Plug Connector Contact Structure for Low-Impedance Power Transfer
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Solution Overview
Problem
Existing plug connections in electric or hybrid vehicles experience increased transfer impedance and oxidation at contact surfaces, limiting the transmission of higher currents and voltages due to multiple contact transitions and interposed contact sleeves.
Innovation Solution
A plug connector assembly with direct contact surfaces formed on electrical conductors or contact elements, orthogonal to the longitudinal axis, and spring elements pressing against mating contact surfaces to maintain constant contact pressure, minimizing transitions and preventing oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact sleeves with contact strips are used between plug connector and mating plug connector, then electrical contacting is achieved, but transfer impedance increases and contact reliability deteriorates over time
Solution Approach 1:
The patent removes the contact sleeve component entirely from the connection path. Instead of having contact element -> contact sleeve -> mating contact element, the invention achieves direct contact between contact element and mating contact element, extracting the harmful intermediate component that caused increased transfer impedance and oxidation issues
Solution Approach 2:
The contact element and electrical conductor are merged into a single integrated component. The contact surface is formed directly on the electrical conductor or on a contact element that is connected as a single piece to the electrical conductor, eliminating the need for separate contact sleeves and reducing the number of contact transitions
2Object-affected harmful factors
If contact surfaces are formed directly on electrical conductors, then transfer impedance is minimized, but contact pressure must be maintained through additional spring elements
Solution Approach 1:
The spring elements serve multiple functions: they maintain constant contact pressure between the contact surfaces, compensate for manufacturing tolerances and thermal expansion, and ensure reliable electrical contact throughout the product lifecycle. This multi-functionality justifies the additional component while achieving the goal of minimized transfer impedance
3Reliability
If spring elements press contact surfaces against mating contact surfaces, then contact pressure is maintained and oxidation is prevented, but device complexity increases
Solution Approach 1:
The spring elements are pre-loaded to exert constant contact pressure on the contact surfaces from the beginning of operation. This preliminary action ensures that contact surfaces remain firmly pressed together throughout the product lifecycle, preventing oxidation and maintaining low transfer impedance without requiring complex active control mechanisms
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
Minimizes transfer impedance and prevents oxidation, ensuring reliable transmission of high currents and voltages by maintaining consistent contact pressure and reducing age-related contact fatigue.
Implementation Method 1
at least one spring element (15) is arranged in the plug connector housing (4) for each electrical conductor (3), which is connected, in each case, to the respective electrical conductor (3), and is configured to press the contact surface (27) against the mating contact surface (26)
Data Source
AI summary
A plug connector assembly having a plug connector and a plug connector housing and multiple electric conductors, each electrical conductor having an axial end region inside the glug connector housing. A contact surface on each electric conductor electrically contacts a mating contact surface of a mating contact element of a mating plug connector. Each contact surface has a directional component orthogonal to a longitudinal axial direction of the electric conductor. At least one spring element for each electric conductor pushes the contact surface against the mating contact surface. The mating contact surface has a directional component orthogonal to the longitudinal axial direction of the mating contact element. Each contact surface additionally has a directional component in a second direction that is orthogonal to the first orthogonal direction. A securing element pushes the contact surface of each electric conductor against the mating contact surface in the second orthogonal direction.