Plug-In Connector Contact Layout for High-Pressure Power Transfer
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Solution Overview
Problem
Existing electrical plug-in connectors with sacrificial contact faces suffer from limited contact pressure, which restricts their current-carrying capacity and service life, especially when transmitting high voltages or currents.
Innovation Solution
The electrical plug-in connector features an operational contact face and a sacrificial contact face arranged on a circumferential surface, with the operational contact face positioned frontally to achieve higher contact pressure and optimized current-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a sacrificial contact face is equipped on the plug-in connector, then the service life and number of plugging cycles are increased, but the contact pressure is limited which restricts current-carrying capacity
Solution Approach 1:
The contact element is segmented into two distinct contact faces: a sacrificial contact face (7) arranged circumferentially for initial contact and a frontal contact face (6) arranged frontally for operational contact. This segmentation allows the sacrificial face to absorb flashover damage while the frontal face maintains high contact pressure for current transmission, resolving the contradiction between extended service life and sufficient contact pressure.
2Productivity
If a sacrificial contact face is equipped on the plug-in connector, then the number of plugging cycles is increased, but the current-carrying capacity is restricted
Solution Approach 1:
The contact element is segmented into two distinct contact faces: a sacrificial contact face (7) arranged circumferentially for initial contact and a frontal contact face (6) arranged frontally for operational contact. This segmentation allows the sacrificial face to absorb flashover damage while the frontal face maintains high contact pressure for current transmission, resolving the contradiction between extended service life and sufficient contact pressure.
3Force
If the operational contact face is arranged frontally, then the contact pressure is enhanced, but the structural complexity increases
Solution Approach 1:
The contact element merges multiple functions into a single integrated structure: it combines the sacrificial contact face (7) for protection, the frontal contact face (6) for high-pressure operational contact, and the electrical connection path between them. This merging achieves enhanced contact pressure without proportionally increasing structural complexity, as all functions are integrated into one component rather than requiring separate elements.
Data Source
AI summary
An electrical plug-in connector (2), having an electrical contact element (4) for electrical and mechanical contacting an electrical mating contact element (5) of an electrical mating plug-in connector (3). The contact element (4) has an operational contact face (6) and a sacrificial contact face (7) arranged on a circumferential surface. The sacrificial contact face (7) and the operational contact face (6) are arranged and designed so that in the course of plugging the plug-in connector (2) together with the mating plug-in connector (3), first the sacrificial contact face (7) contacts the mating contact element (5) and only then the operational contact face (6) contacts the mating contact element (5). The operational contact face (6) is arranged on a front face of the contact element (4) in order to contact the mating contact element (5) frontally.