CNT Electrical Connector with Grooved Blocks for Automotive Wiring
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Solution Overview
Problem
Aluminum wire conductors used in automotive applications have reduced break strength and elongation strength compared to copper, and carbon nanotube strands lack sufficient conductivity and are difficult to terminate due to galvanic corrosion concerns, necessitating a lightweight alternative for small gauge wiring.
Innovation Solution
An electrical connector assembly that uses carbon nanotube conductors with a housing design featuring grooves and locking features to achieve direct physical and electrical contact between connector blocks, eliminating the need for separate terminals and providing an interference fit or compressive force to enhance conductivity and prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum wire conductors are used to reduce vehicle mass, then weight is reduced, but break strength and elongation strength are reduced
Solution Approach 1:
The patent changes the material parameter from traditional metals (copper, aluminum) to carbon nanotubes, which have superior strength-to-weight ratio. This allows achieving both weight reduction and strength improvement simultaneously by selecting a material with different physical properties
Solution Approach 2:
The invention uses composite construction by combining carbon nanotube strands with a connector block and housing structure. The connector assembly acts as a composite system that leverages the high strength of CNTs while providing structural support through the connector block, solving the strength deficiency of lightweight conductors
2Weight of moving object
If carbon nanotube strands are used for lightweight wiring, then weight is reduced and strength is improved, but conductivity is insufficient and termination is difficult
Solution Approach 1:
The connector block serves as an intermediary element between the carbon nanotube strands and the electrical circuit. It provides a interface that facilitates reliable electrical connection without requiring direct termination of CNTs, thus solving the termination difficulty while maintaining the benefits of lightweight conductors
Solution Approach 2:
The invention extracts the termination function from the conductor itself and places it in the connector block. By separating these functions, the CNT strands can focus on providing lightweight conduction while the connector block handles the complex termination and connection tasks, improving overall reliability
3Ease of manufacture
If conventional crimped terminals are used on CNT strands, then connection is achieved, but galvanic corrosion occurs due to dissimilar materials
Solution Approach 1:
The connector block acts as an intermediary that eliminates direct contact between dissimilar metals. By introducing this intermediate component, the patent prevents galvanic corrosion while still enabling easy termination of CNT strands, thus resolving the contradiction between ease of manufacture and corrosion resistance
4Reliability
If soldered terminals are used on CNT strands, then connection is achieved, but soldering is difficult due to poor wetting
Solution Approach 1:
The invention extracts the soldering operation from the CNT strand termination process and relocates it to the connector block. This separation allows standard soldering procedures to be used on the connector block while the CNTs are simply inserted into the block, dramatically easing manufacturing while maintaining connection reliability
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 provides improved strength and conductivity for small gauge wiring, reduces the risk of galvanic corrosion, and eliminates the need for terminal attachments, resulting in a lightweight and cost-effective interconnection method suitable for automotive applications.
Implementation Method 1
the housing is further configured to hold the first and second connector blocks together such that the first electrical conductor is in direct physical and electrical contact with the second conductor and such that the first and second conductors are compressed by one another
Implementation Method 2
The housing may be dimensioned such that the first and second connector blocks cause an interference fit condition between the first and second conductors
Implementation Method 3
the housing may include a spring element configured to exert a compressive force on the first and second connector blocks, thereby causing an interference fit condition between the first and second conductors
Data Source
AI summary
An electrical connector assembly is presented herein. The electrical connector includes a pair of connector blocks each defining a groove in an end surface that is configured to have an electrical conductor of an electrical cable partially disposed within it, e.g. a carbon nanotube conductor. The electrical connector also includes a housing configured to receive connector blocks, align the groove of one connector block with the groove of the other connector block, and hold the connector blocks together such that the electrical conductors within the grooves are in direct physical and electrical contact with the one another and are compressed. An electrical cable assembly incorporating such as connector and an method of manufacturing a cable assembly using such a connector is also presented.