Plug Connector Contact Element Axial Offset Design
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Solution Overview
Problem
Existing plug connectors used in automobile manufacture face challenges in compact design due to the spacing requirements of crimp connections, limiting the number of contact elements and cables that can be accommodated, and are prone to vibration-induced failures.
Innovation Solution
The contact elements in the plug connector are arranged with axially parallel offsetting of plug contacts and crimp connections, featuring mirror-symmetrical primary and secondary locking elements, allowing for a two-row configuration and closer packing without mutual disturbance, and incorporating a crimp-arresting element for secure fixation and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimp connections are used with standard spacing, then reliable cable connection is achieved, but the plug connector size increases and the number of contact elements is limited
Solution Approach 1:
The patent applies dimensional change by offsetting plug contacts and crimp connections axially parallel to each other, and arranging locking elements mirror-symmetrically relative to a plugging means plane. This allows contact elements to be positioned in multiple planes (one alongside the other with 180° rotation), enabling a two-row arrangement that reduces the plug connector's footprint while maintaining reliable crimp connections
2Stability of the object's composition
If contact elements are spaced further apart to accommodate crimp connections, then crimp connection stability is improved, but the density of contact elements decreases
Solution Approach 1:
By transitioning from a single-plane arrangement to a multi-plane arrangement with axial offset, the patent enables closer spacing of contact elements in the mounting plane. The crimp connections are positioned in offset planes where they can overlap transversely without mutual disturbance, allowing higher contact element density while maintaining stability
Solution Approach 2:
The patent implements nesting by allowing crimp connections in adjacent contact elements to overlap in the mounted state transversely relative to the plugging direction. The crimp connections are arranged in different planes (offset axially parallel) so that they can be nested or overlapped without interfering with each other, maximizing space utilization
3Adaptability or versatility
If mirror-symmetrical locking elements are used, then two-row arrangement capability is enabled, but the manufacturing complexity increases
Solution Approach 1:
The patent employs mirror-symmetry (a form of controlled asymmetry) by arranging locking elements to be mirror-symmetrical relative to a plugging means plane. This allows the same contact element design to be used in both rows with 180° rotation, enabling two-row arrangement capability while maintaining manufacturing efficiency through component standardization
Data Source
AI summary
A contact element for plug connectors includes plug contacts arranged on the plug side and a crimp connection arranged on the cable connection side, and at least one primary locking element and at least one secondary locking element. The plug contacts and the crimp connection are offset from one another in an axially parallel manner; the at least one primary locking element has two locking springs which act transversely in relation to the plugging direction, and which are mirror-symmetrically arranged in relation to a plugging device plane; and the at least one secondary locking element is arranged in the contact element in a mirror-symmetric manner in relation to the plugging device plane, and has at least one secondary locking recess running transversely in relation to the plugging direction.