Cable End Connector Assembly With Plug-Locked Busbar Retention
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Solution Overview
Problem
The challenge of maintaining a reliable electrical connection between cable end connectors and circuit board connectors, particularly in high-current applications, where the conductive terminals may be pulled off, leading to instability and potential failure.
Innovation Solution
A connector assembly comprising a first and second connector with engaging structures, a conductive terminal, and a plug system that secures the busbar terminal and conductive terminal to prevent unintentional disconnection, while allowing for a compact design that includes a second plug that engages with the first connector and a second connector with a connector assembly comprising a connector that engages with the first connector and a connector assembly comprising a connector assembly comprising a connector assembly comprising a first connector and a second connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cable end connector and board end connector are designed for large current conduction, then the current carrying capacity is improved, but the risk of terminal disconnection and connection instability increases
Solution Approach 1:
The connector is divided into multiple functional components: a housing, a conductive terminal with cylindrical structure, an engaging structure with latch mechanism, and a securing portion. This segmentation allows each component to perform its specific function - the cylindrical structure provides current conduction while the engaging structure provides mechanical retention, resolving the contradiction between power capacity and connection stability.
Solution Approach 2:
The engaging structure with latch mechanism is pre-configured to automatically engage and lock the conductive terminal in place before current flow begins. The securing portion is pre-positioned to prevent terminal rotation or displacement. This preliminary mechanical securing action ensures connection stability is established before electrical operation, preventing terminal disconnection during high current conduction.
2Power
If the cable end connector is designed with larger conductive terminals for high current, then the power transmission is improved, but the weight and volume of the connector increase
Solution Approach 1:
The conductive terminal features a cylindrical structure with optimized local geometry - the cylindrical shape provides sufficient current conduction cross-section while minimizing material usage. The engaging structure uses a latch mechanism that provides strong mechanical retention with minimal added mass. This local optimization of geometry and structure allows high current capability without proportional increases in overall weight.
Solution Approach 2:
The connector employs composite construction combining conductive materials for current flow with structural materials for mechanical strength and retention. The housing provides structural support while the conductive terminal provides electrical conduction, allowing each material to be optimized for its specific function rather than using a single heavy material for all purposes.
3Reliability
If the connector assembly includes multiple securing structures and plugs, then the connection stability is improved, but the device complexity increases
Solution Approach 1:
Multiple securing functions are merged into integrated structures. The engaging structure combines latch mechanism and locking action in a single component. The securing portion integrates terminal retention and positioning functions. The cylindrical structure of the conductive terminal serves both electrical conduction and mechanical engagement purposes. This merging reduces the number of separate parts while maintaining comprehensive security against disconnection.
Solution Approach 2:
The latch mechanism in the engaging structure is designed to automatically engage and lock when the connector components are assembled, providing self-securing action without requiring additional fastening operations. The cylindrical conductive terminal structure naturally fits into the housing and engaging structure, providing self-positioning and self-retention. This self-service capability ensures connection stability while minimizing the complexity of assembly procedures.
Data Source
AI summary
A connector assembly includes a first connector, a second connector, and a first plug. The first connector includes a first housing, a conductive terminal, and a first engaging structure. The first housing has a chamber. The conductive terminal includes a cylindrical structure partially located in the chamber. The first engaging structure is disposed on an outer surface of the first housing. The two connectors can be coupled along a mating direction. The second connector includes a second housing, a busbar terminal, and a second engaging structure. The second housing is able to be partially accommodated in the chamber. The second housing has a channel and a positioning slot communicating with the channel. The busbar terminal is located in the channel of the second housing. The second engaging structure is engaged with the first engaging structure. The first plug is located in the positioning slot.