High-Current Plug Contact With Split Strands for Vibration Damping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-current applications in electric vehicles require connectors that can efficiently transmit high currents while minimizing contact resistance and thermal stress, which is challenging due to the conflict between flexible mechanical design and high current-carrying capacity.
Innovation Solution
The electrical plug contact system divides the electrical conduction path into multiple strands, allowing for independent vibration damping and mechanical decoupling, using a braided cable structure where each strand is connected to a contacting element, ensuring effective vibration damping without additional damping elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large conductor cross-section is used to achieve high current-carrying capacity, then current-carrying capacity is improved, but flexibility and mechanical design are worsened
Solution Approach 1:
The cable is divided into multiple separate conductor strands instead of using a single solid conductor. Each strand can move independently, providing flexibility while maintaining high total current-carrying capacity. The strands are bundled together to form the cable, allowing mechanical decoupling and vibration damping at the strand level.
2Reliability
If additional damping elements are added to improve vibration damping, then vibration damping is improved, but device complexity and manufacturing cost are worsened
Solution Approach 1:
The conductor strands themselves serve as the damping element through their own flexibility and movement. The strands naturally absorb and dissipate vibration energy through their independent motion, eliminating the need for separate damping components. The cable construction inherently provides vibration damping functionality.
3Reliability
If contact elements are fixed to multiple separate strands, then vibration damping is improved, but manufacturing complexity is worsened
Solution Approach 1:
The contact elements serve multiple functions: they provide electrical contact with the mating connector and simultaneously act as fixation points for multiple conductor strands. Each contact element is designed to accommodate and secure several strands, simplifying the assembly process while maintaining vibration damping benefits.
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
This design achieves better vibration damping while maintaining high current-carrying capacity, is cost-effective, and ensures reliable electrical and mechanical contacting, enhancing the service life of the connector.
Implementation Method 1
the cable has a damping section adjacent to the end, in which the cable is split into a plurality of separate conductor strands
Implementation Method 2
protect the contact points, which are subject to life-limiting frictional wear
Implementation Method 3
The contact elements are suitable for electrically and mechanically contacting the mating contact element
Implementation Method 4
an electrical plug contact for high-current applications is proposed according to claim 1. The plug contact comprises a housing which extends along a longitudinal axis and has an interior space for receiving a mating contact element
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to an electrical plug contact for high-current applications. The plug contact comprises a housing (20), which extends along a longitudinal axis (A) and has an interior space (21) for receiving a mating contact (8). The plug contact also comprises a cable (1), which is formed from a plurality of stranded wires (5a). The cable (1) is guided from an outside space (22) of the housing (20) into the interior space (21) of the housing (20) and is fastened to the housing (20). The cable (1) has an end (1a) in the interior space (21). The cable (1) has a damping portion (4) adjacent to the end (1a), in which damping portion the cable (1) is split into a plurality of separate line strands (5). A contacting element (6) suitable for electrically and mechanically contacting the mating contact (8) is fastened to at least two line strands (5).