Multi-phase Connector with Conductive Metal Casing
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Solution Overview
Problem
Conventional multi-phase connectors for electric powertrain systems face issues with poor shield contact due to non-conductive plastic bodies, requiring complex and costly shield contact designs, and often necessitate tool usage for installation, which is cumbersome and time-consuming.
Innovation Solution
A multi-phase connector featuring a terminal block with a conducting metal casing and a plug member with contact pins and cable gland assemblies for robust, tool-free engagement, providing improved electrical continuity and grounding without the need for tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional quick-connectors with plastic bodies are used, then installation is easy and tool-free, but shield contact quality is poor and connection robustness is insufficient
Solution Approach 1:
The patent changes the material parameter of the connector body from non-conductive plastic to conductive metal (aluminum alloy), which fundamentally alters the electrical conductivity parameter. This enables the metal body itself to serve as the shielding path, eliminating the need for complex additional shielding structures while maintaining tool-free installation capabilities
Solution Approach 2:
The metal connector body performs multiple functions simultaneously: it provides structural support, enables tool-free engagement through the quick-connect mechanism, and serves as the electrical shielding path. This multi-functionality resolves the contradiction by making the same component responsible for both ease of operation and reliable shield contact
2Reliability
If conventional pass-through connectors with metal bodies are used, then shield contact quality is good, but installation requires tools and is time-consuming
Solution Approach 1:
The patent incorporates dynamic engagement features including spring-loaded contact pins that automatically make electrical contact during insertion, and a latching mechanism that secures the connection without requiring tools for tightening. This maintains reliable electrical contact while enabling tool-free, rapid installation
Solution Approach 2:
The connector is pre-configured with spring-loaded contacts and latching mechanisms that automatically engage upon insertion. The spring contacts are pre-positioned to make electrical connection before the final latched position is reached, ensuring reliable shield contact is established as part of the tool-free installation process
3Reliability
If complex shield contact designs are used to overcome poor plastic conductivity, then shield contact quality improves, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent extracts the shielding function from separate shielding components and integrates it directly into the connector body itself. By making the connector body conductive, the shielding path is built-in and inherent to the structure, eliminating the need for additional shielding layers, meshes, or separate grounding components that would increase complexity and manufacturing cost
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 offers a robust, efficient, and cost-effective electrical connection with enhanced shield contact quality, simplifying installation and reducing manufacturing costs by using metal components for improved conductivity and grounding.
Implementation Method 1
a terminal block having a casing formed of a conducting metal
Implementation Method 2
at least one cable gland assembly to ground the shielded cable and maintain electrical continuity between a shielded cable and the plug member
Data Source
AI summary
A multiphase connector for electric powertrain systems includes a terminal block and a plug member that are, at least in part, made from electrically conductive metal. The terminal block has at least one socket surrounding a retaining spring and the plug member has at least one contact pin configured to be inserted in to the at least one socket. The plug member can be engaged with the terminal block without use of installation tools and includes one or more cable gland assembly in contact with a shield of a shielded cable.