High Power Electrical Connector Assembly Grounding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high-power electrical connectors for large gauge cables face challenges in handling and assembly due to the need for large current and high voltage transmission, often requiring complex assembly techniques and costly systems, especially when dealing with bipolar cables in electric or hybrid vehicles and industrial applications.
Innovation Solution
A high-power electrical connector design featuring an insulative housing, contact path assemblies, a grounding or shielding layer, and a compression ring to secure the ground layer to a conductive outer housing, along with a High Voltage Interlock terminal retainer and strain relief components, facilitates secure and efficient transmission of electrical signals while simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large gauge cables with large gauge conductors are used to transmit high current and high voltage, then the current and voltage transmission capability is improved, but the cable becomes relatively difficult to handle during assembly and repair
Solution Approach 1:
The connector is divided into separate plug and receptacle components, each handling high power transmission independently. The plug contains contact assemblies that receive cable conductors, while the receptacle provides the mating interface. This segmentation allows the heavy-duty cable connections to be made in separate locations, improving ease of assembly and repair while maintaining high power transmission capability.
Solution Approach 2:
The connector acts as an intermediary device between the large gauge cable and the dash panel electrical connections. It provides a standardized interface that simplifies the connection process, allowing technicians to work with the connector components rather than directly with the difficult-to-handle large gauge cable ends.
2Power
If conventional connector designs are used for high power applications, then the basic electrical connection is achieved, but complicated assembly techniques and components are required leading to costly connector systems
Solution Approach 1:
Multiple functions are merged into the connector assembly: the contact assemblies provide electrical connection, the compression rings provide grounding and shielding, the housing provides structural support and alignment, and the interlock mechanisms provide safety interlocks. This consolidation of functions into a single integrated component reduces the number of separate parts and simplifies assembly procedures while maintaining high power transmission capability.
Solution Approach 2:
The connector design incorporates universal features that serve multiple purposes: the compression rings provide both mechanical compression and electrical grounding, the housing provides both structural support and alignment guidance, and the contact assemblies provide both electrical connection and mechanical retention. This multi-functionality reduces the number of components needed and simplifies the overall system while achieving high power transmission.
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
The connector system effectively transmits high currents and voltages with improved ease of assembly and reduced costs, ensuring reliable connections and enhanced safety through the use of a compression ring for grounding and strain relief, while the High Voltage Interlock ensures fault detection and power shut-off.
Implementation Method 1
The ground layer is connected to a conductive outer housing by a compression ring positioned between the cable insulator and ground layer
Implementation Method 2
The cable is constructed from a large gage inner conductor that is surrounded by an insulator
Data Source
AI summary
The present disclosure provides a conductive terminal and an electrical connector assembly. A high power electrical connector is provided for transmitting electrical signals from a pair of cables, such as high current capable cables, to an associated member, such as a dash panel. The high power electrical connector includes an insulative housing and a pair of contact path assemblies therethrough for transmission of the electrical signals. The cables include a shield layer that is biased to the backshell providing a ground path for the cables and connector.