Compact Connector Assembly for High Power Applications
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-power electrical devices face challenges in packaging due to the bulkiness and cost of external terminal blocks, as well as cumbersome electrical connections, which hinder compact design and increase costs.
Innovation Solution
A compact connector assembly featuring a conductor member with a wire cradle, tab members, and a nut, all unitarily formed from conductive metal, which securely couples wires using crimp members and is encapsulated in insulating plastic, allowing for a more compact and cost-effective solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external terminal block is used for high-power electrical connections, then reliable electrical connection is achieved, but the device becomes bulky and difficult to package
Solution Approach 1:
The patent merges the terminal block functionality directly into the motor housing by integrating a conductor assembly with terminal faces into the housing structure. This eliminates the need for separate external terminal blocks while maintaining reliable electrical connections for high-power applications.
Solution Approach 2:
The motor housing serves multiple functions: it provides mechanical protection for the motor components and simultaneously houses the electrical terminal connections. This multi-functionality reduces the overall device volume by eliminating separate components.
2Power
If external terminal blocks with conductors are used, then high-power electrical connections are established, but the connections become cumbersome due to conductor size and stiffness
Solution Approach 1:
The patent provides for terminal faces on opposite sides of the conductor assembly, allowing electrical connections to be made from different directions. This dimensional arrangement facilitates easier wiring by enabling connections from convenient access points rather than requiring long, stiff conductors to reach distant terminals.
3Power
If external terminal blocks are used, then high-power connections are achieved, but additional cost is incurred
Solution Approach 1:
By combining the terminal block functionality into the motor housing as an integrated conductor assembly, the patent eliminates the need for separate terminal block components, reducing part count and assembly steps, thereby lowering manufacturing costs while maintaining high-power electrical connection capabilities.
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 enables a compact, cost-effective, and secure electrical connection suitable for high-power applications, reducing bulkiness and improving packaging efficiency while maintaining high electrical integrity.
Implementation Method 1
The at least one crimp member is deformed against the wire to at least one of electrically and mechanically couple the wire to the wire cradle
Implementation Method 2
The threaded fastener cooperates with the nut to exert a clamping force that secures the terminal face and the mating terminal face to one another
Implementation Method 3
The wire cradle, the tab members and the conductor body are unitarily and integrally formed of a single piece of an electrically conductive metal
Data Source
AI summary
An electrical device with a conductor assembly having a conductor member and a nut. The conductor member has a wire cradle, a conductor body and a plurality of tab members. The wire cradle has a wire support portion and at least one crimp member extending from the wire support portion. The conductor body defines a terminal with a terminal face having a first hole formed therethrough. The wire cradle and the terminal face are disposed on opposite ends of the conductor body. Each of the tab members has a first portion, which is fixedly coupled to the conductor body, and a second portion that is coupled to the first portion and being spaced apart from the terminal. The tab members and the terminal form a cage. The nut is received in the cage and has a threaded aperture that is aligned to the first hole in the terminal face.