Modular Cable Adapter Assembly for Stable Wire Connections
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Solution Overview
Problem
Existing connector systems for conductor members in vehicles lack efficient and secure methods to connect and secure flat cables and wires, leading to potential disconnection and instability in electrical connections.
Innovation Solution
A modular adapter assembly comprising adapter modules with male and female connectors, housing shells, and fasteners that allow for secure stacking and connection of flat cables and wires, enhancing structural integrity and electrical stability through complementary engagement mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing connector systems are used to connect flat cables and wires, then the connection can be established, but the connection stability and security are insufficient leading to potential disconnection
Solution Approach 1:
The connector system is divided into separate adapter modules, each handling specific connection functions. The adapter assembly includes multiple adapter modules that can be independently configured and stacked, allowing each module to specialize in securing particular conductor members (flat cables or wires) while maintaining overall system reliability through modular redundancy
Solution Approach 2:
The adapter modules are designed to stack and nest together in a hierarchical arrangement, with each module containing its own internal securing mechanisms (latches, retention members) while also interfacing with adjacent modules through complementary male and female connectors. This nested structure provides multiple levels of security and prevents disconnection at any single interface
2Strength
If existing connector systems are used, then connection can be made, but structural integrity and electrical stability are compromised
Solution Approach 1:
The adapter modules combine multiple functions into single integrated components: each module simultaneously provides mechanical securing (through latches and retention members), electrical connection (through conductor members), and structural support (through housing shells). This merging of functions strengthens the overall connection while the modular design prevents excessive complexity by using standardized interfaces
Solution Approach 2:
The adapter assembly employs composite construction combining rigid housing shells for structural integrity with flexible retaining members and latches for secure engagement. The conductor members integrate metallic electrical conductors with insulating materials, creating composite structures that maintain both electrical stability and mechanical strength
3Reliability
If existing connector systems are used, then basic connection is achieved, but disconnection and instability occur
Solution Approach 1:
The adapter modules incorporate dynamic latching mechanisms that automatically engage when modules are stacked together, providing secure connection without requiring manual fastening operations. The latches are designed to snap into place through simple stacking motion, while disconnection is facilitated by releasing the stacking force, allowing easy separation. This dynamic behavior ensures reliable electrical connections while maintaining ease of operation
Solution Approach 2:
The adapter modules feature self-aligning and self-securing mechanisms where the complementary male and female connectors guide the modules into proper alignment during stacking, and the latches automatically engage to secure the connection. This self-service capability ensures stable electrical connections without requiring complex manual assembly procedures, and allows easy disconnection by simply separating the stacked modules
Data Source
AI summary
A modular electrical adapter assembly for connecting a plurality of flat cables and a plurality of wires may include a plurality of male connectors, female connectors, and adapter modules. The adapter modules may be releasably connected to one another. Each adapter module may include a first housing shell, a second housing shell, an interior space defined between the housing shells, a wire opening via which an associated wire extends into the interior space, a cable opening via with an associated flat cable extends into the interior space, a male connector disposed on the second housing shell outside of the interior space, and a female connector disposed on the first housing shell outside of the interior space. Adjacent adapter modules may be releasably connected to one another via engagement of the male connector of a first adapter module and the female connector of an adjacent second adapter module.