Resilient BDU Connector Support for Misalignment-Tolerant Assembly
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Solution Overview
Problem
In applications where space is limited, maintaining tight tolerances for electrical connectors increases component complexity, manufacturing time, and assembly time, while relaxed tolerances are necessary to accommodate misalignments but not suitable for all applications.
Innovation Solution
A compliant electrical connector with a resilient connector support integrated into a battery disconnect unit (BDU), allowing the connector to shift relative to the connection axis, thereby accommodating misalignments without compromising connection integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight tolerances are maintained for electrical connectors in space-constrained applications, then connection precision is improved, but component complexity and manufacturing time increase
Solution Approach 1:
The connector support is designed with resilient properties that allow it to dynamically adjust and shift position during connection formation. This dynamic capability enables the support to compensate for misalignments between connectors, achieving precise connections without requiring tight manufacturing tolerances on the rigid components.
Solution Approach 2:
The invention changes the physical state of the connector support from rigid to resilient, allowing it to deform and shift position. This parameter change enables the system to accommodate misalignments through elastic deformation rather than requiring precise dimensional control of all components.
2Manufacturing precision
If tight tolerances are maintained for electrical connectors, then connection precision is improved, but assembly time increases
Solution Approach 1:
The resilient connector support performs self-alignment by automatically shifting to the correct position during assembly. This self-correcting mechanism eliminates the need for precise manual positioning or complex alignment procedures, significantly reducing assembly time while maintaining connection precision.
Solution Approach 2:
The dynamic resilience of the support allows it to automatically adapt to misalignments during the assembly process, eliminating the need for time-consuming adjustment procedures and enabling faster assembly while maintaining precise connections.
3Ease of manufacture
If relaxed tolerances are used for electrical connectors, then assembly simplicity is improved, but connection reliability may be compromised
Solution Approach 1:
By changing the connector support from rigid to resilient, the system can use relaxed tolerances on the rigid components while the resilient support compensates for variations through elastic deformation, maintaining both assembly simplicity and connection reliability.
Solution Approach 2:
The resilient support dynamically adjusts its position to accommodate misalignments that would result from relaxed tolerances, ensuring reliable electrical connections are formed even when component dimensions vary within wider tolerance ranges.
4Adaptability or versatility
If resilient connector support is added to accommodate misalignments, then adaptability is improved, but device complexity increases
Solution Approach 1:
The resilient support is integrated directly with the rigid connector support structure, merging the rigid mounting function with the resilient alignment compensation function into a single unified component. This integration provides adaptability without adding separate complex subsystems.
Solution Approach 2:
The invention uses a resilient support structure that can deform elastically to accommodate misalignments. This flexible element provides adaptability to various connection positions and orientations while maintaining a relatively simple overall structure compared to rigid alternative solutions.
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 allows for flexible alignment of electrical connectors, reducing the need for tight tolerances and simplifying assembly, while maintaining reliable electrical connections even in space-constrained environments.
Implementation Method 1
a resilient connector support coupled to the rigid base, wherein the first electrical connector is mounted to the resilient connector support... the resilient connector support is selectively shiftable relative to the connection axis
Data Source
AI summary
A system, in accordance with a non-limiting example, includes a first member including a first electrical connector and a second member including a second electrical connector. The first member includes a rigid base and a resilient connector support coupled to the rigid base. The first electrical connector is being mounted to the resilient connector support.