Threaded Power Harness Connector for Sealed Vibration Resistance
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Solution Overview
Problem
Existing power connector systems for electric vehicles face challenges such as difficulty in connecting power cables, susceptibility to vibration and environmental deterioration, and complex assembly processes with potential for component misplacement or loss.
Innovation Solution
A power harness system with a housing having a chamber extending between a terminating end and a mating end, featuring a hub with a bore, a power conductor, a power contact with a base plate and side walls, and a threaded connector configured for secure mating with a corresponding connector, providing a robust and reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power cables are connected using traditional connectors, then electrical connection is achieved, but the connection is susceptible to vibration and environmental deterioration
Solution Approach 1:
The patent combines multiple protective functions into a single integrated housing structure that encapsulates the power contacts and provides vibration resistance, environmental sealing, and mechanical support simultaneously, eliminating the need for separate protective components and improving overall connection reliability
Solution Approach 2:
The patent employs a sealed housing structure with integrated sealing elements that protect the internal power contacts from environmental deterioration while maintaining electrical connection integrity, creating a protective barrier against moisture, debris, and vibration
2Productivity
If traditional power connector assembly is used, then electrical connection is established, but assembly time is consuming with potential to misplace or lose components
Solution Approach 1:
The patent integrates multiple previously separate components into unified structures, such as combining the housing with built-in sealing and mounting features, and integrating the power contact retention mechanisms into the housing itself, thereby reducing the total number of discrete parts and simplifying assembly procedures
Solution Approach 2:
The patent employs modular design where the housing, power contacts, and sealing elements are designed as interchangeable modules that can be assembled in a standardized sequence, reducing assembly complexity and minimizing the risk of component misplacement or loss
Data Source
AI summary
A power harness includes a housing configured to be mated with a mating harness connector. The power harness includes a power conductor extending from the housing and a power contact received in the housing having a terminating end terminated to the power conductor and a mating end for mating with a mating power contact of the mating harness connector. The power contact includes a base plate and side walls extending from the base plate on opposite sides of a gap with outer edges forming mating interfaces for mating engagement with the mating power contact. The power harness includes a threaded connector passing through the housing and located in the gap between the side walls for threadably coupling to a mating threaded connector of the mating harness connector.