Plug Connector Bridging Layout for Compact Current Distribution
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Solution Overview
Problem
Existing plug connectors face challenges in safely distributing currents of individual conductors within multi-strand cables, particularly in data centers, due to the need for sufficient space and reliable mechanical connections, which can lead to hazards if the bridging of conductors inside the housing fails.
Innovation Solution
A compact plug connector design featuring a contact insert with multiple contact elements and bridging elements that are arranged in specific configurations to securely connect and distribute currents, utilizing crimping technology and snap-in mechanisms for reliable electrical connections and secure attachment, while allowing for customization through interchangeable bridging elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are bridged inside the plug connector housing using conductor terminals, then electrical connection between conductors is achieved, but the housing size must be increased and hazard potential increases
Solution Approach 1:
The bridging function is extracted from the housing interior and relocated to external bridging elements that connect to contact elements on the housing surface. This allows the bridging function to be implemented without increasing housing volume, while maintaining reliable electrical connection through dedicated bridging elements that can be securely attached to contact elements.
2Reliability
If conductors are bridged inside the plug connector housing, then electrical connection is established, but hazard potential increases due to mechanical connection failure risk
Solution Approach 1:
The bridging function is extracted from the housing interior to external bridging elements. This relocation eliminates the hazard of internal conductor exposure while maintaining reliable electrical connection. The bridging elements can be securely attached to contact elements and provide isolated bridging connections that do not pose the same safety risks as internal conductor bridging.
Solution Approach 2:
Bridging elements serve as intermediary components that establish electrical connection between contact elements without requiring direct conductor-to-conductor contact inside the housing. These intermediaries provide a controlled and safe bridging mechanism that reduces hazard potential while maintaining connection reliability.
3Ease of operation
If a larger housing is selected to accommodate bridging components, then sufficient space for conductor bridging is provided, but the overall device size increases
Solution Approach 1:
The bridging functionality is extracted from the housing interior and implemented through external bridging elements that attach to contact elements on the housing surface. This allows full bridging capability to be maintained while avoiding the need to increase housing volume, as the bridging components are located outside the housing boundaries.
4Ease of manufacture
If standard contact elements are used without customization, then manufacturing is simplified, but adaptability to different bridging configurations is reduced
Solution Approach 1:
Contact elements are designed with universal gripping hands that can accommodate different bridging element configurations. The gripping hands are shaped to universally engage with various bridging element geometries, allowing a single contact element design to support multiple bridging configurations. This maintains manufacturing simplicity while providing adaptability through the universal interface between contact elements and bridging elements.
Data Source
AI summary
A plug connector is provided having a plug-in side, a connection side, and a plug-in direction, which extends from the connection side to the plug-in side, towards a mating connector or a socket, the plug connector having a contact insert and at least four contact elements, the contact elements being positioned in the contact insert in dedicated receiving regions, the plug connector having at least two bridging elements for the electrical connection of in each case at least two contact elements, the bridging elements being positioned one behind the other as viewed in the plug-in direction.