CONNECTORS

BACKGROUND

[0001] The use of electrification of loads and accessories for vehicles is increasing for a number of reasons. Electrified accessories and loads allow for greater control, utilization of otherwise wasted energy such as braking and regenerative energy, and provide for incremental improvements toward fully electric vehicles that do not have combustion engines, and (depending upon the source of electrical energy) that can potentially reduce the production of greenhouse gases. Additionally, it is desirable to reduce non-useful operating time for prime movers, such as idling internal combustion engines when motive power is not required.

[0002] Presently known systems for electrically powering loads on a vehicle suffer from a number of challenges. For example, high voltage systems require expensive connectors to a power converter/electronic heater controller, wherein the connector’s structure includes a portion subject to failure due to the physical weight of the cable load, the length of the cable, and vehicle vibration which may cause the wires to move and/or vibrate. The overhang wires and the weight of the wires causes stress on the connector block and the printed circuit board (PCB) due to vehicle vibration. Solutions are needed to reduce the overhang and provide support to the wires, which will help to reduce the stress on the connector block and the PCB.

BRIEF SUMMARY

[0003] Wire support brackets for reducing vibration to an electronic product are described. The electronic product can be, for example, a power converter/electronic heater controller, a power distribution unit (PDU), inverter, battery equalizer or any components with overhang wires connected to a PCB.

[0004] A wire support bracket for reducing vibration to an electronic product includes a body with recesses to accommodate corresponding wires, and a mount, where the mount is shaped to attach to an enclosure for an electronic product to which the corresponding wires connect.

[0005] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 illustrates a perspective view of an electronic product with connected wires.

[0007] FIG. 2 illustrates the failure zone of the wires connected to the electronic product of FIG. 1.

[0008] FIG. 3 illustrates experimental data for a connector embodiment.

[0009] FIGs. 4A - 4D illustrate experimental data for a connector embodiment.

[0010] FIGs. 5A and 5B illustrate an embodiment of a wire support bracket.

[0011] FIGs. 6A - 6D illustrate an embodiment of a wire support bracket.

[0012] FIGs. 7A - 7C illustrate an embodiment of a wire support bracket.

[0013] FIGs. 8A - 8D illustrate embodiments of a wire support bracket.

DETAILED DESCRIPTION

[0014] Wire support brackets for reducing vibration to an electronic product are described. The electronic product can be, for example, a power converter/electronic heater controller, a power distribution unit (PDU), inverter, battery equalizer or any components with overhang wires connected to a PCB. Example embodiments of the present disclosure provide for support of wires to the power converter/electronic heater controller (or a power distribution unit (PDU), inverter, battery equalizer or any components with overhang wires connected to a PCB) and reduction of stress on the wires. For example, the described wire support brackets may restrict the movement of wires and hold them together with the enclosure of the wire support bracket. With the illustrated designs, it is possible to provide the reduction of vibration to an electronic product under certain constraints, including: lower cost solution (e.g., HPDC Enclosure Casting design with two plate die design (no side core recommended)), packaging casting dimension, simple bracket locking, ease of connecting and/or removing connectors, and use of low-cost materials (e.g., sheet metal, polymer, or another material).

[0015] A wire support bracket for reducing vibration to an electronic product includes a body with recesses to accommodate corresponding wires; and a mount, wherein the mount is shaped to attach to an enclosure for an electronic product to which the corresponding wires connect. [0016] FIG. 1 illustrates a perspective view of an electronic product with connected wires; and FIG. 2 illustrates the failure zone of the wires connected to the electronic product of FIG. 1.

[0017] Referring to FIG. 1, an electronic product 110 is depicted in a perspective view with an enclosure 106. Wire 108a, wire 108b, wire 108c, and wire 108d (e.g., wires 108) are attached to the connector block 102 of the electronic product 110 with corresponding connector 104a, connector 104b, connector 104c, and connector 104d (e.g., connectors 104). The connector block 102 is bolted to the enclosure 106 of the electronic product 110. The electronic product 110 may include connectors 104 for input and output of signals and/or power and ground connections. The connectors 104 can include, but are not limited to, a ground connector, a power input connector, and a power output connector.

[0018] In some cases, the electronic product 110 is a DC/DC converter. The DC/DC converter can bridge system voltages (e.g., a 48V system and a 12V system with bidirectional power flow). For example, a 48V DC/DC converter includes a power input connector and a power output connector in order to transform 12 V power to 48 V power and vice versa. The 48V DC/DC converter stabilizes and connects the two voltage levels of a vehicle‘s electrical system. A 48 V DC/DC converter can be used for vehicles equipped with mild hybrid, autonomous systems, and the like.

[0019] In some cases, the electronic product 110 is an electronic heater controller. The electronic heater controller can receive power commands from an aftertreatment system, provide soft-start and soft-stop capabilities for assisting in maintaining system voltage control, and diagnostic feedback of the heater element.

