Plug-in Connector Crimping Element for Contact Fixation
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Solution Overview
Problem
Existing connector parts face challenges in reliably and precisely fixing contact elements to a housing part, especially in scenarios with limited installation space and high conductor cross-sections, requiring methods that maintain low tolerances and handle stiff cable cores.
Innovation Solution
The use of a caulking element on the housing part that moves along a caulking direction to interact with a caulking section, allowing contact elements to be inserted without force and then caulked into place, creating a resilient and precise fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If contact elements are pressed into the housing component, then they are firmly attached, but the positioning precision and tolerance control deteriorate
Solution Approach 1:
The fixing process is segmented into two distinct phases: a preliminary insertion phase where contact elements are inserted into receiving openings without force, and a subsequent crimping phase where the crimping element is moved in the crimping direction to create positive connection. This segmentation allows precise positioning during insertion and secure fixation during crimping, resolving the contradiction between attachment strength and positioning precision.
2Reliability
If contact elements are snapped into place with positive connection, then they are reliably fixed, but the device complexity increases
Solution Approach 1:
The crimping element is designed to perform multiple functions: it provides the crimping action for positive connection, guides the contact elements during insertion, and ensures uniform fixation across all contact elements. By merging these functions into a single element, the patent achieves reliable fixing without proportionally increasing device complexity.
Solution Approach 2:
The crimping element interacts with crimping sections on the housing component to automatically achieve the crimping action when moved in the crimping direction. This self-service mechanism reduces the need for complex external tools or manual operations, maintaining simplicity while ensuring reliable fixation.
3Quantity of substance
If conductors with large cross-section are connected, then the electrical capacity increases, but the handling difficulty and stress on contact elements increases
Solution Approach 1:
Contact elements are first inserted into receiving openings without force, establishing their position before the conductors are connected. This preliminary action allows the stiff conductors with large cross-section to be connected to the positioned contact elements without requiring precise alignment during the connection process, thereby easing handling while maintaining electrical capacity.
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 method enables simple and defined fixing of contact elements with low tolerances, effectively handling stiff cable cores and ensuring reliable assembly without the need for external tools, while also providing an electrical connection for shielding conductors.
Implementation Method 1
the crimping element is movable along a crimping direction to the housing part and can be brought into interaction with a crimping section of the housing part by moving it in the crimping direction, so that in an assembly state at least one contact element is crimped to the housing part
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A plug-in connector part (1) for plug-in connection to a mating plug-in connector part (3) comprises a housing part (21), which has at least one receiving opening (210), and at least one electrical contact element (23), which is arranged in the at least one receiving opening (210). In this case, a caulking element (22) is additionally provided, which caulking element is arranged on the housing part (21), can be moved along a caulking direction (V) in relation to the housing part (21) in a preassembly state of the plug-in connector part (21) and can be brought into interaction with a caulking section (212) of the housing part (21) by movement in the caulking direction (V), so that the at least one contact element (23) is caulked with the housing part (21) in an assembly state. A plug-in connector part which allows manufacture while contact elements are reliably held in a precise position on a housing part and additionally allows simple handling is provided in this way.