Impact-Resistant Cable Connector Strain Relief for Wire Separation
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Solution Overview
Problem
Existing strain relief systems fail to protect electrical wiring from high-impact forces, such as those encountered in vehicle collisions, particularly in high-voltage systems like electric vehicle traction systems and air conditioning systems.
Innovation Solution
A resilient block with specific hardness and electrical insulation properties is positioned around the wires to limit bending and maintain spacing, preventing arcing and short-circuiting, and is secured with an abrasion-resistant sleeve to absorb impacts and minimize sliding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If strain relief systems are used to protect conductors from bending, then conductor bending protection is improved, but protection against high-impact forces remains insufficient
Solution Approach 1:
A resilient block made of elastomeric material is positioned between the connector body and the conductors to absorb and cushion high-impact forces before they can damage the conductors. This pre-positioned cushioning element compresses during impact events, protecting the wiring harness from collision damage while strain relief systems continue to protect against bending.
2Volume of moving object
If wires are positioned close together for compact design, then device size is reduced, but risk of arcing and short-circuiting increases
Solution Approach 1:
The resilient block serves as an intermediary barrier between adjacent wires, maintaining physical separation through its structure with individual wire receptacles. This intermediary element prevents direct contact between wires even when the connector is compact, thereby eliminating arcing and short-circuiting risks while allowing close wire positioning for space efficiency.
3Strength
If a hard connector body is used for structural strength, then connector durability is improved, but wire insulation damage from direct impact increases
Solution Approach 1:
The connector assembly employs different material properties in different locations: the connector body maintains hard structural material for overall strength and durability, while the resilient block positioned at the interface with conductors uses soft elastomeric material to protect wire insulation from impact damage. This local differentiation of material quality allows both structural strength and conductor protection.
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 solution effectively protects wires from damage and failure under high-impact conditions by absorbing forces and maintaining mechanical separation, reducing the risk of arcing and short-circuiting.
Implementation Method 1
a resilient block having a first surface facing the connector body and separated from the connector body by a first distance, and a second surface opposite the first surface. The resilient block is configured to limit bending of the one or more wires about a first axis parallel to the first surface.
Implementation Method 2
the resilient block has a first hardness, and the connector body has a second hardness higher than the first hardness. In an instance of that first aspect, the first hardness may have a Durometer Shore A value of 60.
Data Source
AI summary
An impact-resistant cable connector includes a connector body, and a resilient block having a first surface facing the connector body and separated from the connector body by a first distance, a second surface opposite the first surface, and one or more bores, each of the one or more bores running through both the first surface and the second surface. One or more wires are coupled to the connector body, each respective one of the wires passing through a respective one of the bores. The resilient block is configured to limit bending of the one or more wires about a first axis parallel to the first surface. Such configuration may include spacing the resilient block away from the first surface by a first distance that is less than half the height of the resilient block.