Header Power Connector Alignment and Direct Busbar Connection
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Solution Overview
Problem
Existing header power connectors face challenges in aligning electrical components, leading to improper mating and potential damage, and they include an extra plug connector that increases system cost and complexity.
Innovation Solution
A header power connector design featuring a housing assembly with busbar cavities and terminals, along with a header busbar assembly and positioner, which allows direct electrical connection between components without the need for a plug connector, improving mating tolerances and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plug connector is used to connect electrical components to the header power connector, then the connection is easier to align and assemble, 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 integrating the connection functionality directly into the header power connector. The header power connector is designed with built-in alignment features and receptacles that directly receive busbars from electrical components, eliminating the need for separate plug connectors and reducing component count while maintaining ease of alignment.
Solution Approach 2:
The patent combines the alignment and connection functions into a single integrated header power connector assembly. The housing includes integrated alignment features such as positioning ribs, guide slots, and receptacles that work together to align and secure electrical components directly, merging what were previously separate functions of the plug connector and header into one unified structure.
2Device complexity
If the plug connector is eliminated to reduce component count, then system cost decreases, but alignment precision deteriorates leading to improper mating and damage
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the header power connector housing, such as positioning ribs that engage with corresponding features on electrical components, guide slots that direct busbar insertion, and receptacles pre-positioned to receive connections. These features perform the alignment function in advance of the actual electrical connection, ensuring precise mating without requiring an intermediate plug connector.
Solution Approach 2:
The patent introduces alignment mediating structures within the header power connector housing, such as positioning ribs, guide slots, and receptacles, that act as intermediaries to facilitate precise alignment between electrical components and the header. These features mediate the alignment process, ensuring proper positioning and preventing improper mating or damage while eliminating the need for separate plug connectors.
3Reliability
If alignment tolerances are tightened to prevent improper mating, then connection reliability improves, but manufacturing cost increases and assembly difficulty increases
Solution Approach 1:
The patent uses preliminary alignment features such as positioning ribs, guide slots, and receptacles built into the header power connector housing to establish precise alignment before the electrical connection is made. These features guide the busbars into correct positions and maintain proper alignment throughout the connection process, ensuring reliable mating without requiring tight manufacturing tolerances on the electrical components themselves, thus keeping manufacturing costs reasonable.
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 cavity configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal cavity. A terminal is received in the terminal cavity 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 cavity to accommodate misalignment of the first busbar and the second busbar in the terminal cavity.