Contact Assembly with Biasing Device for Electronics Module
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Solution Overview
Problem
The existing methods for making electrical connections in vehicles require multiple individual connectors, fasteners, seals, and covers, leading to increased time and expense in assembly due to the complexity and redundancy of these components.
Innovation Solution
A contact assembly comprising a terminal, a biasing device, and a plunger is used to establish and maintain electrical contact with an electronics module, where the biasing device biases the terminal to ensure secure contact, and the plunger allows for pivoting to accommodate conductive surfaces that may be out of plane, reducing the need for multiple fasteners and seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual connectors are used to make electrical connections, then each connection can be secured reliably, but the assembly time and expense increase due to the large number of fasteners, seals, and covers required
Solution Approach 1:
The patent combines multiple individual connectors into a single integrated contact assembly that can establish multiple electrical connections simultaneously. The contact assembly includes a terminal with multiple contact points and a single biasing device that applies force to all contacts, eliminating the need for multiple separate fasteners, seals, and covers while maintaining reliable electrical connections.
Solution Approach 2:
The contact assembly is designed as a universal component that can make multiple electrical connections through a single attachment operation. The terminal structure provides multiple contact points that can engage with different conductive surfaces, and the single biasing device serves multiple functions by securing all contacts simultaneously, reducing assembly complexity and time.
2Reliability
If multiple individual connectors with fasteners and seals are used, then each electrical connection can be secured, but the complexity and expense of assembly increase
Solution Approach 1:
The patent merges multiple separate components (connectors, fasteners, seals, covers) into a single integrated contact assembly. The terminal structure incorporates multiple contact points, and the single biasing device replaces multiple fasteners, while the insulative housing provides structural support and electrical isolation, eliminating the need for separate seals and covers.
Solution Approach 2:
The contact assembly is segmented into functional components (terminal, biasing device, plunger, insulative housing) that work together as an integrated unit. This segmentation allows each component to perform its specific function while being part of a unified structure that reduces overall complexity compared to multiple separate connectors.
3Strength
If individual fasteners are required for each electrical connection, then secure attachment is achieved, but the assembly process becomes more expensive and time-consuming
Solution Approach 1:
The patent combines the attachment function for multiple connections into a single fastening operation. The contact assembly is designed to be attached to the electronics module through one attachment mechanism, and the single biasing device provides sufficient attachment strength for all electrical connections simultaneously, reducing assembly cost and complexity.
Solution Approach 2:
The contact assembly serves as a universal attachment component that provides secure electrical connections for multiple circuits through a single attachment operation. The terminal structure with multiple contact points and the single biasing device work together to provide both attachment strength and electrical connectivity, eliminating the need for multiple separate fastening operations.
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
This solution simplifies the assembly process by allowing a single fastener to secure multiple electrical connections, reducing assembly time and cost while ensuring reliable and flush contact between conductive surfaces, thereby improving the efficiency and reliability of electrical connections.
Implementation Method 1
The biasing device is configured to bias the terminal in a first direction to establish electrical contact with the electronics module
Implementation Method 2
the conductive surface biases the terminal in a second direction, opposite the first direction
Implementation Method 3
The terminal is configured to transmit electrical current to the conductive surface of the electronics module
Data Source
AI summary
A power electronics module includes an electronics module and a connector housing. The electronics module includes at least one interface section having at least one conductive surface. At least one connector is configured for attachment to the electronics module to establish electrical communication between the connector and the electronics module. The connector includes a connector housing, an insulative housing, a terminal and a biasing device. The insulative housing is supported by the connector housing. The terminal is configured to transmit electrical current to the conductive surface of the electronics module. The biasing device is configured to bias the terminal in a first direction to establish electrical contact with the conductive surface and the conductive surface biases the terminal in a second direction, opposite the first direction.