Floating Header Power Connector for Busbar Misalignment
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Solution Overview
Problem
Existing header power connectors face challenges in aligning electrical components, leading to improper mating and potential damage due to the need for a plug connector, which increases system cost and complexity.
Innovation Solution
A header power connector design featuring a movable inner housing and terminal assembly with spring beams to accommodate misalignment between busbars, allowing for direct coupling and improved mating tolerances by enabling tilt and rotation within a housing cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug connector is used to connect electrical components, then the connection can be achieved, but the system cost increases and the number of components increases
Solution Approach 1:
The patent removes the intermediate plug connector from the system by enabling direct coupling between electrical components. The header power connector is integrated directly into the electrical component housing, eliminating the need for separate plug connectors and reducing overall system complexity while maintaining reliable electrical connection.
Solution Approach 2:
The patent combines the header power connector with the electrical component housing into a single integrated assembly. The header housing is formed as part of the electrical component housing, merging two previously separate components into one unified structure that reduces part count and assembly steps.
2Device complexity
If electrical components are directly coupled to the header power connector, then the number of components is reduced, but alignment difficulty increases leading to improper mating and potential damage
Solution Approach 1:
The patent incorporates movable elements within the header power connector, specifically a movable terminal assembly that can shift position within the header housing. This dynamic capability allows the terminal to self-align with the busbar during insertion, accommodating misalignment and preventing damage while maintaining reliable electrical connection.
Solution Approach 2:
The patent utilizes spring beams that can change their physical state from compressed to relaxed, allowing the terminal to move along the insertion direction. This parameter change enables the terminal to accommodate misalignment between the electrical component and header power connector, ensuring proper mating without damage.
3Manufacturing precision
If strict alignment is required for direct coupling, then mating accuracy can be maintained, but manufacturing tolerances become more difficult and costly to achieve
Solution Approach 1:
The patent designs the header power connector with self-aligning features where the movable terminal automatically adjusts its position to match the busbar during insertion. This self-service mechanism eliminates the need for tight manufacturing tolerances, as the system self-corrects for misalignment, significantly easing manufacturing requirements.
Solution Approach 2:
The patent incorporates spring beams that provide cushioning force to accommodate misalignment before the terminal makes contact with the busbar. This beforehand cushioning allows for greater manufacturing tolerance by absorbing alignment errors through the elastic deformation of the spring beams, preventing damage and ensuring proper connection.
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 enables reliable and cost-effective direct coupling of electrical components by accommodating misalignment, reducing the risk of damage and system complexity while maintaining electrical contact.
Implementation Method 1
The first and second upper spring beams configured to engage opposite sides of the first busbar. The first and second lower spring beams configured to engage opposite sides of the second busbar.
Data Source
AI summary
A header power connector includes a header housing assembly including an inner housing received in a cavity of an outer housing. The inner housing has upper and lower openings open to a terminal channel configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal channel. A terminal is received in the terminal channel having a terminal base, an upper mating end and a lower mating end. The upper mating end includes an upper socket flanked by upper spring beams that receives the first busbar and the lower mating end includes a lower socket flanked by lower spring beams that receives the second busbar. The terminal is movable in the terminal channel to accommodate misalignment of the first busbar and the second busbar in the terminal channel.