Low-Profile Electrical Connector Assembly with Integrated Latch
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Solution Overview
Problem
Existing electrical connector assemblies for solar panels to AC power grids face challenges in forming reliable and efficient connections between DC-to-AC inverters and AC power cables, particularly in terms of low-profile design, secure latching, and environmental sealing, which affect the reliability and flexibility of power transmission.
Innovation Solution
A low-profile cable electrical connector with integrally molded latch members and a lead assembly that forms secure connections with contact pins on the inverter, utilizing a ribbed structure for support and flexibility, and a sealing gasket for environmental protection, allowing for flexible cable routing and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cable connector uses a traditional high-profile design with separate latch components, then the latching mechanism can be robust, but the overall height of the connector increases
Solution Approach 1:
The latch members are integrally molded as part of the cable connector housing, combining the latch function with the connector body. This eliminates the need for separate latch components and reduces the overall connector height while maintaining latching robustness through the integrated x-shaped support structure with rib reinforcement.
Solution Approach 2:
The latch members are positioned below the contact barrels, utilizing the vertical space beneath the main connector body. This dimensional repositioning allows the latching mechanism to operate in an underutilized space, reducing the overall connector height while maintaining functional robustness.
2Adaptability or versatility
If the contact pins are spaced far apart to facilitate cable routing, then cable routing flexibility improves, but the connector size increases
Solution Approach 1:
The contact pins are arranged in a linear spacing pattern along the connector length rather than distributing them across a larger area. This one-dimensional linear arrangement provides sufficient spacing for cable routing while maintaining a compact two-dimensional footprint.
3Ease of operation
If the latch arms are made flexible to engage latch surfaces, then the latching mechanism becomes easier to operate, but the latch arms may over-flex and lose structural integrity
Solution Approach 1:
The x-shaped support structure includes a rib that changes the structural parameters of the latch arm by providing reinforcement at critical stress points. This allows the latch arm to maintain flexibility for easy engagement while the rib prevents over-flexing and maintains structural integrity.
Solution Approach 2:
The latch members are made from a composite structure combining the x-shaped support geometry with integrated rib reinforcement, creating a composite structural system that provides both flexibility and strength within a single molded component.
Data Source
AI summary
A connector socket with a body, a circuit board in the body and a header on the board. The contacts of terminals on the header are positioned in desired locations in openings in the body.