Round Plug Connector Equipotential Bonding for Conductive Housings
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Solution Overview
Problem
Existing circular connectors lack effective equipotential bonding, particularly in their electrically conductive housings, posing potential hazards during handling.
Innovation Solution
A circular connector design featuring an electrically conductive housing with an equipotential bonding element that connects to an equipotential bonding conductor, allowing fault currents and overvoltages to be diverted through the equipotential bonding conductor, ensuring safe handling and reduced interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an electrically conductive housing is used in circular connectors, then shielding and structural strength are improved, but equipotential bonding and user safety deteriorate
Solution Approach 1:
The connector is divided into electrically isolated components: the conductive housing forms one electrical domain, while the contact elements with insulating bodies form separate electrical domains. The insulating bodies segment the conductive paths, preventing unwanted electrical coupling between the housing and contact elements, thus maintaining equipotential bonding within each domain while preserving shielding from the conductive housing.
Solution Approach 2:
Insulating bodies are introduced as intermediary elements between the conductive housing and the contact elements. These intermediaries electrically isolate the housing from the contact elements, preventing fault currents from propagating through the housing to the user, thus improving equipotential bonding and safety while allowing the housing to maintain its shielding function.
2Reliability
If contact elements are embedded in insulating bodies, then electrical isolation is improved, but manufacturing complexity increases
Solution Approach 1:
The insulating bodies and contact elements are merged into a single integrated component. The contact elements are directly embedded within the insulating bodies during one manufacturing process, eliminating the need for separate assembly steps. This merging reduces manufacturing complexity while maintaining the electrical isolation provided by the insulating bodies.
Solution Approach 2:
The contact elements are pre-positioned and embedded within the insulating bodies before the final assembly of the connector. This preliminary action of embedding during the insulator fabrication process simplifies subsequent assembly steps and reduces overall manufacturing complexity while ensuring proper electrical isolation is achieved.
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
The design provides improved equipotential bonding, safely dissipating fault currents and overvoltages, enhancing user safety and reducing interference in electrical connections.
Implementation Method 1
the equipotential bonding element electrically contacts the equipotential bonding conductor, and the equipotential bonding element is electrically connected to the connector housing by means of a contact shell
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The present invention relates to a circular connector (100) comprising: - an electrically conductive connector housing (20); - a plurality of contact conductors (10; 12), wherein the plurality of contact conductors (10; 12) comprises an equipotential bonding conductor (12); - an insulator (40), wherein the plurality of contact conductors (10; 12) is embedded at least section by section in the insulator (40); and - an equipotential bonding element (50); -- wherein the equipotential bonding element (50) receives the insulator (40) section by section, -- wherein the equipotential bonding element (50) electrically contacts the equipotential bonding conductor (12), and -- wherein the equipotential bonding element (50) is electrically connected to the connector housing (20) by means of a contact shell (30). The invention further relates to the use of such a circular connector (100), as well as a method for manufacturing such a circular connector (100).