Nested Shroud Power Connector for Automotive Safety
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Solution Overview
Problem
Existing power terminal connectors in automotive applications face challenges such as limited space around batteries, requiring complex and large touch-safe designs that are not robust, and often necessitate special tools for connection and disconnection, which can be time-consuming and costly.
Innovation Solution
A power connector system featuring a header assembly with a conductive pin surrounded by inner and outer shrouds, a plug housing with a cavity and insert assembly, and a shield for electromagnetic interference protection, allowing for a quick connect/disconnect mechanism with a low profile to conserve space and incorporate touch-safe features using ribs and slots to prevent accidental contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If touch-safe power terminal connectors are designed with complex structures to meet safety regulations, then safety compliance is improved, but device complexity and overall size increase
Solution Approach 1:
The connector employs nested shrouds where an inner shroud is positioned within an outer shroud, creating multiple protective layers. The inner shroud directly surrounds the power terminal contact, while the outer shroud provides additional protection and structural support. This nested configuration achieves touch-safe compliance through layered isolation without requiring complex external mechanisms.
Solution Approach 2:
The connector is divided into distinct functional segments: the power terminal contact, inner shroud, outer shroud, and housing. Each segment performs a specific function - the contact carries current, the inner shroud provides primary isolation, the outer shroud adds secondary protection, and the housing provides structural support. This segmentation allows each component to be optimized independently while collectively achieving safety compliance.
2Reliability
If power terminal connectors are designed with larger dimensions to ensure touch-safe compliance, then safety compliance is improved, but the available space around the battery is exceeded
Solution Approach 1:
The nested shroud configuration allows multiple protective layers to be contained within a compact volume. The inner shroud fits within the outer shroud, which in turn fits within the housing, creating a space-efficient layered structure that provides touch-safe compliance without excessive dimensional increases.
Solution Approach 2:
The connector utilizes three-dimensional spatial arrangement where the inner and outer shrouds are positioned at different radial distances from the power terminal contact. This dimensional layering provides comprehensive protection while maintaining a compact overall footprint that fits within limited battery space.
3Productivity
If conventional power terminal connectors are used without quick-connect mechanisms, then structural simplicity is maintained, but connection and disconnection time increases and special tools are required
Solution Approach 1:
The connector incorporates self-aligning features where the housing and contact are designed with geometric constraints that automatically guide proper alignment during connection. The latch mechanism automatically engages when the connector is properly inserted, eliminating the need for external alignment tools or complex manual assembly procedures.
Solution Approach 2:
The latch mechanism serves as an intermediary that mediates between the connector housing and the power terminal contact. It provides a simple mechanical interface that secures the connection without requiring complex fastening operations or specialized tools, enabling quick connect and disconnect operations.
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 provides a compact, robust, and efficient power connector system that is easy to connect/disconnect, meets safety regulations with touch-safe features, and prevents accidental contact, while maintaining electromagnetic compatibility and reducing the need for special tools.
Implementation Method 1
The insert assembly has a shield that surrounds the dielectric insert and provides shielding for the terminal body
Data Source
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Figure 4
AI summary
A power connector system (100) including a header assembly (120) that includes a conductive pin (124), an inner shroud (128) that surrounds the pin (124), and an outer shroud (130) that surrounds the inner shroud (128). The inner shroud (128) has slots (154) therethrough. The power connector system (100) includes a power terminal connector (102) having a plug housing that has a cavity and an insert assembly that is received in the cavity. The insert assembly has a terminal body configured to be terminated to an end of a conductor of a power cable (108) and is electrically connected to the pin (124) of the header assembly (120). The insert assembly has a dielectric insert that holds the terminal body. The insert assembly has a shield that surrounds the dielectric insert and provides shielding for the terminal body. The plug housing has optional ribs which are received in corresponding slots (154) to orient the power terminal with respect to the header assembly (120).