Grounding Connector Assembly With Single-Fastener Multi-Wire Mounting
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Solution Overview
Problem
Existing grounding electrical connectors require multiple eyelets and fasteners for multiple wires, making installation and removal difficult, especially in crowded spaces like vehicle applications, where packaging space is limited and tools are often necessary.
Innovation Solution
A grounding electrical connector assembly with a single fastener attached to the grounding structure, comprising two sub-assemblies that allow for easy assembly and disassembly, providing liquid-tight sealing and accommodating different terminal sizes, with a telescopically slidable terminal housing and connector subassembly that can be securely mounted and easily removed, allowing terminals to be moved independently of the connector subassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple eyelets and fasteners are used to ground multiple wires, then grounding capability is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
Multiple individual eyelets and fasteners are merged into a single integrated grounding housing with multiple terminals. The housing consolidates what would otherwise require separate fastening operations into one unified component that grounds multiple wires simultaneously through a single fastener attachment to the grounding structure.
Solution Approach 2:
The grounding housing serves multiple functions: it provides structural support for multiple terminals, acts as a single fastening point for the grounding structure, and organizes multiple wire connections in one location. This multi-functional design eliminates the need for separate eyelets and fasteners for each wire.
2Adaptability or versatility
If a housing with multiple terminals is used, then grounding capability is improved, but ease of operation deteriorates due to tool requirement
Solution Approach 1:
The grounding bar incorporates a self-clamping mechanism with resilient arms that automatically engage with the housing when the fastener is attached to the grounding structure. This self-clamping action eliminates the need for additional tools during installation, as the components self-assemble through the fastening operation alone.
3Adaptability or versatility
If wires are attached to terminals during housing installation, then grounding capability is improved, but ease of operation deteriorates due to wiring interference
Solution Approach 1:
The grounding system is divided into three separable components: the housing with terminals, the grounding bar with clamping mechanism, and the fastener. This segmentation allows the housing to be pre-assembled with wire connections in a comfortable workspace, then the complete housing assembly can be installed by simply attaching the grounding bar and fastener, eliminating the difficulty of wiring during constrained installation.
Solution Approach 2:
Wire connections to terminals can be made in advance during housing assembly before final installation. The housing serves as a pre-assembly platform where all electrical connections are established, and then the complete assembly is installed as a unit by simply securing the grounding bar to the grounding structure with the fastener.
4Device complexity
If a single fastener is used to secure grounding bar, then device complexity is reduced, but reliability deteriorates due to wire interference during removal
Solution Approach 1:
The system is segmented into removable sub-assemblies (housing with terminals, grounding bar) that can be separated in a controlled sequence. During removal, the grounding bar can be detached first by operating the single fastener, while wires remain securely connected to the housing. This segmentation prevents wire damage that would occur if the entire assembly were forced apart simultaneously.
Solution Approach 2:
The housing acts as an intermediary between the wires and the grounding bar. Wires connect to the housing, not directly to the grounding bar or fastener. This intermediary structure allows the grounding bar and fastener to be removed or adjusted without directly disturbing wire connections, maintaining connection stability while enabling easy maintenance.
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
Facilitates easy installation and removal of the connector assembly without tools, maintaining electrical connections and sealing, even in tight spaces, by allowing the terminal subassembly to be securely mounted and reconnected to the connector subassembly, improving ease of use and reducing complexity.
Implementation Method 1
the terminal subassembly including a radial seal in the gap that is compressed against the retention arm by the body when the terminal subassembly is assembled to the connector subassembly
Data Source
AI summary
A grounding electrical connector assembly may have a connector subassembly and a terminal subassembly. The connector subassembly may include a connector housing having a body defining a terminal cavity therein and a ground bar, secured to the connector housing, having electrical contacts extending into the terminal cavity and a portion that secures to grounding structure. The terminal subassembly may include a terminal housing having a main body defining terminal cavities extending therethrough that each receive one of a plurality of terminals, the main body telescopically slidable into and releasably secured to the terminal cavity.