Patent Publication Number: US-7713097-B2

Title: Variable direction cable connector adapter

Description:
TECHNICAL FIELD 
     This disclosure relates to connection and routing of cables to electrical components in automotive vehicles, such as power inverter modules. 
     BACKGROUND OF THE INVENTION 
     An electrical connection made by a connector has a fixed cable takeoff direction, which may be dependent on the design of the connector and the electrical unit to which it connects. Cables, especially large gauge, high-voltage cables (those having thicker diameter), are difficult to bend during installation. Large cables may have a minimum bend radius below which the cable cannot be bent and perform properly. Furthermore, the amount of sheathing or insulation may limit the ability of cables to achieve small-radius bends. 
     SUMMARY 
     An adjustable adapter for a cable connector is provided. The cable takeoff direction is fixed relative to the cable connector for first and second cables. The adjustable adapter includes an input member having first and second terminals. A connecting member having a first bus bar and a second bus bar is configured to selectively mate to the input member in at least two different connecting member positions relative to the input member. This provides connection such that in each of the different connecting member positions, each of the first and second bus bars is in electrical communication with a respective one of the first and second terminals. 
     The connecting member is configured to accept attachment of one or more cable connectors. The first bus bar is configured to communicate with the first cable on one cable connector and the second bus bar is configured to communicate with the second cable. Therefore, the connecting member provides the cable connector (or multiple cable connectors) with at least two different cable takeoff directions relative to the input member. 
     The connecting member may include an adapter plate configured to facilitate mating of the cable connectors to the connecting member and mating of the connecting member to the input member. The first and second bus bars may be embedded in the adapter place. 
     The input member may further include a third terminal, and a third bus bar may be embedded in the adapter plate or connecting member and in communication with the third terminal. The cable connectors may then carry three cables, and retain the ability to be connected in different positions relative to the input member. 
     The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes and other embodiments for carrying out the invention when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic, exploded, perspective view of one embodiment of a variable direction cable connector adapter, configured for two-phase electrical communication with two, two-cable connectors; 
         FIGS. 2A-2D  are schematic, exploded, perspective views of a portion of the variable direction cable connector adapter of  FIG. 1 , shown with the connecting member oriented to provide four selectable, different cable takeoff directions  20 A- 20 D, respectively, for attachment of the cable connectors; 
         FIG. 3  is a schematic, exploded, perspective view showing the interface between the input member and bus bars of the partial variable direction cable connector adapter as shown in  FIG. 2B , with corresponding cable takeoff direction  20 B; 
         FIG. 4  is a schematic, exploded, perspective view showing another embodiment of the interface between the input member and bus bars for a variation on the variable direction cable connector adapter of  FIGS. 1-3 , this embodiment having concentric bus bars configured to provide the same polarity to the cable connectors in each of the four different cable takeoff directions  20 A- 20 D; 
         FIG. 5  is a schematic, perspective view showing another embodiment of the interface between the input member and bus bars, having a solid inner bus bar and concentric outer bus bar; 
         FIG. 6  is a schematic, perspective view showing another embodiment of the interface between the input member and bus bars, having a central inner bus bar and a round concentric outer bus bar, providing infinite selectable attachment positions about the central axis; and 
         FIG. 7  is a schematic, exploded, perspective view showing yet another embodiment of the interface between the input member and bus bars for another embodiment of a variable direction cable connector adapter, this embodiment having three concentric bus bars configured to provide the same polarity for selectable, different cable takeoff directions and three-phase electrical communication with two, three-cable connectors. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to the drawings, wherein like reference numbers correspond to like or similar components throughout the several figures, there is shown in  FIG. 1  a partially exploded view of one embodiment of a variable direction cable connector adapter  10 . One or more cable connectors  12  attach to an electrical module  14  via an adjustable header or connecting member  16 . The electrical module  14  may be any of several devices known to those having ordinary skill in the art as having connections for cables—possibly large or high-voltage cables—such as, without limitation, a traction power inverter module (TPIM), transmission power inverter module, or another type of power inverter module. 
     The cable connector  12  shown in  FIG. 1  has two cable ports  18  and  19 , into which cables (not shown) may be inserted or attached. In this embodiment, the cable ports  18  and  19  define a fixed cable takeoff direction  20  relative to the cable connector  12  (and corresponding to direction  20 A in  FIG. 2A , described in more detail below). 
