Cable Connector Prong Layout for Higher Interconnection Density
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Solution Overview
Problem
Existing cable connectors for autonomous vehicles are limited in their ability to facilitate multiple physical and electrical interconnections within a small physical space, adhering to standardized design conventions that typically allow only single interconnections per cell, which restricts the efficiency and space utilization in automotive electrical systems.
Innovation Solution
A cable connector design featuring first and second electrical prongs with specific configurations, including straight and curved portions, and a mounting structure that allows multiple interconnections within a standardized physical space, enabling multiple discrete conductors to be connected simultaneously, thereby increasing interconnection density without altering the physical dimensions of the connector cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standardized design conventions are followed with single interconnection per cell, then compatibility with existing design conventions is maintained, but the number of interconnections per unit space is limited
Solution Approach 1:
The connector cell is divided into multiple compartments, with each compartment housing a separate contact element. This segmentation allows multiple independent interconnections to coexist within a single standardized cell footprint, effectively multiplying the interconnection density while preserving the external dimensions required by existing design conventions
Solution Approach 2:
The invention transitions from a single-plane contact arrangement to a three-dimensional multi-compartment structure. By stacking contact elements vertically and organizing them in multiple layers within the cell, the design achieves higher interconnection density without increasing the cell's external footprint, thus maintaining compatibility with standardized spacing requirements
2Quantity of substance
If multiple interconnections are implemented within a small physical space, then interconnection density is increased, but the complexity of the connector structure increases
Solution Approach 1:
The mounting structure is designed as a universal platform that can accommodate multiple different contact element configurations within the same cell type. The standardized mounting features and compartment arrangement allow the same physical cell design to support various interconnection patterns, reducing the need for multiple specialized connector designs
Solution Approach 2:
Multiple contact elements and their associated mounting features are integrated into a single molded connector body. This merging of multiple functional elements into one unified structure reduces the total number of separate components, simplifies assembly, and decreases overall connector complexity while maintaining high interconnection density
3Productivity
If multiple contact elements are integrated into a single connector, then the number of assembly steps is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
Contact elements are pre-positioned and secured within their respective compartments during the connector molding process itself, rather than being attached separately afterward. This preliminary action ensures precise positioning is achieved during manufacturing, and the pre-assembled connector requires minimal additional assembly steps, maintaining both high precision and assembly efficiency
Data Source
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AI summary
A cable connector includes a first portion, a second portion, a first electrical prong, and a second electrical prong. The first portion defines a cavity. The second portion is adjacent to the first portion. The second portion includes a mounting structure defining a first cross-sectional void region within the cable connector and a second-cross-sectional void region within the cable connector opposite the first cross-sectional void region. The first electrical prong is disposed, in part, in the first cross-sectional void region and extends from the second portion. The second electrical prong is disposed, in part, in the second cross-sectional void region and extends from the second portion.