Wiring Harness Adapter Assembly for Aftermarket Control Board Compatibility
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Solution Overview
Problem
Existing HVAC furnace control systems face complexity and compatibility issues when replacing OEM control boards, as male header pins are not designed for incorporation into wiring assemblies, leading to challenges in connecting aftermarket control boards with different connector types to existing wiring harnesses.
Innovation Solution
A wiring harness assembly is provided with a male connector for connection to a wiring harness and a second connector for mounting to a panel, using encapsulated male header pin connectors and flexible conductors with insulated wiring, allowing connection to female connectors of existing harnesses, and including a method of soldering conductors to male header pins with molding material for protection and strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If male header pin connectors are used for connecting control boards, then connection simplicity is improved, but compatibility with wiring harnesses deteriorates because they are not designed for incorporation into wiring assemblies
Solution Approach 1:
The patent introduces an adapter assembly that acts as an intermediary between the male header pin connector on the control board and the wiring harness. The adapter includes a connector portion that receives the male header pin and a harness portion that interfaces with the wiring harness, enabling compatibility without modifying the original male header pin design.
2Adaptability or versatility
If aftermarket control boards with different connector types are used, then replacement flexibility is improved, but integration complexity increases due to compatibility issues with existing wiring harnesses
Solution Approach 1:
The adapter assembly is designed to be universal, working with various male header pin connector types found on different control boards while maintaining a consistent interface with the wiring harness. This allows different aftermarket control boards to be integrated without requiring custom adapter designs for each specific connector type.
3Reliability
If encapsulated male header pin connectors are used in wiring assemblies, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the male header pin connector with the wiring harness assembly through encapsulation, where the connector is permanently integrated into the harness housing. This merging eliminates the need for separate connector installation steps and ensures reliable electrical connections while simplifying the overall assembly process through pre-integration.
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
Enables the use of aftermarket control boards with different connector types to replace OEM boards by facilitating connections between matrix PCB headers and in-line style plug crimp terminal housings, ensuring seamless integration and flexibility in wiring arrangements.
Implementation Method 1
molding material around the solder joint(s) to protect the solder joint(s) from moisture and/or contact
Data Source
AI summary
In exemplary embodiments, wiring harness assemblies for electrical equipment and related methods are disclosed. In an exemplary embodiment, a wiring harness assembly for electrical equipment generally includes a first connector configured for connecting to a wiring harness, a second connector configured for mounting to a panel, and one or more conductors connecting the first connector with the second connector.