     Because large gauge cables, such as those used in high-voltage applications, are difficult to flex or bend, the cable takeoff direction  20 —which may be defined by the cable ports  18  and  19 —determines the path of the cables adjacent to the adapter  10 . Different vehicle designs may require that the takeoff direction  20  be adjustable or selectable relative to the electrical module  14  in order for the different vehicles to use the same electrical module  14  and cable connector  12 . 
     Bending or otherwise redirecting high gauge cables to account for an improper takeoff direction may add length (and mass) to the cables, take up extra space in the redirection area, and may increase the probability of damage or wear to the cables or sheathing. Because the cable takeoff direction  20  is fixed relative to the cable connector  12 , selection and adjustability of the takeoff direction  20  relative to the electrical module  14  is provided by the adjustable connecting member  16 . 
     An input member  22  contains the electrical interface for the electrical module  14 . In the embodiment shown in  FIG. 1 , input member  22  includes two terminals  24  and  25 . Each of the two terminals  24  and  25  will provide electrical communication between the electrical module  14  and one cable port  18  (corresponding to one cable) of the cable connector  12 . The two phase cable connector  12  shown in  FIG. 1  may be designed for DC circuits, in which one cable carries positive charge and the other cable negative. 
     The adjustable connecting member  16  is configured to allow the cable connector  12  to be selectively attached in different orientations relative to the input member  22  and electrical module  14 , such that the cable takeoff direction  20  correspondingly varies with respect to the input member  22 . Furthermore, the adjustable connecting member  16  provides structure configured to allow the fixed terminals  24  and  25  to communicate with the cable connector  12 . 
     Adjustable connecting member  16  includes two cradles  26 , each configured to accept one cable connector  12 . The cable connector  12  may be mated to one of the cradles  26  by a snap or press fit between walls of the cradle  26  and the cable connector  12 . Alternatively, as shown in  FIG. 1 , the cable connector  12  may be mated to the cradle  26  by a fastener or bolt  28 , which threads into the cradle  26 . 
     Those having ordinary skill in the art will recognize that, while only one cable connector  12  is shown, the adapter  10  contains structure configured to accept two cable connectors  12 . Those having ordinary skill in the art will further recognize that, in the embodiment shown, the two cradles  26  provide for the two cable connectors  12  to be mounted to the adjustable connecting member  16  with substantially parallel cable takeoff directions  20 . However, the cradles  26  could be configured to provide for different cable takeoff directions  20  for each connector  12 . 
     The adjustable connecting member  16  further includes an adapter plate  30 . The cradles  26  may be attached or fastened to the adapter plate  30 , or may be formed integrally as features of the adapter plate  30 . As will be recognized by those having ordinary skill in the art, the adapter plate could be configured to directly accept attachment of the cable connectors  12  without cradles  26 . 
     The adapter plate  30  contains structure to mount the adjustable connecting member  16  to either the input member  22  or the electrical module  14 , or both. In the embodiment shown in  FIG. 1 , four fasteners or bolts  32  pass through holes  34  in the adapter plate  30  and thread or otherwise lock into holes  35  in the electrical module  14 . Alternatively, the adapter plate  30  could be fastened to holes  36  in the terminals  24  and  25  of input member  22 . 
     Those having ordinary skill in the art will recognize that the adapter plate  30  shown in  FIG. 1  may be selectively mated to the electrical module  14  in one of four positions, providing for four different, selectable positions for the connecting member  16  relative to the electrical module  14 .  FIGS. 2A ,  2 B,  2 C, and  2 D show partial, exploded views of the electrical module  14  and adjustable connecting member  16  in four different connecting member positions, with the cable connectors  12  removed for clarity. 
     Because the position of cable connector  12  is fixed with respect to the adjustable connecting member  16 , the four different connecting member positions, in turn, selectively provide four different cable takeoff directions  20 A,  20 B,  20 C, and  20 D, relative to the electrical module  14  (and to the input member  22 ). In the embodiment shown, the four cable takeoff directions  20 A-D are separated by approximately ninety degrees, and rotate about an axis  38  running generally through the center of the terminals  24  and  25 . 