[0020] FIG. 2 illustrates a side view of a connector block 102 portion of the electronic product 110 with an attached wire 108b at a corresponding connector 104a. A failure zone 202 of the wire 108b is depicted. When the wires 108 (e.g., wire 108b) are connected to the connector block 102 at the corresponding connectors 104 (e.g., connector 104a), the wires 108 overhang (e.g., 10-inch overhang) from the connector block 102. The weight of the wires 108 may be ~ 1200 gm (300 x 4). The overhang and weight of the wires 108 increases stress on the connection of the wires 108 to the corresponding connectors 104 at the connector block 102. This connection area, deemed a failure zone 202, can be subject to stress failure, requiring replacement of the wires and/or the PCB or other parts of the electronic product.

[0021] FIG. 3 illustrates experimental vibration data due to a vehicle. Data 302 were gathered from on road vehicle tests and contain frequency content of excitation up to 250 Hz only. Data 304 are derived from ISO standard 16750 vibration profile, which is severe in terms of loading (energy content = grms = area under the curve) up to 100 Hz as compared to data 302. Data 302 is severe in the frequency range of 100-250 Hz than ISO 16750 vibration profile. In modelling to capture the worst-case dynamics of the system, the model considered the combined severe excitation across frequency range of 10-2000 Hz as depicted by data 306 (Final excitation). [0022] FIGs. 4A - 4D illustrate experimental data relating to the effect of wire (e.g., wires 108 of FIG. 1 and FIG. 2) vibration on the enclosure (e.g., enclosure 106 of FIG. 1 and FIG. 2) and PCB connectors (e.g., connectors 104 of FIG. 1 and FIG. 2). The strain on the connector block (e.g., connector block 102 of FIG. 1 and FIG. 2) is reflected in the lighter coloring on portions of the connector block of the electronic product due to the vibration on the wires.

[0023] FIGs. 5A and 5B illustrate an embodiment of a wire support bracket. The wire support bracket 502 includes a body 506 with recesses (e.g., recess 508) to accommodate wires 108 and a mount 510 to attach the wire support bracket 502 to the enclosure 106 of an electronic component. FIG. 5B illustrates the wire support bracket 502 mounted on the enclosure 106 (e.g., such as with the same screws that are used for the enclosure flange). In FIG. 5B, wires 108 are resting in the recesses (e.g., wire 108c in recess 508) of the wire support bracket 502. The wire support bracket 502 may be made from plastic. The wire support bracket 502 may extend to an edge of an end of the connector block 102. Vibrations may transfer to the plastic wire support bracket 502 and enclosure 106. In an embodiment, no mounting (e.g., at the chassis) is required to hold cables. Instead, the wire support bracket 502 has self-press fit recesses (e.g., recess 508) to hold together all the cables.

[0024] The mount 510 of the wire support bracket 502 adopts the same profile as the enclosure 106, conforming the wire support bracket 502 to the enclosure 106. The mount 510 attaches the wire support bracket 502 to the enclosure 106. In some cases, the wire support bracket 502 mounts to the enclosure 106 by conforming to an end of the enclosure 106 without requiring screws or other fastening mechanisms. The wire support bracket 502 can include a hole 504 in the mount 510 to attach the wire support bracket 502 to the enclosure 106 via a fastening mechanism, for example, a screw (as depicted in FIG. 5B). Although four recesses 508 are shown, the number of recesses may be greater or fewer depending on the number of wires to be connected to the electronic product.

[0025] FIG. 6A - FIG. 6D illustrate an embodiment of a wire support bracket 610. The wire support bracket 610 includes a body 608 with U-shaped recesses (e.g., U-shaped recess 604) and a mount 606 in the form of round snaps. The round snap mount 606 is a mounting feature that is shaped to attach the wire support bracket 610 to the connector block 102 or enclosure 106, as depicted in FIG. 6B.

[0026] FIG. 6C illustrates the wire support bracket 610 mounted to the enclosure 106 via round snaps (e.g., round snap mount 606). The wire support bracket 610 may be snap-fitted with the enclosure 106 by adding a boss (e.g., corresponding protruding feature that is mostly cylindrical and can be used as a fixation point for a snap) on the enclosure 106. In this manner, cylinder features 612 in the enclosure 106 can hold the wire support bracket 610 to the enclosure 106, such as through the round snap mount 606. A close-up is shown in FIG. 6D. [0027] All wires 108 may be held together by pressing inside the U-shaped recesses (e.g., U- shaped recess 604), which may be flexible and may avoid the need for extra screws to lock the wire support bracket 610 or other tools. In an embodiment, no mounting (e.g., to the chassis) is required to hold wires 108. Instead, the wire support bracket 610 has self-press fit recesses (e.g., U-shaped recess 604) to hold together all the wires 108. In FIG. 6C, wires 108 are shown fitted in the U-shaped recesses (e.g., wire 108c in U-shaped recess 604) of the wire support bracket 610. Although four recesses 604 are shown, the number of recesses may be greater or fewer depending on the number of wires to be connected to the electronic product.

