Header Power Connector With Movable Housings 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 additional components like plug connectors, which increase costs and complexity.
Innovation Solution
A header power connector design featuring a movable inner housing and terminals within a multipiece housing assembly, allowing for tilt and rotation to accommodate misalignment of busbars, eliminating the need for plug connectors by directly connecting upper and lower busbars within the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug connector is used to connect electrical components, then the connection reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent combines the plug connector and header power connector into a single integrated header power connector assembly. The electrical components are directly coupled to the header power connector, eliminating the need for a separate plug connector. This merging reduces the number of components while maintaining reliable electrical connections through the integrated design with multiple terminals and housing structures.
2Reliability
If a plug connector is used to connect electrical components, then the connection reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent integrates multiple functions into a single header power connector assembly, combining what would traditionally require separate plug and header components. This reduces the total number of parts that need to be manufactured, stored, and assembled, thereby reducing manufacturing costs while maintaining reliable electrical connections through the integrated multi-terminal structure.
3Device complexity
If electrical components are directly coupled to the header power connector, then the device complexity is reduced, but the manufacturing precision requirement increases
Solution Approach 1:
The patent incorporates movable inner housings that can shift and tilt relative to the outer housing to accommodate misalignment between electrical components and the header power connector. This dynamic adjustment capability allows the connector to adapt to variations in alignment precision during assembly, reducing the stringency of manufacturing precision requirements while maintaining direct coupling and low device complexity.
Solution Approach 2:
The patent allows the inner housing and terminals to change their positional parameters (shift and tilt angles) to compensate for misalignment. By enabling these parameter changes, the system can accommodate a wider range of alignment tolerances, reducing the manufacturing precision requirements for direct coupling of electrical components.
4Device complexity
If electrical components are directly coupled to the header power connector, then the component count is reduced, but the alignment difficulty increases
Solution Approach 1:
The patent employs movable inner housings capable of shifting and tilting to accommodate misalignment during the direct coupling of electrical components. This dynamic adjustment mechanism makes the alignment process easier by allowing the connector to self-adjust to minor misalignments, reducing the skill and precision required for assembly while maintaining a reduced component count.
Data Source
AI summary
A header power connector includes a header housing assembly including an outer housing having cavities that receive corresponding inner housings, which hold terminals for electrically connecting upper and lower busbars. The inner housings are movable relative to the outer housing to accommodate misalignment of the corresponding upper and lower busbars. The terminals are movable in the terminal channels of the inner housings to accommodate misalignment of the corresponding upper and lower busbars.