     Two bus bars  40  and  41  provide structure within the adjustable connecting member  16  for electrical communication between the terminals  24  and  25  and the cable ports  18  and  19 . The bus bars  40  and  41  may be attached to, or embedded in, the adapter plate  30 . Additionally, the bus bars  40  and  41  may be overmolded in the material of the adapter plate  30  and cradles  26 . The bus bars  40  and  41  are configured such that, when the adapter plate  30  is mated to the electrical module  14  in any one of the four positions, each of the bus bars  40  and  41  come into electrical communication with one of the terminals  24  and  25 . 
     The bus bars  40  and  41  are further configured to communicate, directly or through connector blades  42  and  43  (described below), with the cable connectors  12  and the cable ports  18  and  19 . In the embodiment shown in FIGS.  1  and  2 A- 2 D, one terminal  24  or  25  communicates with one bus bar  40  or  41 , such that each bus bar  40  and  41  carries a single polarity charge (positive, negative, or neutral) in the electrical circuit. 
     As may be best viewed in  FIG. 1 , each cable port  18  or  19  communicates with only one of the bus bars  40  or  41 , such that each cable port  18  or  19  (and attached cable) correspondingly has only one polarity (carries a single direction of electron flow). One of the blades  42  plugs into a slot or channel (not shown) in the cable connector  12 , which communicates with the cable port  18 , and one of the blades  43  plugs into cable connector  12  and communicates with the cable port  19 . Those having ordinary skill in the art will recognize that the adjustable connecting member position shown in  FIG. 1 , and having cable takeoff direction  20 , is also shown in  FIG. 2A , with corresponding cable takeoff direction  20 A. 
       FIG. 3  shows an exploded, isolated view of the input member  22  and the bus bars  40  and  41 . To better show the structure of the bus bars  40  and  41  and the connections between the adjustable connecting member  16  and the electrical module  14 , the remainder of the adjustable connecting member  16  and the cable connectors  12  have been removed for clarity. The orientation shown in  FIG. 3  corresponds generally to that shown in  FIG. 2B , having cable takeoff direction  20 B. To facilitate connection to two cable connectors  12 , bus bar  40  has two connector blades  42  and bus bar  41  has two connector blades  43 . 
     Those having ordinary skill in the art will recognize that, in the embodiment shown in  FIGS. 1-3 , moving from one position of the adapter plate  30  to another position may result in reversing the polarity of the bus bars  40  and  41  by changing the terminal  24  or  25  to which each bus bar  40  or  41  connects. Referring again to  FIGS. 2A-2D , the configuration of the terminals  24  and  25  and bus bars  40  and  41  is such that the polarity of the bus bars  40  and  41  is the same in  FIGS. 2A and 2D , and the polarity is similarly unchanged between  FIGS. 2B and 2C . 
     The two-phase input member  22  shown in  FIGS. 1 ,  2 A- 2 D, and  3  may have, for example, terminal  24  as the positive pole and terminal  25  as the negative pole. In such a case, Table 1 shows the corresponding negative and positive poles for bus bars  40  and  41  in  FIGS. 2A-2D : 
                                         TABLE 1                               Terminal 24   Terminal 25           FIGS.   Direction   Positive Bus   Negative Bus                          1, 2A   20A   40   41           2B, 3   20B   41   40           2C   20C   41   40           2D   20D   40   41                        
From the above table, those having ordinary skill in the art will recognize that cable takeoff directions  20 A and  20 D communicate identical polarity to the cable connector  12 . Additionally, cable takeoff directions  20 B and  20 C are identical to each other, but have reversed polarity relative to directions  20 A and  20 D.
 
     Because each of the cable ports  18  and  19  may have different polarity, depending upon the position of adjustable connecting member  16 , the adapter  10  may include structure or markings configured to identify the polarity of each cable or cable port  18  or  19  once the adapter  10  is fully assembled. Those having ordinary skill in the art will recognize structures capable of identifying the polarity of the assembled adapter  10 . Possible structures include, without limitation, markings on the walls of the electric module  14  that identify the resulting polarity of cables passing over the specified wall for the corresponding cable takeoff direction  20 A,  20 B,  20 C, or  20 D. 
