Tensioned Electrical Module Assembly for Secure Connector Retention
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Solution Overview
Problem
Existing electrical assemblies for vehicle seats face challenges in maintaining secure and efficient connections between modules, particularly in configurations with multiple interconnected components, leading to potential disconnection and wear of electrical connectors.
Innovation Solution
The assembly employs a modular design with housings featuring projections and recesses that allow for connections under tension, utilizing ramped portions and interference fits, along with tracks and channels to restrict relative movement, ensuring stable intermodule connections and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modules are connected without tension in existing electrical assemblies, then assembly is simpler, but connections become insecure and electrical connectors experience wear and disconnection
Solution Approach 1:
The housing is designed to be deformable and is stretched during assembly to create tension in the electrical connectors. This dynamic approach transforms a static connection into a tension-based secure connection, resolving the contradiction between connection stability and assembly simplicity by introducing controlled deformation and tensioning mechanisms
Solution Approach 2:
The physical state of the housing changes from unstretched to stretched during assembly, creating tension in the electrical connectors. This parameter change (from relaxed to tensioned state) ensures secure connections while maintaining modular assembly, addressing both reliability and complexity concerns
2Reliability
If electrical connectors are allowed to move freely between modules, then assembly is easier, but connector wear and disconnection increase
Solution Approach 1:
The housing includes specific localized features (ramped portions, tracks, and channels) that provide directional guidance and restriction only where needed for connector stability, while maintaining overall assembly simplicity. This localized constraint approach prevents unwanted connector movement without complicating the overall assembly process
3Reliability
If multiple modules are interconnected without tension, then manufacturing is simpler, but unintentional disconnection occurs
Solution Approach 1:
The manufacturing process incorporates a stretching step that dynamically tensions the housing and electrical connectors during assembly. This dynamic tensioning ensures secure intermodule connections while integrating smoothly into the manufacturing workflow, balancing reliability with ease of manufacture
Solution Approach 2:
The housing is pre-designed with ramped portions and tracking features that guide the tensioning process during assembly. This preliminary design of the housing structure enables the tension-based connection system to be implemented without significantly complicating the assembly process
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
The solution provides stable, tension-based connections that prevent unintentional disconnection and minimize wear of electrical connectors, enhancing the reliability and durability of the electrical assembly.
Implementation Method 1
the housing may comprise one or more materials that are configured to deform (e.g., stretch, bend, flex, etc.), at least to some degree, during assembly
Implementation Method 2
projections and ramped portions of a first module may be stretched and/or deformed such that the projections are disposed at least partially within recesses of a second module
Data Source
AI summary
An assembly includes a module including a housing having a first portion, a second portion including a projection, and a first interior cavity; and a circuit board disposed at least partially in the first interior cavity; and an additional module connected under tension with the module, the additional module including: an additional housing having a recess and an additional interior cavity; and an additional circuit board disposed at least partially in the additional interior cavity. The second portion of the housing may be disposed at least partially in the additional interior cavity. The projection of the housing may be disposed at least partially in the recess of the additional housing. The circuit board may be electrically connected to the additional circuit board.