Header Power Connector Choke Positioner for EMI and Alignment
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Solution Overview
Problem
Header power connectors in electric vehicles face challenges with alignment difficulties and electromagnetic interference (EMI), leading to potential damage from chokes used to reduce EMI, which can cause mechanical issues and limit component movement during mating.
Innovation Solution
A header power connector design featuring a choke positioner that interfaces with the choke to stabilize its position relative to the outer housing, separating it from the terminal assemblies to prevent damage and allow for alignment, while also using a separating wall to isolate the choke from the terminals, allowing for independent movement of the inner housing for alignment with busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a choke is added to reduce EMI, then electromagnetic interference is reduced, but the choke may move within the header power connector from vibration which may damage the terminals, the busbars, the housing, or other components
Solution Approach 1:
The patent applies preliminary action by pre-positioning the choke within the header housing using a choke positioner structure before vibration or mechanical shock occurs. The choke positioner includes positioning features such as ribs or tabs that engage with corresponding features in the header housing to secure the choke in a predetermined location, preventing movement that could cause damage to terminals, busbars, or other components during subsequent vibration events.
Solution Approach 2:
The patent uses the choke positioner as an intermediary component between the choke and the header housing. This positioner structure acts as a mediator that absorbs and isolates the mechanical stresses from vibration and shock, preventing direct transmission of these forces to the choke and surrounding components. The positioner includes cushioning or damping features that reduce the impact of mechanical movements on the electrical components.
2Object-affected harmful factors
If a choke is added to reduce EMI, then electromagnetic interference is reduced, but the choke limits movement or alignment of the electrical components during mating
Solution Approach 1:
The patent applies segmentation by dividing the header power connector into distinct functional zones: a choke reception area with the positioner structure, a terminal assembly area, and a busbar reception area. The choke is positioned in a dedicated space within the header housing that is spatially separated from the terminal assemblies and busbar mating areas. This segmentation allows the choke to be secured in place without interfering with the movement and alignment of electrical components during the mating process.
Solution Approach 2:
The patent resolves the spatial conflict by positioning the choke in a different dimensional plane or orientation within the header housing. The choke positioner places the choke in a location that is offset from the path of moving components during mating, allowing vertical or lateral clearance. This dimensional arrangement enables the choke to perform its EMI filtering function while leaving sufficient space for proper alignment and insertion of plug connectors and busbars.
3Reliability
If the choke is secured firmly to prevent movement, then vibration damage is prevented, but the choke may still interfere with alignment of electrical components during mating
Solution Approach 1:
The patent applies local quality by providing different structural characteristics in different regions of the header housing. The choke positioner includes localized positioning features such as ribs, tabs, or recesses that precisely secure the choke in a specific location with appropriate tolerance. These positioning features are strategically placed to ensure the choke remains stable during vibration while maintaining sufficient clearance from the terminal assemblies and busbar mating areas, thus achieving both firm securing and proper alignment tolerance.
Data Source
AI summary
A header power connector includes a header housing assembly having an outer housing with an outer wall forming a cavity and a separating wall separating the cavity into a choke chamber and a terminal chamber. The outer housing is configured to receive an upper busbar through the top and a lower busbar through the bottom. An inner housing is received in the terminal chamber and holds a terminal assembly with terminals arranged in a terminal stack configured to electrically connect the upper and lower busbars. The header power connector includes a choke received in the choke chamber between the outer wall and the separating wall. The choke has a choke body surrounding the terminal assembly. The choke body has an opening therethrough receiving the terminal assembly.