Electrical Connector Insulation Arrangement for Safe Fastening
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Solution Overview
Problem
Conventional electrical connector assemblies in motor vehicles pose a risk of electrical hazards during assembly due to direct contact with high voltage components, as the fastening assembly is not electrically isolated from the energized terminals.
Innovation Solution
The electrical connector assembly incorporates an insulation arrangement using an electrically insulating sleeve and washer, along with a terminal holder made of insulating material, to ensure that the fastening assembly remains electrically isolated from the terminals, allowing safe assembly with standard metallic tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the fastening assembly is made of metallic material for mechanical strength, then the fastening capability is improved, but electrical hazard risk increases due to direct contact with energized terminals
Solution Approach 1:
An insulating material is introduced as an intermediary between the metallic fastening assembly and the energized terminals. This insulating material allows the fastening assembly to maintain its metallic structure and fastening capability while preventing direct electrical contact with the terminals, thus eliminating the electrical hazard risk.
2Object-affected harmful factors
If special electrically insulated tools are used to fasten the connector assembly, then electrical safety is improved, but assembly complexity and cost increase
Solution Approach 1:
The connector assembly is designed to be self-protecting against electrical hazards through the integrated insulating material. This eliminates the need for special electrically insulated tools, allowing standard metallic tools to be used safely for assembly while maintaining electrical safety.
3Device complexity
If the case has separate insertion space and fastening area, then the connector assembly structure is simplified, but the effective use of limited space in the vehicle is reduced
Solution Approach 1:
The insertion space and fastening area are merged into a single integrated region. The fastening assembly is designed to perform both insertion and fastening functions within the same spatial envelope, eliminating the need for separate dedicated spaces and improving vehicle space utilization.
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 completely isolates the fastening assembly from the electrical connection, eliminating the risk of electrical hazards during assembly and enabling safe handling with usual tools.
Implementation Method 1
an insulation arrangement (30, 30') comprising an electrically insulating sleeve (31) and washer (33)
Implementation Method 2
a terminal holder (18) made of insulating material
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An electrical connector assembly 1 comprising: a terminal holder 18, and a fastening assembly 20, accommodated within the terminal holder 18, for clamping a plurality of terminals 3, 4 in the direction of a longitudinal axis L for an electrical connection between said terminals 3, 4, said fastening assembly 20 including a first fastening member 23 made of a metal material and a second fastening member 29 which first and second fastening members 23, 29 are connected to each other for clamping said terminals 3, 4 and which define a terminal receiving area 37, wherein the electrical connector further comprises an insulation arrangement 30 which is arranged between said first fastening member 23 and the terminal receiving area 37.