Compact Power Connector With Reverse Crimping and Integrated Flange
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Solution Overview
Problem
Traditional power connectors are elongated due to crimping, which occupies more horizontal space and compromises the cosmetic finish and tensile strength when a separate flange is used to address the gap, especially in short profile applications.
Innovation Solution
A compact electrical power connector design featuring reverse crimping of wires to terminals within a cable holder, integrated with an over mold and inner mold to reduce horizontal length and enhance tensile strength, while incorporating an integrated flange for a flush cosmetic effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crimping is used to connect wires to terminals, then the connector achieves reliable electrical connection, but the connector becomes more elongated and occupies more horizontal space
Solution Approach 1:
The patent applies reverse crimping where the terminal is crimped onto the wire from the opposite direction compared to traditional crimping. This inversion allows the crimp to occur within the cable holder rather than extending outward, reducing the connector's horizontal length while maintaining reliable electrical connection through the same fundamental crimping mechanism
2Shape
If a separate flange is added to cover the gap around the receiving inlet frame, then the cosmetic finish is improved, but the connector integrity and tensile strength are compromised
Solution Approach 1:
The patent merges the flange into the main connector body as an integrated component rather than a separate attachment. This integration ensures that the flange and connector body move and deform together as a single unit, maintaining structural integrity and tensile strength while providing the cosmetic flush effect against the equipment surface
3Shape
If a separate flange is used to provide flush effect with equipment profile, then the cosmetic finish is enhanced, but the connector integrity is lessened
Solution Approach 1:
The flange is merged into the connector body as an integral part, ensuring that the structural composition remains unified and stable. This integration prevents the flange from acting as a separate weak point that could compromise connector integrity, while still achieving the desired flush effect with the equipment profile
Data Source
AI summary
A compact electrical power connector including a cable with cores surrounded by cable insulation. Each core includes a wire surrounded by core insulation. Removed cable insulation exposes each core and removed core insulation exposes each wire. Each wire is reverse crimped to a corresponding terminal placed within a cable holder that supports and routes each core. The assembled cable holder is inserted into a housing including housing terminal slots corresponding to each terminal. An inner mold is injected around the exposed end of the cable holder, any exposed core and a first portion of the terminal end of the cable. An over mold with integrated flange is injected around the exposed surfaces of the housing, the inner mold and a second portion of the terminal end of the cable adjacent the first portion.