Electrical Splice Assembly with Bus Plate and Retention Beams

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Solution Overview

Problem

Existing splice assemblies, such as IDC and ultrasonic welding methods, face issues with inadequate performance for certain conductive core materials like aluminum and are time and cost intensive, especially in environments with vibrations and require complex multi-housing connections.

Innovation Solution

An electrical splice assembly featuring an insulative housing with a conductive bus plate and resilient retention beams that securely hold terminals in place, allowing for efficient electrical communication between multiple wires without the need for separate stations or complex housing configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If IDC splice assemblies are used, then electrical connection is achieved, but performance is inadequate for certain conductive core materials like aluminum and in vibrational environments

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidcompatibility with conductive materials

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The splice assembly is divided into separate functional components: an insulative housing with terminal retention cavities, a conductive bus plate, and individual conductive terminals. This segmentation allows each component to be optimized independently - the retention cavities provide mechanical stability while the bus plate ensures electrical connectivity, resolving the contradiction between connection reliability and material compatibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductive bus plate acts as an intermediary element between the terminals and the housing structure. It provides a stable electrical connection pathway that is independent of the terminal material, allowing different conductive materials (including aluminum) to be connected reliably through the mediating bus plate structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If ultrasonic welding process is used, then wires are spliced, but separate station is required making the process time and cost intensive

Engineering Contradiction:

Improvesplice connection strengthVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The splice assembly is designed as a self-contained unit where all splicing functions are integrated into the housing structure. The terminal retention cavities and bus plate work together to automatically secure and electrically connect terminals without requiring external welding equipment or separate processing stations, eliminating time losses while maintaining connection strength.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mechanical retention function and electrical connection function are merged into a single integrated assembly. The conductive terminals simultaneously provide mechanical support through the retention cavities and electrical connectivity through the bus plate, combining multiple functions into one operation rather than requiring separate welding and connection steps.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If multiple insulative bodies or housings are used, then terminals are retained, but assembly becomes time and cost intensive

Engineering Contradiction:

Improveterminal retention securityVSAvoidnumber of housing components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple terminal retention functions are merged into a single insulative housing structure. The housing contains multiple terminal retention cavities that can securely hold multiple terminals simultaneously, eliminating the need for multiple separate housings or insulative bodies while maintaining secure retention for all terminals.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulative housing is designed as a universal structure that serves multiple functions: providing mechanical support, containing terminal retention cavities, isolating electrical components, and securing the bus plate. This multi-functional design eliminates the need for separate specialized components for each function, reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8992251B2Electrical splice assembly

Publication Date: 2015.03.31 APTIV TECHNOLOGIES AG

AI summary

An electrical splice assembly includes a housing having a forward portion, a rearward portion, and an intermediate portion defining a plurality of terminal retention cavities between the forward portion and the rearward portion. A conductive bus plate is retained within the forward portion of the housing. A plurality of terminals each extend into a respective terminal retention cavity and each terminal is in electrical contact with the bus plate. Each of the terminal retention cavities is defined by 1) a pair of opposing sidewalls connected to the forward portion and to the rearward portion and 2) a pair of opposing retention beams. The retention beams each include a latch which engages a respective terminal to retain the terminals in the terminal retention cavities.