Sealed Connector System for Vehicle Power Management
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Solution Overview
Problem
Conventional power distribution components in motor vehicles face challenges such as space constraints, harsh operating conditions, vibration, and high failure rates due to incorrect installation and dislodgment, leading to significant repair and warranty costs.
Innovation Solution
A connector system with a sealed and grounded electrical connection, featuring a male connector assembly and an adaptor assembly with a female terminal assembly, including a capacitor assembly and a busbar with a grounding coupler, designed for reliable operation in high-stress applications, eliminating the need for bolted connections and reducing electromagnetic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fasteners (elongated fasteners, washers, nuts and/or studs) are used to couple busbars to power sources and power distribution assemblies, then the connection is mechanically secure, but the installation becomes extremely difficult due to protective equipment requirements and the complexity of the fastening process
Solution Approach 1:
The patent replaces conventional mechanical fastening systems (fasteners, washers, nuts, studs) with a push-connect electrical connector system. The connector uses a push-in mechanism with retention features that mechanically secure busbars to power sources and power distribution assemblies without requiring traditional fasteners, thereby simplifying installation while maintaining mechanical strength
Solution Approach 2:
The connector system is divided into separate modular components: a connector body, a terminal, and retention features. This segmentation allows for easier assembly and installation compared to integrated conventional fastening systems, as each component can be independently positioned and connected
2Adaptability or versatility
If custom fabricated busbars are used in power distribution assemblies, then the power distribution system can be configured to meet specific needs, but any alterations require altering the configuration of busbars which is expensive and time-consuming
Solution Approach 1:
The power distribution system uses modular connectors that can be independently configured and replaced. This segmentation allows for easy alterations and reconfigurations without requiring custom fabrication or alteration of the entire busbar system, reducing both cost and time for modifications
Solution Approach 2:
The connector design provides universal adaptability through standardized interfaces and configurations that can accommodate different power distribution needs. The modular nature allows the same connector type to be used across various applications, eliminating the need for custom-fabricated solutions for each specific configuration
3Ease of operation
If conventional power distribution assemblies are used, then the system can be installed in motor vehicles, but the assemblies have high failure rates due to incorrect installation and dislodgment in harsh operating conditions
Solution Approach 1:
The connector incorporates preliminary alignment features and guide structures that ensure correct installation before the final connection is made. These preliminary actions prevent incorrect installation by guiding the busbar into the proper position, thereby improving reliability
Solution Approach 2:
The connector includes a curved retention feature that engages with the busbar in a curved or arc-shaped manner. This curved geometry provides mechanical retention that resists dislodgment from vibration and shock, improving reliability in harsh operating conditions while maintaining ease of installation
4Object-affected harmful factors
If sealed electrical connections are implemented in the connector system, then the connection is protected from environmental factors, but the manufacturing complexity increases
Solution Approach 1:
The sealing structure uses a nested design where the terminal is inserted into the connector body, and the retention feature is nested within the connector assembly. This nested configuration provides sealed protection against environmental factors while maintaining a compact and relatively simple manufacturing process, as the sealing surfaces are integrated into the nested interfaces
Data Source
AI summary
The present disclosure relates to a connector system that provides a sealed and grounded electrical connection for a component of a power management system, like those found in a battery-powered motor vehicle. The connector system includes a male connector assembly and an adaptor assembly. The adaptor assembly includes: (i) a capacitor assembly, (ii) a female terminal assembly, and (iii) a busbar assembly. An internal electrical connection state is defined when: (a) the female terminal assembly is electrically coupled to the capacitor assembly, (b) the capacitor assembly is electrically coupled to the busbar assembly, and (c) the busbar assembly is electrically coupled to an extent of the component of the power management system. In the internal electrical connection state, the electrical couplings are sealed from the external environment which increases the operating life, durability and reliability of the adaptor assembly, the connector system and the power management system component.