Modular Plug Connector With Integrated Overvoltage Protection

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Solution Overview

Problem

Existing modular connectors often require significant assembly, cabling, and space for overvoltage protection modules, which can be cumbersome and inefficient, especially when retrofitting electrical devices without a DIN rail.

Innovation Solution

A modular plug connector with an integrated overvoltage protection module that includes a contact spring for diverting overvoltages to a metal holding frame, allowing for separate and flexible installation of overvoltage protection within individual electrical devices, reducing the need for conventional overvoltage protection devices and saving space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional overvoltage protection devices are used, then reliable overvoltage protection is achieved, but assembly complexity and space requirements increase significantly

Engineering Contradiction:

Improveovervoltage protectionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the overvoltage protection function with the modular plug connector by integrating a protection element and contact spring directly into the connector housing. This merging eliminates the need for separate overvoltage protection devices, reducing assembly steps from multiple component installations to a single integrated unit installation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The modular plug connector is designed to serve multiple functions: signal transmission, power supply, and overvoltage protection. The connector housing simultaneously provides structural support, electrical insulation, and housing for the protection element, while the contact spring provides both mechanical contact and overvoltage diversion pathways.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate overvoltage protection modules are installed, then adequate protection is provided, but space requirements and cabling efforts increase

Engineering Contradiction:

Improveovervoltage protectionVSAvoidinstallation space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The protection element and contact spring are integrated within the existing connector housing volume, eliminating the need for separate protection modules and their associated mounting spaces. The overvoltage protection functionality is achieved within the same spatial envelope as the signal and power transmission functions.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If retrofitting is performed with conventional protection devices, then overvoltage protection is added, but assembly time and complexity increase

Engineering Contradiction:

Improveovervoltage protectionVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The overvoltage protection functionality is pre-integrated into the modular plug connector during manufacturing. The protection element and contact spring are positioned and configured in advance, so that when the connector is installed, the overvoltage protection is immediately operational without requiring additional assembly steps or configuration.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If modular connector without integrated protection is used, then flexibility in module selection is maintained, but overvoltage protection requires additional components

Engineering Contradiction:

Improvemodule selection flexibilityVSAvoidcomponent quantity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The modular plug connector design allows different module types (signal modules, power modules, combined modules) to all include the integrated overvoltage protection functionality. The protection element and contact spring are designed to work with various module configurations, maintaining flexibility while eliminating the need for separate protection components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution simplifies the installation of overvoltage protection, reduces space and cabling requirements, and allows for tailored protection for each device, enhancing flexibility and reducing the risk of inappropriate protection configurations.

Implementation Method 1

The connector module has at least one contact spring for making electrical contact with the metal holding frame and for diverting overvoltages to the metal holding frame

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3510676B1Overvoltage protection module for a modular plug connector

Publication Date: 2023.08.16 HARTING ELECTRIC GMBH & CO KG

Figure 1~1b
Figure 2~2e
Figure 3~4

AI summary

The invention relates to a connector module (1) for a modular plug connector (5), said plug module (1) having an overvoltage protection with at least one earth connection. The invention further relates to a connector and a modular plug connector having a connector module (1) of the above type.