Splice Connector Assembly for High-Power Cable Termination
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Solution Overview
Problem
High-power circuit configurations in electric or hybrid electric vehicles are costly and labor-intensive to assemble, and they require significant packaging space due to the use of Y-splice devices, which connect high-power wire cables with varying cross-sectional areas.
Innovation Solution
A splice connector assembly that directly connects two wire cables with different cross-sectional areas to a terminal, which is then connected to a power source, using a dielectric housing and sonic welding, with a terminal position assurance device to secure the terminal within the housing and provide electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If Y-splice devices are used to connect high-power wire cables with varying cross-sectional areas, then the circuit can accommodate different cable sizes, but the assembly cost and labor increase significantly
Solution Approach 1:
The patent merges the functions of multiple separate components (Y-splice device, connectors, insulation elements) into a single integrated splice connector assembly. The housing contains integrated cable clamps for different cable sizes, built-in insulation barriers, and terminal connection structures all in one unit, eliminating the need for separate Y-splice devices and reducing assembly steps
Solution Approach 2:
The splice connector assembly is designed as a universal component that can accommodate multiple cable cross-sectional areas through integrated cable clamps with different opening sizes. The single assembly performs multiple functions: mechanical support, electrical insulation, cable securing, and terminal connection, replacing several specialized components
2Adaptability or versatility
If Y-splice devices are used to connect high-power wire cables, then cable connections with different cross-sectional areas are achieved, but the packaging space required increases
Solution Approach 1:
The splice connector assembly nests multiple functional elements within a compact housing structure. Smaller cable clamps and insulation components are positioned within the housing cavity, with cable clamps arranged to accommodate different cable sizes in a space-efficient manner, reducing the overall volume compared to separate Y-splice devices
3Ease of operation
If traditional connector assembly methods are used, then assembly is straightforward, but assembly costs and labor intensity are high
Solution Approach 1:
The patent combines multiple assembly steps into a single pre-assembled unit. The housing, cable clamps, insulation barriers, and terminal structures are integrated beforehand, allowing the entire assembly to be installed as one component rather than requiring sequential assembly of multiple parts, thereby reducing labor intensity and cost
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
This configuration reduces assembly costs and space requirements by eliminating the need for Y-splice devices, while maintaining the ability to conduct over 1 kilowatt of electricity, and ensures reliable electrical connections through sonic welding and insulation.
Implementation Method 1
a terminal position assurance device defining a lance configured to contact the attachment portion of the terminal, thereby securing the terminal within the cavity
Implementation Method 2
using a dielectric housing and sonic welding
Data Source
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AI summary
A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.