Right Angle Header Assembly for High Voltage Shielding
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Solution Overview
Problem
Current 90° connector assemblies for high voltage automotive applications face challenges in routing high voltage circuits and shield continuity, particularly in compact designs that can be mass produced, and achieving robust shielding continuity in tight spaces.
Innovation Solution
A high voltage right angle header assembly with a right angle body comprising two perpendicular segments, including a mating interface and a mounting flange, with HV contacts and shields that provide electrical connections and shielding, allowing for compact and efficient routing of high voltage and interlock circuits through a 90° bend.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the 90° bend is accomplished in the plug assembly, then the connector can provide high voltage connection, but a large amount of room is required to mate the plug assembly to the device
Solution Approach 1:
The patent moves the 90° bend from the plug assembly to the header assembly, changing the spatial orientation of the connection. The header assembly's right angle configuration allows the plug to mate perpendicular to the panel while the header extends parallel to the panel, effectively utilizing a different dimensional arrangement to reduce mating space requirements
2Object-affected harmful factors
If robust shielding continuity is provided along the 90° bend, then electromagnetic interference is reduced, but the design complexity increases in tight spaces
Solution Approach 1:
The shielding system is divided into multiple segments: a first shield portion in the first segment, a second shield portion in the second segment, and an interconnecting shield portion at the right angle bend. Each segment can be independently designed and assembled, reducing overall design complexity while maintaining continuous shielding effectiveness
Solution Approach 2:
The shields are nested within the header assembly structure, with the interconnecting shield portion positioned at the right angle bend and the first and second shield portions extending into各自的 segments. This nested arrangement provides robust shielding continuity while utilizing the existing structural space efficiently
3Productivity
If the connector is designed for mass production, then manufacturing efficiency is improved, but achieving compact packaging with 90° bend becomes more difficult
Solution Approach 1:
The header assembly is divided into separable segments (first segment, second segment, and interconnecting portion) that can be manufactured independently using standard molding or fabrication processes, then assembled through straightforward operations. This segmentation enables mass production while achieving the compact right angle configuration
Data Source
AI summary
A high voltage (HV) header assembly includes an outer housing having a right angle body including a first segment and a second segment oriented perpendicularly to the first segment. The first segment has a mating interface at a distal end for mating with a plug assembly. The second segment has a mounting flange at a distal end for mounting to a device. The second segment extends from the first segment such that the mounting flange is oriented perpendicularly to the mating interface. The body defines a right angle chamber extending through the first and second segments between the mating interface and the mounting flange. The chamber has first and second openings therethrough in the first and second segments, respectively. HV contacts are received in the chamber of the outer housing and are configured to electrically connect to plug contacts of the plug assembly.