Plug Connector With Laterally Inserted Protective Conductor Bridge
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Solution Overview
Problem
Existing connectors for large current transmission are complex to assemble, require significant installation space, and are often heavy, making them difficult to handle and manufacture efficiently.
Innovation Solution
A plug connector design featuring a holding frame with a screw connection area for the plug insert and a laterally inserted protective conductor bridge with tabs, allowing for secure electrical and mechanical connections, and utilizing fastening means for secure locking within a housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protective conductor bridge and plug insert are mounted separately in the housing, then secure electrical connection is achieved, but assembly becomes complex and installation space requirements increase
Solution Approach 1:
The protective conductor bridge is integrated into the plug insert as a single component. The bridge is formed as an integral part of the plug insert body, eliminating the need for separate mounting operations and reducing assembly steps while maintaining reliable electrical connection between protective conductors.
Solution Approach 2:
The plug insert is designed to perform multiple functions: it provides mechanical support for electrical contacts, establishes electrical connections, and simultaneously houses the protective conductor bridge structure. This multi-functional design reduces the number of separate components needed in the connector assembly.
2Reliability
If separate mounting of protective conductor bridge and plug insert is used, then electrical connection is secure, but installation space must be kept free increasing connector size
Solution Approach 1:
The protective conductor bridge structure is nested within the plug insert body. The bridge forms an internal framework that is contained within the outer dimensions of the plug insert, allowing both components to occupy the same spatial envelope without requiring additional installation space.
3Reliability
If traditional connector design is used, then electrical connection is established, but connectors become heavy making them difficult to handle
Solution Approach 1:
The protective conductor bridge is formed from a flexible conductive sheet material that can be bent and shaped to create the bridge structure. This thin-film approach significantly reduces the weight of the connector while maintaining electrical conductivity and mechanical integrity for securing the plug insert.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a plug (1) to be mechanically and electrically connected to a corresponding mating plug, comprising a housing, a protective conductor bridge (3), a retaining frame (4), and a plug insert (5); the retaining frame (4) is mounted on the housing and includes at least one connecting section (9) to be connected to the plug insert (5), and the plug insert (5) is mounted on the at least one connecting section (9); the protective conductor bridge (3) is laterally inserted into the retaining frame (4).