Protective Conductor Bridge Connector for Compact Serviceable Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing connectors for high-current applications are complex to assemble, require significant space, and are heavy, making them difficult to handle.

Innovation Solution

A connector design featuring a plastic housing with a protective conductor bridge and plug insert, where the bridge is mounted on the housing and the insert is attached directly to the bridge, using screw or snap-fit connections, allowing for a compact, lightweight, and easy-to-assemble structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If a connector is designed to be disassemblable for repair and replacement, then ease of repair is improved, but reliability deteriorates due to potential contamination during disassembly and reassembly

Engineering Contradiction:

ImprovedisassemblabilityVSAvoidcontamination risk

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

A protective circuit bridge is introduced as an intermediary component between the housing and plug insert. This bridge remains in place during disassembly and reassembly operations, serving as a protective barrier that prevents contamination while allowing the connector to be serviced. The bridge acts as a mediator that enables ease of repair without compromising reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If the protective conductor bridge is integrated directly into the housing, then device complexity is reduced, but reliability deteriorates because the bridge cannot be replaced independently when damaged

Engineering Contradiction:

Improveintegration levelVSAvoidreplaceability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The connector is segmented into distinct replaceable components: the housing, the protective circuit bridge, and the plug insert. This segmentation allows the protective conductor bridge to be independently replaced when damaged, improving reliability without significantly increasing overall device complexity. Each component can be serviced independently.

Inventive Principle:

Principle #1Segmentation

3Strength

If the connector components are tightly integrated, then mechanical strength is improved, but ease of operation deteriorates due to difficulty in disassembly and reassembly

Engineering Contradiction:

Improvemechanical integrationVSAvoiddisassembly ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The connector employs dynamic fastening mechanisms that allow for easy disassembly and reassembly while maintaining strong mechanical connections during normal operation. The fastening system can transition between a locked state (providing strength) and an unlocked state (enabling ease of operation), resolving the contradiction between mechanical strength and ease of operation.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP4235976B1Connector comprising a protective circuit bridge

Publication Date: 2026.04.29 PHOENIX CONTACT GMBH & CO KG

Figure 1
Figure 2
Figure 3

AI summary

The invention relates to a connector (1) for mechanical and electrical connection with a corresponding mating connector, comprising a housing (2), a protective conductor bridge (3) and a plug insert, wherein the protective conductor bridge (3) is held on the housing (2), wherein the protective conductor bridge (3) has at least one connection area (9) for connection with the plug insert, and the plug insert is held on the at least one connection area (9).