Snap-Lock Contact Carrier Assembly for High-Power Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high power contacts and cables face challenges in assembly complexity, positioning accuracy, and deformation rigidity, particularly when transmitting high charging currents, which limits their design and increases installation space and weight.
Innovation Solution
A contact carrier with a locking apparatus, such as tongue and groove means or snap-in hooks, allows for tool-less assembly and secure fixation within a plug-in connector housing, ensuring accurate positioning and reliable locking through visual verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect lines to contacts, then electrical conductivity and mechanical strength are improved, but assembly complexity and manufacturing time increase
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical pressing system. The contact carrier features pressing elements that mechanically press the contact elements into the housing, achieving reliable electrical connection through controlled mechanical force rather than welding, thus simplifying assembly while maintaining conductivity
Solution Approach 2:
The contact elements are designed to be self-positioning and self-securing within the contact carrier. The elastic pressing elements automatically apply the necessary contact force when the housing is assembled, eliminating the need for external welding equipment or complex assembly procedures while ensuring reliable electrical connection
2Power
If contact element size is increased to transmit higher charging currents, then current carrying capacity is improved, but installation space and weight increase
Solution Approach 1:
The patent changes the design parameters of the contact elements and their arrangement within the contact carrier. By optimizing the cross-sectional area, material properties, and geometric configuration of the contacts, the system achieves high current carrying capacity in a compact form factor, reducing installation space while maintaining power transmission capability
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement and vertical stacking of contact elements within the contact carrier. This allows multiple contact paths to be packed into a smaller footprint by utilizing the third dimension, effectively increasing current carrying capacity without proportionally increasing the installation footprint
3Power
If line cross section is increased for high power transmission, then power transmission capability is improved, but deformation rigidity and assembly difficulty increase
Solution Approach 1:
The patent divides the contact system into modular contact elements that are separately manufactured and then assembled into the contact carrier. This segmentation allows each element to be optimized for power transmission while maintaining flexibility for assembly, as the modular units can be independently positioned and secured without requiring manipulation of large rigid assemblies
4Reliability
If locking apparatus is added to secure contact carrier, then positioning accuracy and reliability are improved, but device complexity increases
Solution Approach 1:
The patent integrates the locking function directly into the contact carrier structure itself. The locking elements are combined with the carrier body, and the pressing elements serve dual purposes of both securing the contact elements and providing the locking mechanism, thereby achieving reliable positioning without adding separate complex locking apparatus
Data Source
AI summary
Disclosed is a contact carrier for receiving and retaining at least one plug contact, at which a line, cable can be electrically connected, the contact carrier having at least one locking device for fastening the contact carrier within a plug connector housing, the at least one locking device being formed by at least one snap hook, which, when the contact carrier is in the locked position within the plug connector housing, engages in a cut-out such that the contact carrier is fastened in the plug connector housing. The invention also relates to a method for mounting a contact carrier in a plug connector housing and to a plug connection, comprising a plug connector housing and a contact carrier received and fastened therein.