Segmented Bow-Shaped Earthing Connector for Circular Plug
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Solution Overview
Problem
Existing electrical connectors with metal housings face challenges in protecting against electric shock and require efficient protective grounding while optimizing assembly and installation space.
Innovation Solution
An electrical connector design featuring an electrically insulating contact holder with one contact connected to a metal housing, utilizing a bow-shaped electrically conductive connector that springs against the housing during assembly, providing a reliable and space-efficient protective grounding mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ring-shaped electrically conductive connector is used for protective earthing, then reliable electrical connection to the metal housing is achieved, but the connector requires excessive space in the insertion direction and complicates assembly
Solution Approach 1:
The electrically conductive connector is segmented into multiple contact elements distributed around the circumference, rather than using a continuous ring. This segmentation allows the contact elements to be positioned at different radial distances from the axis, enabling compact arrangement in the insertion direction while maintaining reliable electrical connection to the metal housing through at least one contact element
Solution Approach 2:
The contact elements are arranged in a multi-dimensional configuration rather than a simple planar ring. By distributing contact elements at different radial positions and angular positions around the circumference, the design achieves reliable electrical connection without requiring excessive length in the insertion direction, effectively utilizing three-dimensional space
2Reliability
If a ring-shaped electrically conductive connector is used for protective earthing, then electrical connection is established, but the assembly process becomes complex due to the need to insert the contact holder through the connector
Solution Approach 1:
The continuous ring-shaped connector is divided into separate contact elements. This segmentation allows the contact holder to be assembled first with the electrical contacts, and then the electrically conductive connector can be attached to the metal housing independently, eliminating the complex step of inserting the contact holder through the connector
Solution Approach 2:
The contact holder is pre-assembled with the electrical contacts before attaching the electrically conductive connector. This preliminary assembly simplifies the overall manufacturing process by separating the assembly steps and avoiding the need to maneuver the contact holder through the connector structure
3Reliability
If the connector length is increased to accommodate a ring-shaped electrically conductive connector, then protective grounding is achieved, but additional space for O-rings and coding features cannot be saved
Solution Approach 1:
The segmented contact elements allow for a more compact overall connector design. By positioning contact elements at different radial distances rather than requiring a large-diameter ring, the connector achieves protective grounding functionality with reduced volume, freeing up space for O-rings and coding features
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 solution ensures reliable protective grounding with reduced space requirements, allowing for easier assembly and the inclusion of additional features like O-rings or coding without increasing the connector's length, while compensating for manufacturing and assembly tolerances.
Implementation Method 1
an electrically conductive connector (6) which springs in the insertion direction of the connector against the electrically conductive part with a mechanical preload in the insertion direction
Data Source
Figure 1~4
Figure 5~8
AI summary
The invention relates to a multipole electrical plug connector (6) (circular connector) with a metallic housing (4). To ensure protective earthing of the housing (4) the invention proposes a U-shaped, axially resilient and electrically conductive connector (6), which reaches laterally around a contact holder (2) in the housing (4), is axially elastically pushed down by the housing (4) such that the housing (4) is contacted, and through which an earthing contact (7) extends, such that the connector electrically conductively connects the housing (4) to the earthing contact (7).