Plug Connector Lance Element Arc Diversion

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Solution Overview

Problem

Existing plug connectors face damage from arcs when establishing or breaking connections under load, particularly in connectors with switching capacity, as arcs can cause destruction during frequent switching processes.

Innovation Solution

A plug connector part with a lance element featuring a resilient shaft and a contacting portion that remains in contact with the mating contact element after the primary contact is broken, diverting arcs away from the main contact element and using an arc-resistant material for the contacting portion to tolerate damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the contact element is used for both power transmission and switching under load, then the connector can perform multiple functions, but the contact element is damaged by arcs during switching

Engineering Contradiction:

Improveswitching capacityVSAvoidcontact element durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The connector is divided into two separate contact elements: a first contact element for power transmission and a second contact element for switching operations. This segmentation allows each contact element to be optimized for its specific function, preventing arc damage to the power transmission contact while maintaining switching capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second contact element acts as an intermediary that handles the arc-producing switching operations, protecting the first contact element from direct arc exposure. The intermediary contact element absorbs the harmful effects of arcing during connection and disconnection

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If measures are provided to protect against arc damage, then the contact element is protected, but the device complexity increases

Engineering Contradiction:

Improvearc protectionVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second contact element is designed as a sacrificial component that can be easily replaced. It absorbs arc damage during switching operations, protecting the more critical first contact element. When worn, only the second contact element needs replacement

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Effectively prevents damage to the contact element by ensuring arcs occur between the lance element and the mating contact element, rather than the primary contact, thus protecting the contact element from arc-induced damage.

Implementation Method 1

a lance element that comprises an at least partially resilient shaft

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

an arc may be produced between the contact element and the mating contact element... the contacting portion remains in electrical contact with the mating contact element

Methodology Applied

Scientific EffectElectric Arc: Electric Arc

Data Source

PatentUS10784617B2Plug connector with a contacting portion for diverting an electric arc

Publication Date: 2020.09.22 PHOENIX CONTACT GMBH & CO KG

AI summary

A plug connector part for electrically contacting a mating plug connector part includes: a contact element, which is engageable in a plug-in manner with a mating contact element of an associated mating plug connector part in an insertion direction for electrical contacting; and a lance element that includes an at least partially resilient shaft and a contacting portion, the shaft being connected to the contact element at a first end and the contacting portion being arranged at a second end of the shaft such that the contacting portion remains in electrical contact with the mating contact element of the mating plug connector part when the connector part is released from the mating plug connector part after the electrical contact between the contact element and the mating contact element has already been broken.