Header Power Connector Assembly for EMI-Stable Busbar Mating
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Solution Overview
Problem
Existing header power connectors face challenges in aligning electrical components for proper mating, leading to potential damage and interference issues, such as electromagnetic interference (EMI), especially when chokes are used for EMI reduction.
Innovation Solution
A header power connector design featuring a dual-housing assembly with a movable inner housing and choke positioners to accommodate misalignment, along with a choke positioned by horizontal and vertical positioners to stabilize the choke within the connector, ensuring secure and interference-free electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a choke is added to reduce EMI, then electromagnetic interference is suppressed, but the choke may cause damage to the header power connector over time due to movement from vibration
Solution Approach 1:
The patent introduces a foam material as an intermediary between the choke and the header power connector housing. This foam intermediary absorbs vibrations and prevents the choke from moving, thereby eliminating the harmful effect of vibration-induced damage while maintaining the EMI suppression function of the choke.
Solution Approach 2:
The patent applies cushioning material (foam) in advance around the choke before the connector is assembled and subjected to vibrations. This beforehand cushioning protects the connector components from potential vibration-induced damage by absorbing and dampening mechanical shocks and vibrations that would otherwise cause the choke to move and damage terminals or busbars.
2Manufacturing precision
If alignment tolerances are tightened to prevent improper mating, then component damage is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent introduces a movable inner housing that can shift position relative to the outer housing. This dynamic mechanism allows the connector to self-align during mating, accommodating variations in alignment tolerance without requiring tight manufacturing precision. The movable housing moves to compensate for misalignment, ensuring proper mating while simplifying manufacturing requirements.
3Reliability
If a plug connector is used to connect electrical components, then proper electrical connection is achieved, but the overall system cost increases due to additional components
Solution Approach 1:
The patent merges the electrical connection function directly into the header power connector by providing terminals that receive busbars from electrical components. This eliminates the need for separate plug connectors by combining the connector housing, terminals, and busbar reception features into a single integrated header power connector assembly, thereby reducing component count while maintaining reliable electrical connections.
Data Source
AI summary
A header power connector includes a header housing assembly including an outer housing having an outer wall forming a cavity configured to receive upper and lower busbars. The header housing assembly includes an inner housing received in the cavity having a terminal channel holding a terminal assembly including a plurality of terminals arranged in a terminal stack. Each terminal includes upper and lower sockets at upper and lower mating ends configured to receive the upper and lower busbars, respectively. The header power connector includes a choke received in the cavity having a chock body with an opening therethrough receiving the terminal assembly. The header power connector includes a choke positioner in the cavity interfacing with the choke to position the choke relative to the outer housing.