Integrated Ground Block Assembly for Vehicle Chassis Grounding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current motor vehicles face challenges in efficiently grounding electrical components to the vehicle chassis, leading to complex installations and increased weight due to multiple grounding points and traditional grounding terminal blocks that do not integrate compression limiter functionality.
Innovation Solution
Integrated compression limiter and ground block assemblies that combine the functions of a compression limiter and ground block into a single unit, using a single-piece connector body made of conductive metallic material, which includes a central compression region and transverse grounding platforms to securely mount and electrically couple wiring harness wires to the vehicle chassis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional grounding terminal blocks are used separately from compression limiters, then grounding functionality is provided, but the number of parts increases and installation complexity increases
Solution Approach 1:
The patent combines the compression limiter and grounding terminal block into a single integrated assembly. The compression limiter body includes integrally formed grounding terminals that provide both mechanical mounting and electrical grounding functions simultaneously, eliminating the need for separate components and reducing installation steps.
Solution Approach 2:
The integrated assembly serves multiple functions: it acts as a compression limiter to secure the wiring harness to the vehicle body, provides electrical grounding through integrated terminals, and offers mechanical support. This multi-functionality reduces the overall number of components needed in the electrical system.
2Reliability
If multiple separate grounding locations are used, then grounding reliability is maintained, but vehicle weight increases
Solution Approach 1:
Multiple grounding terminals are integrated into a single compression limiter assembly, allowing multiple grounding connections to be made at one location rather than requiring separate grounding points distributed throughout the vehicle. This consolidates the grounding function while maintaining reliability.
Solution Approach 2:
The integrated compression limiter assembly provides both mechanical support and multiple electrical grounding paths through its integrated terminals. This multi-functional design eliminates the need for additional separate grounding components, thereby reducing vehicle weight while maintaining grounding reliability.
3Productivity
If traditional separate mounting and grounding methods are used, then functionality is achieved, but assembly time increases
Solution Approach 1:
The compression limiter and grounding terminals are manufactured as a single integrated component rather than separate parts. This integration allows the assembly process to be completed in one step rather than requiring separate mounting and grounding operations, significantly reducing assembly time.
Solution Approach 2:
The integrated assembly performs both mechanical mounting and electrical grounding functions simultaneously. This multi-functionality simplifies the assembly design by eliminating the need for multiple separate components and assembly steps, thereby improving productivity.
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 reduces the number of grounding locations, simplifies installation, decreases assembly time and weight, and optimizes the assembly design by integrating compression limiter and ground block functions into a compact, lightweight unit.
Implementation Method 1
The ground conductivity of the wire is transferred from the grounding platform, through the compression region, and to the vehicle chassis/body using a conductive threaded fastener
Data Source
AI summary
Presented are integrated compression limiter and ground block (CLB) assemblies for electrically coupling and physically mounting components to vehicle structures, methods for making/using such CLB assemblies, and vehicles equipped with such CLB assemblies. A CLB assembly includes a substantially rigid and electrically conductive central body, which defines therethrough a compression limiter slot that receives a mounting fastener to thereby physically mount a vehicle component and electrically couple multiple ground wires to the vehicle's load-bearing ground structure. An electrically conductive platform projects from one side of the central body and includes a ground terminal that electrically couples, e.g., via a conductive fastener and terminal connector, with one of the electrical ground wires. Another electrically conductive platform projects from another side of the central body and includes another ground terminal that electrically couples, e.g., via another conductive fastener and terminal connector, with another one of the electrical ground wire.