Segmented Contact Insert Assembly for Compact Electrical Connectors
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Solution Overview
Problem
Existing electrical connectors for applications in automation technology fail to meet criteria of minimal space usage and cost-effectiveness, particularly in Single Pair Ethernet interfaces, as they often require complex assembly processes that can damage coding and undercuts.
Innovation Solution
Designing the contact insert in multiple parts, comprising a contact body and a contact sleeve, with projecting retaining elements for a positive and/or force-fit connection, allowing for easy assembly and modular design, and connecting the contact insert to a locking unit via stops and fastening elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece contact insert is used, then the structure is simple, but it requires pressing through an opening in the locking unit which damages the necessary undercuts and coding
Solution Approach 1:
The contact insert is divided into two separate parts: a contact body and a contact sleeve. These parts are inserted into the locking unit separately through opposite openings, avoiding the need to press a one-piece insert through a single opening which would damage the undercuts and coding. The segmented design allows each part to be positioned without compromising the locking unit's structural integrity.
2Device complexity
If a one-piece contact insert is used, then the structure is simple, but it requires excessive compression of the circumferential stop which could damage coding
Solution Approach 1:
By segmenting the contact insert into a contact body and contact sleeve that are inserted from opposite sides, the assembly process distributes the mechanical stress and eliminates the need for excessive compression of the circumferential stop. This prevents damage to any coding located on the stop while achieving secure positioning.
3Ease of manufacture
If a multi-part contact insert is used, then assembly is easier and less damaging, but the device complexity increases
Solution Approach 1:
The contact body and contact sleeve are designed to connect to each other through retaining elements, merging their functions into a unified contact insert assembly. This connection mechanism ensures that while the parts are assembled separately to avoid damage, they ultimately function together as an integrated unit, minimizing the practical impact of the increased part count.
4Adaptability or versatility
If a multi-part contact insert is used, then modular design is enabled, but the number of components increases
Solution Approach 1:
The contact sleeve is designed as a universal component that can be used across different connection types. The modular design allows the contact body to be varied for different connection requirements (crimping, soldering, screw terminals, cage clamp) while the contact sleeve remains consistent, reducing the overall variety of unique components needed compared to fully custom designs for each connection type.
Data Source
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AI summary
An electrical connector comprising a locking unit (1) and a contact insert (11) at least partially surrounded by the locking unit (1), wherein at least one contact (9) is arranged in and/or on the contact insert (11), and wherein the contact insert (11) is formed from a contact body (12) and a contact sleeve (13) connected to the contact body (12). Furthermore, a contact insert (11) and a method for manufacturing an electrical connector are described.