Overmolded Electrical Connector Minimizing Parasitic Inductance
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Solution Overview
Problem
Conventional electrical connectors for motor vehicle electronic control units are bulky and expensive, posing placement difficulties and inefficiencies in electrical machine integration.
Innovation Solution
A compact electrical connector design featuring overmolded power traces with lugs at the ends, adjacent to each other, and mechanically connected, which reduces size and production costs, optimizing electrical machine operation by minimizing parasitic inductance and facilitating connections to electronic units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connectors are used to connect electronic control units to power sources, then reliable electrical connection is achieved, but the connector size becomes bulky and placement becomes difficult
Solution Approach 1:
The patent merges the power traces and insulation layers into a single integrated structure where insulation material is molded directly over the power traces to form an unified electrical connector assembly, eliminating the need for separate connectors and reducing overall volume
Solution Approach 2:
The patent implements a nested structure where multiple power traces are stacked vertically with insulation layers between them, creating a compact multi-layer configuration that reduces the horizontal footprint while maintaining reliable electrical connections
2Reliability
If conventional electrical connectors with separate components are used, then electrical connection is achieved, but production costs increase
Solution Approach 1:
The patent combines multiple manufacturing steps into a single molding process where power traces and insulation layers are formed together in one operation, reducing the number of assembly steps and lowering production costs while maintaining connection reliability
Solution Approach 2:
The patent creates a universal electrical connector structure that can accommodate multiple power traces and configurations through a single standardized molding process, enabling economies of scale and reduced tooling costs across different applications
3Reliability
If power traces are arranged in conventional configurations, then electrical connection is established, but parasitic inductance increases and operational efficiency decreases
Solution Approach 1:
The patent transitions from conventional planar power trace arrangements to a three-dimensional stacked configuration with vertical layering, reducing the loop area for current flow and thereby minimizing parasitic inductance and energy losses
Data Source
Figure 1a~1b
Figure 2a~3
Figure 4~6
AI summary
The invention relates to an electrical connector (10) intended to be electrically connected to an electrical power source, the electrical connector (10) comprising: - at least one first power trace (12a) intended to be electrically connected to a positive polarity pole (B+) of the electrical power source, and - at least one second power trace (12b) intended to be electrically connected to a negative polarity pole (B-) of the electrical power source, in which the at least one first and second power traces (12a, 12b) are overmolded at least in part with electrically insulating material, and in which the at least one first and second power traces (12a, 12b) are intended to be electrically connected to an electronic unit (206), in particular an electronic board, in particular intended to be integrated into an electrical machine, so as to supply electrical power to the electronic unit (206).