L-Shaped Electrical Connector Assembly for Simplified Wiring
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Solution Overview
Problem
Existing electrical units, such as power distribution boxes, face challenges in assembly due to complexity with electrical connectors, cables, terminals, and wiring harnesses, necessitating simpler and more efficient connection methods.
Innovation Solution
An L-shaped electrical connector design with a base portion and body portions that are releasably connected to define an internal space for electrical components, allowing for easy insertion and connection of components via openings in the connector, facilitated by a protrusion engaging a housing member projection for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional electrical connectors with multiple separate components are used, then electrical connection functionality is achieved, but assembly complexity increases and assembly time is extended
Solution Approach 1:
The patent combines multiple separate electrical connector components (housing, contacts, insulation) into a single integrated electrical connection assembly. The housing and contacts are pre-assembled as one unit, which then connects to the circuit board as a single component, eliminating the need for separate assembly steps and reducing overall assembly complexity while maintaining connection reliability.
Solution Approach 2:
The electrical connection assembly is segmented into modular components (housing assembly with pre-installed contacts, circuit board with mounting features) that can be independently manufactured and tested, then easily combined. This modular segmentation allows for simplified assembly while ensuring each component meets reliability standards before integration.
2Productivity
If traditional electrical connectors requiring multiple fastening steps are used, then secure connection is achieved, but assembly time increases
Solution Approach 1:
The housing and electrical contacts are pre-assembled into a complete housing assembly before final installation. Mounting features, alignment pins, and connection interfaces are pre-positioned and pre-configured, allowing the entire assembly to be installed in a single operation without requiring multiple fastening steps or complex alignment procedures during final assembly.
Solution Approach 2:
The electrical connection assembly incorporates self-aligning features such as positioning protrusions that fit into corresponding recesses on the circuit board, and self-retaining mechanisms that automatically secure the connection upon insertion. This eliminates the need for manual alignment and multiple fastening operations, significantly improving assembly efficiency and ease of operation.
3Device complexity
If electrical connectors with separate housing and contact components are used, then electrical connection functionality is achieved, but the number of required components increases
Solution Approach 1:
The patent merges the housing and electrical contacts into a single integrated housing assembly where contacts are permanently mounted within the housing structure. This reduces the total component count from multiple separate parts to two main components (housing assembly and circuit board), simplifying inventory management and assembly while maintaining manufacturing capability through modular design.
Solution Approach 2:
The housing assembly serves multiple functions simultaneously: it provides mechanical support for the contacts, electrical insulation, structural protection, and mounting interface to the circuit board. This multi-functionality consolidates what would otherwise require multiple separate components into a single versatile assembly, reducing complexity without compromising manufacturing ease.
Data Source
AI summary
An electrical connector may include an L-shaped body portion and a base portion. The body portion may include (i) a first body portion extending in a first direction, and (ii) a second body portion extending from the first body portion in a second direction. The base portion may include a protrusion configured to engage a projection of a housing member to releasably connect the base portion to said housing member. The first body portion may be connected to the base portion to define an internal space in which a first electrical component and a second electrical component are electrically connectable to each other. The base portion may at least partially define a first opening via which said first electrical component is insertable into the internal space. The second body portion may include a second opening via which said second electrical component is insertable into the internal space.