Vehicle Electrical Connector Assembly for Flat Cable and Busbar Retention
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Solution Overview
Problem
Current electrical assemblies for vehicles face challenges in efficiently connecting and securing flat cables and busbars, particularly in ensuring reliable electrical connections and retention without causing damage or interference.
Innovation Solution
The electrical assembly comprises a configuration of covers, male and female inserts, a busbar, and spring clips, where the inserts are connected to the covers and the busbar, facilitating alignment and retention of conductors through specific hole configurations and protrusions, allowing for secure electrical connections and easy assembly using an insertion tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional electrical assemblies use separate connection methods for flat cables and busbars, then the assembly process becomes complex and time-consuming, but the connection reliability may be compromised
Solution Approach 1:
The patent combines the connection functions for flat cables and busbars into a single integrated connector assembly. The connector simultaneously receives both the flat cable and busbar, establishing multiple electrical connections in one operation. This merging of connection functions eliminates the need for separate connection steps, thereby improving assembly speed while maintaining connection reliability through the unified design.
Solution Approach 2:
The connector is designed as a universal component that can accommodate both flat cables and busbars with different configurations. It features multiple contact points and adaptable clamping mechanisms that can handle various conductor types and sizes. This multi-functionality allows a single connector to perform multiple connection tasks, enhancing productivity without sacrificing the reliability needed for different electrical components.
2Reliability
If the electrical assembly uses a secure retention mechanism for conductors, then the connection reliability improves, but the risk of damaging conductors during assembly increases
Solution Approach 1:
The connector incorporates cushioning elements and compliant clamping structures that are pre-positioned to protect conductors during the assembly process. These elements provide a buffer between the retention mechanism and the conductor surfaces, distributing forces evenly and preventing concentrated stress points that could cause damage. This beforehand cushioning ensures secure retention while minimizing the risk of conductor damage.
Solution Approach 2:
The retention mechanism utilizes materials and designs that change physical parameters under load, such as elastic deformation of clamping arms or thermal expansion characteristics. These parameter changes allow the connector to adapt its retention force dynamically, applying sufficient pressure for reliable connection while automatically reducing stress to prevent conductor damage. The compliant materials enable the system to maintain reliable retention without exceeding damage thresholds.
3Adaptability or versatility
If the electrical assembly accommodates various conductor configurations, then the versatility improves, but the device complexity increases
Solution Approach 1:
The connector employs a universal design with standardized contact points and modular clamping structures that can accommodate different conductor configurations without requiring multiple specialized components. The same basic connector structure can handle various flat cable arrangements and busbar types through adjustable elements and multiple contact options, achieving versatility while controlling complexity through design standardization.
Solution Approach 2:
The connector incorporates dynamic elements such as movable clamping arms, flexible contacts, and adjustable positioning features that can adapt to different conductor configurations. These dynamic components allow the rigid connector body to interface with varying conductor shapes and positions, providing versatility through motion and adjustment rather than through multiple complex fixed structures.
Data Source
AI summary
An assembly includes a first cover, a second cover, a first male insert, a first female insert, a second male insert, a second female insert, and/or a busbar, in some configurations. The second cover may be connected with the first cover. The first male insert may be connected to the first cover. The first female insert may be connected to the second cover and the first male insert. The second male insert may be connected to one of the first cover and the second cover. The second female insert may be connected to the second male insert and the other one of the first cover and the second cover. The busbar may be in contact with the first female insert and the second female insert.