows the connector to achieve compact installation space while maintaining structural simplicity through the modular housing design with integrated contact elements.
2Device complexity
If the connector is designed as a fixed non-modular unit, then the structure is simpler, but the connector cannot be adapted to different current requirements
Solution Approach 1:
The connector is divided into modular housing parts (first housing part, second housing part, third housing part) that can be selectively assembled. Each housing part contains connection contact elements for electrical connection to lines, allowing the connector to be configured for different current capacities (400A, 800A, 1200A) by adding or removing modules while maintaining a simple base structure.
3Reliability
If the pin contact is completely enclosed by the insulating body, then insulation is improved, but space is required for electrical contacting of connection contact elements
Solution Approach 1:
The insulating body is designed with differentiated regions: it completely encloses the pin contact in the connection region to provide excellent insulation, while leaving the contact region protruding from the housing to enable electrical contacting. This local differentiation of insulating properties allows both complete insulation where needed and accessible contact where required.
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 modular design enables cost-effective production and simple, space-efficient installation, allowing for higher current transmission capacities (e.g., 400A, 800A, 1200A) while maintaining media-tight sealing and resistance to vibration.
Implementation Method 1
the pin contact has two circumferential grooves, in each of which there is arranged a ring seal. This protects the high-current connector on the plug-in side against the ingress of undesirable media (oil, water, dust, etc).
Data Source
AI summary
A modular high-current connector (1) has a first housing part (7) and a second housing part (8) connected thereto. The high-current connector (1) has a pin contact (9), the pin contact (9) being substantially cylindrical and having a connection region (A′) and a contact region (K′) for making electrical contact with a device socket or a mating connector. The contact region (K′) of the pin contact (9) projects out of the high-current connector (1) on the plug-in side.