Electrical Connector Damping Structure Against Cable Vibration
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Solution Overview
Problem
Automotive electrical connectors face issues with mechanical vibration transmitted through wire cables, leading to fretting corrosion and increased electrical resistance due to excessive vibration amplitude or resonance frequency, which degrades signal transmission.
Innovation Solution
Incorporation of vibration damping elements, such as elastomeric materials with specific Shore-A hardness and design features like circumferential ribs, between the electrical terminal and the connector housing to reduce vibration amplitude and change frequency, preventing damage from resonant vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire cable is attached directly to electrical terminal, then electrical connection is simple and reliable, but vibration amplitude is too great causing fretting corrosion and increased electrical resistance
Solution Approach 1:
A vibration dampener is introduced as an intermediary component between the wire cable and electrical terminal. This dampener includes a first portion attached to the wire cable and a second portion attached to the electrical terminal, with a vibration damping material positioned between these portions to absorb and dissipate vibration energy, thereby reducing vibration amplitude transmitted to the terminal while maintaining electrical connection reliability
2Object-affected harmful factors
If vibration damping material is added between wire cable and terminal, then vibration amplitude is reduced, but device complexity increases
Solution Approach 1:
The vibration dampener is designed to merge multiple functions into a single integrated component. The first portion, second portion, and vibration damping material are combined into one assembly that simultaneously provides mechanical attachment and vibration damping functions, reducing the need for separate components and simplifying the overall connector structure
3Reliability
If vibration damping material is used, then fretting corrosion is prevented, but manufacturing complexity increases
Solution Approach 1:
The vibration dampener is pre-assembled with the wire cable before final installation into the connector. The first portion is attached to the wire cable in advance, and the vibration damping material is already positioned between the portions, allowing for simplified final assembly and reducing manufacturing complexity while ensuring proper installation for preventing fretting corrosion
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 damping elements effectively reduce vibration amplitude and alter frequency, preventing fretting corrosion and maintaining signal integrity by dissipating vibratory energy and avoiding resonant frequencies, thus enhancing the durability and performance of electrical connectors.
Implementation Method 1
vibration damping material positioned between the first portion and the second portion
Implementation Method 2
dissipating vibratory energy
Data Source
AI summary
An electrical connector assembly includes an electrical terminal attached to a wire cable, a connector housing defining a cavity in which the electrical terminal is disposed, and a resilient damping element disposed intermediate the electrical terminal and an inner wall of the cavity. The damping element is configured to reduce the amplitude and/or change the frequency of vibratory mechanical energy transmitted to the electrical terminal in the electrical connector through the wire electrical cable attached to the terminal.