Modular Electrical Connector Assembly with Offset Apertures

Solution Overview

Problem

Conventional high-current electrical connector assemblies face issues with significant voltage drop and heat increase due to the use of hard materials, which can lead to failures under high torque or force applications, and require complex and costly manufacturing processes.

Innovation Solution

A modular electrical connector assembly design featuring a conductive body with offset post apertures and externally threaded fasteners, allowing for robust mechanical fixation and reduced conduction losses, using commercially available steel components for posts and a copper alloy for the body to enhance conductivity and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If hard materials are used for high-current electrical connector assemblies, then structural strength is improved, but voltage drop and heat increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidvoltage drop

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The electrical connector assembly is divided into separate components: a conductive body for electrical connection and a separate fastening mechanism. This segmentation allows the conductive body to be made of highly conductive material while the fastening function is handled by a separate threaded fastener, reducing overall resistance and heat generation in the electrical path.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The assembly uses composite construction combining a copper alloy conductive body (high electrical conductivity) with a steel fastener (high mechanical strength). This composite approach allows each material to perform its optimal function - the copper alloy minimizes electrical resistance and heat while the steel provides structural integrity under torque and force loads.

Inventive Principle:

Principle #40Composite materials

2Strength

If hard materials are used for high-current electrical connector assemblies, then structural strength is improved, but heat increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidheat generation

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The electrical connector assembly is divided into separate components: a conductive body for electrical connection and a separate fastening mechanism. This segmentation allows the conductive body to be made of highly conductive material while the fastening function is handled by a separate threaded fastener, reducing overall resistance and heat generation in the electrical path.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The assembly uses composite construction combining a copper alloy conductive body (high electrical conductivity) with a steel fastener (high mechanical strength). This composite approach allows each material to perform its optimal function - the copper alloy minimizes electrical resistance and heat while the steel provides structural integrity under torque and force loads.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional manufacturing processes are used for high-current electrical connector assemblies, then manufacturing capability is maintained, but manufacturing costs increase

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The threaded fastener serves multiple functions: it provides mechanical fastening, establishes electrical connection through the conductive body, and allows for adjustable positioning. This multi-functionality reduces the need for specialized components and complex assembly processes, enabling use of standard manufacturing techniques while lowering overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The threaded fastener design allows for self-alignment and self-securing through standard threading engagement with the conductive body. The modular design enables easy assembly and disassembly without specialized tools or complex procedures, making the manufacturing process simpler and more cost-effective while maintaining capability.

Inventive Principle:

Principle #25Self-service

4Device complexity

If modular design with standardized components is used, then manufacturing costs are reduced, but structural integrity may be compromised

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstructural integrity

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The assembly uses composite construction combining a copper alloy conductive body (high electrical conductivity) with a steel fastener (high mechanical strength). This composite approach allows each material to perform its optimal function - the copper alloy minimizes electrical resistance and heat while the steel provides structural integrity under torque and force loads.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The conductive body is pre-formed with integrated threading features that precisely match standard fastener specifications. This preliminary preparation ensures that when the standardized fastener is installed, it achieves optimal mechanical engagement and electrical connection, maintaining structural integrity while using cost-effective standardized components.

Inventive Principle:

Principle #10Preliminary action

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 design provides efficient high-current connections with minimized resistance and heat generation, is adaptable to various applications, and reduces manufacturing costs by using standardized components, while maintaining structural integrity and isolating posts from contaminants.

Implementation Method 1

A fastener is sized to be received within the second aperture of the conductive body and extend through the aperture in the first post to retain the first post in the conductive body

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

for electrical communication between the first electrical connector and the conductive body. A second post is exposed externally from the conductive body for receipt of a second electrical connector for electrical communication with the first electrical connector

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS10700451B1Electrical connector assembly

Publication Date: 2020.06.30 LEAR CORP

AI summary

An electrical connector assembly is provided with a conductive body with a first aperture formed therein, and a second aperture formed therein intersecting the first aperture. A first post has an aperture formed radially therethrough. The first post is sized to be received within the first aperture of the conductive body with an end of the first post accessible externally from the conductive body for receipt of a first electrical connector. A fastener is sized to be received within the second aperture of the conductive body and extend through the aperture in the first post to retain the first post in the conductive body for electrical communication between the first electrical connector and the conductive body. A second post is exposed externally from the conductive body for receipt of a second electrical connector for electrical communication with the first electrical connector.