Compact Power Connector Reverse Crimping for Short-Profile Assembly
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Solution Overview
Problem
Traditional power connectors are elongated due to crimping, occupying more horizontal space and compromising the cosmetic finish and tensile strength when used in short profile applications, where a separate flange is often needed to address these issues but can weaken the connector.
Innovation Solution
A compact power connector design featuring reverse crimping of wires to terminals within a cable holder, integrated with an over mold that includes a flange to cover the housing and enhance cosmetic finish without compromising strength, using a combination of inner and over molds made from non-conductive materials like PVC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crimping is used to connect wires to terminals, then the connector achieves reliable electrical connection, but the connector becomes more elongated and occupies more horizontal space
Solution Approach 1:
The patent applies reverse crimping where the terminal is crimped onto the wire from the opposite direction compared to traditional crimping. This inversion allows the crimping operation to occur within a shorter horizontal distance, reducing the overall connector length while maintaining reliable electrical connection between the wire and terminal
2Shape
If a separate flange is added to cover the gap around the receiving inlet frame, then the cosmetic finish is improved, but the connector integrity and tensile strength are compromised
Solution Approach 1:
The patent merges the flange function with the main connector body by integrating it as an integral part rather than a separate component. This combination eliminates the need for additional fastening elements and maintains the structural integrity and tensile strength of the connector while still providing the cosmetic benefit of covering the gap around the receiving inlet frame
3Shape
If a separate flange is used to provide flush effect with equipment profile, then the cosmetic finish is enhanced, but the device complexity increases
Solution Approach 1:
The flange is integrated as an integral part of the connector body, eliminating the need for separate assembly steps and reducing device complexity. This merging of functions allows the connector to achieve flush effect with equipment profile while maintaining a simple, unified structure
Data Source
AI summary
A compact electrical power connector including a cable with cores surrounded by cable insulation. Each core includes a wire surrounded by core insulation. Removed cable insulation exposes each core and removed core insulation exposes each wire. Each wire is reverse crimped to a corresponding terminal placed within a cable holder that supports and routes each core. The assembled cable holder is inserted into a housing including housing terminal slots corresponding to each terminal. An inner mold is injected around the exposed end of the cable holder, any exposed core and a first portion of the terminal end of the cable. An over mold with integrated flange is injected around the exposed surfaces of the housing, the inner mold and a second portion of the terminal end of the cable adjacent the first portion.