[0028] FIGs. 7A - 7C illustrate an embodiment of a wire support bracket. Referring to FIG. 7 A, the wire support bracket 702 includes a body 710 (e.g., 710a and 710b) that forms a single recess to accommodate wires 108. The wire support bracket 702 includes a mount 708 with a hole 704 to mount the wire support bracket 702 onto the chassis (see chassis mount 706 of FIG. 7C). The body 710 of the wire support bracket 702 includes a U-shaped section 710a and a ribbed section 710b. The U-shaped section 710a receives the ribbed section 710b, connecting to form a continuous receptacle (e.g., clamp) for receiving wires 108.

[0029] FIG. 7B illustrates an example of the wire support bracket 702 in use. The design of the wire support bracket 702 uses a plastic clamp with a self-locking arrangement (i.e., when ribbed section 710b connects with U-shaped section 710a) to keep wires 108 together. The wire support bracket 702 can accommodate any number of wires. In the illustration, two wires (e.g., wire 108a and wire 108d) are within the wire support bracket 702. In some cases, the wire support bracket can accommodate all four wires (e.g., wire 108a, wire 108b, wire 108c, and wire 108d). The wire support bracket 702 may be bolted via the mount 708 to the chassis to reduce the movement of the wires. The wire support bracket 702 may be made from plastic. The wire support bracket 702 may be moved along the length of the wires

108. Multiple wire support brackets 702 may be used. The wire support bracket 702 may be used in conjunction with other wire support brackets (e.g., wire support bracket 502 of FIGs. 5 A and 5B, wire support bracket 610 of FIGs. 6A - 6D, wire support bracket 802 of FIGs. 8A and 8B, wire support bracket 812 of FIGs. 8C and 8D) described herein.

[0030] FIG. 7C illustrates the wire support bracket 702 with a chassis mount 706. The chassis mount 706 attaches the wire support bracket 702 to the chassis (not shown). [0031] FIGs. 8A and 8B illustrate an embodiment of a wire support bracket. Referring to FIGs. 8A and 8B, a wire support bracket 802 can include a body 804 with recesses (e.g., recess 806) to accommodate corresponding wires 108 and a mount 808. The mount 808 is in the form of an L-shaped bracket and attaches the wire support bracket 802 to the enclosure 106 shown in FIG. 8B. In some cases, the mount 808 includes a hole 810 to secure the wire support bracket 802 to the enclosure 106 via a fastening mechanism (e.g., a screw).

[0032] FIG. 8B illustrates the wire support bracket 802 attached to the enclosure 106 to support wires 108. The wire support bracket 802 is mounted to the enclosure 106 via the mount 808. In FIG. 8B, the mount 808 attaches to the enclosure 106 at the top of the enclosure 106. In FIG. 8B, the wires 108 are resting in the recesses (e.g., wire 108b in recess 806) of the wire support bracket 802.

[0033] FIGs. 8C and 8D illustrate an embodiment of a wire support bracket. Referring to FIGs. 8C and 8D, the wire support bracket 812 can include a body 814 with recesses (e.g., recess 816) to accommodate corresponding wires 108 and a mount 818. The mount 818 is in the form of an L-shaped bracket and attaches the wire support bracket 812 to the enclosure 106 as shown in FIG. 8D. In some cases, the mount 818 includes a hole 820 to secure the wire support bracket 812 to the enclosure 106 via a fastening mechanism (e.g., a screw).

[0034] FIG. 8D illustrates the wire support bracket 812 attached to the enclosure 106 to support wires 108. In FIG. 8D, the wires 108 are resting in the recesses (e.g., wire 108b in recess 816) of the wire support bracket 812. In FIG. 8D, the mount 818 attaches to the enclosure 106 at the bottom of the enclosure 106 and is secured by a fastening mechanism (e.g., a screw). It should be noted that the bracket 812 is shown in FIG. 8C with the opposite orientation than that shown in FIG. 8D in order to see where the body 814 can have cutaways for accommodating protrusions on the connector block.

[0035] Referring to FIGs. 8 A - 8D, the wire support brackets 802, 812 may be sheet metal wire support brackets for holding the wires 108, which may also include a cable tie, to reduce vibration. In embodiments, the brackets 802, 812 may use the enclosure bolts to clamp the sheet metal part to the enclosure 106. The wire support brackets 802, 812 may adopt the same profile as the enclosure 106, thus saving space and making the design compact. The wire support brackets 802, 812 may use the high stiffness metal parts (e.g., sheet metal or casting wire support bracket). Although four recesses 806, 816 are shown, the number of recesses may be greater or fewer depending on the number of wires to be connected to the electronic product. [0036] Although the subject matter has been described in language specific to structural features and/or acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as examples of implementing the claims and other equivalent features and acts are intended to be within the scope of the claims.