     Using the embodiment shown in  FIGS. 1-3  as an example, several manufacturing strategies are possible for the adapter  10 . Generally, the last component attached to the assembled adapter  10  will be the cable connector (or connectors)  12 . The electrical module  14  and adjustable connecting member  16  may be assembled together and then attached to the vehicle chassis (not shown) or portion of the drivetrain (not shown). One or more cable connectors  12  may then be attached to the adjustable connecting member  16  (already in position for the appropriate cable takeoff direction  20 A- 20 D) and the opposing end of the cables attached to the relevant vehicle component (such as, for example: a similar adapter  10 , an electric motor/generator, or an energy storage device). 
     The adjustable connecting member  16  and electrical module  14  may be manufactured and delivered separately, such that final assembly may be made into vehicles needing any of the cable takeoff directions  20 A- 20 D. Under this type of manufacturing process, the electrical module  14  and adjustable connecting member  16  would have individual part numbers and identification of resulting cable polarity after assembly may be important to ensure that the cables are not affixed to other vehicle components with improper (reversed) polarity. 
     Alternatively, the electrical module  14  and adjustable connecting member  16  may be supplied as an assembled unit, with the final cable takeoff direction  20 A,  20 B,  20 C, or  20 D selected by the supplier during assembly. In such a manufacturing process, each pre-assembled adapter  10  with pre-selected cable takeoff direction  20 A,  20 B,  20 C, or  20 D would have its own unique part number to identify the proper adapter  10  for each vehicle. Furthermore, the associated vehicle components receiving the cables would have corresponding harnesses (or cable connectors) to ensure that the proper polarity is maintained between the uniquely-numbered adapter  10  and corresponding component. 
     As shown in  FIG. 1 , the adjustable connecting member  16  may be configured with two cradles  26 , such that two cable connectors  12  may be mated thereto. In order to attach two or more cable connectors  12 , each bus bar  40  and  41  must have structure configured to communicate with a respective cable port  18  or  19  on each of the cable connectors  12 . 
     In the embodiment shown in  FIG. 1 , each of the connector blades  42  of bus bar  40  communicates with the cable port  18  on a respective cable connector  12  (only one of which is shown), such that the upper cable (as viewed in  FIG. 1 ) extending from each cable connector  12  communicates with bus bar  40  (and therefore with terminal  24 ). Similarly, both of the connector blades  43  of bus bar  41  communicate with the cable ports  19  and the lower cables extending from each cable connector  12 . 
     The capability to attach multiple cable connectors  12  to the adjustable connecting member  16 , and provide the different cable takeoff directions  20 A- 20 D, results from respective single contact points between the bus bars  40  and  41  and the terminals  24  and  25  being in communication with multiple cable ports  18  or  19 . Those having ordinary skill in the art will recognize that variations on this structure could allow attachment of more than two cable connectors  12  by utilizing additional contact elements (such as, but not limited to, additional connector blades  42  or  43 ) between the bus bars  40  and  41  and the cable connectors  12 . 
     In the embodiment shown in  FIGS. 1-3 , the connector blades  42  and  43  form a plug to which the cable connectors  12  may be attached. Those having ordinary skill in the art will recognize that other connector shapes may be used to electrically communicate between the bus bars  40  and  41  and the cable connectors  12  and cable ports  18  and  19 . It will also be recognized by those having ordinary skill in the art that the connection need not necessarily be a plug-in type connection. 
     Those having ordinary skill in the art will recognize other variations on the embodiment shown in  FIGS. 1-3 . Such variations include, without limitation: an embodiment having two, single-cable connectors, where each bus bar  40  and  41  connects to a respective single-cable connector, such that each single-cable connector carries a single charge into a single cable (as opposed to individual cables on each connector  12  having a single charge). 
     Those having ordinary skill in the art will further recognize that the terminals  24  and  25  and bus bars  40  and  41  need not be square shaped. Alternative embodiments may, for example, utilize other polygonal shapes to provide other fixed positions, or circular terminals to allow infinite positions (as will be described below). 
     Referring now to  FIG. 4 , there is shown an alternative embodiment to the input member  22  and bus bars  40  and  41  shown in  FIGS. 1-3 . Similar to  FIG. 3 ,  FIG. 4  shows an exploded, isolated view of an input member  122  and bus bars  140  and  141 , oriented to provide the cable takeoff direction  20 B. 
     In the embodiment partially shown in  FIG. 4 , regardless of the position in which the adjustable connecting member (of which only the bus bars  140  and  141  are shown) is attached to the electrical module  14 , the bus bars  140  and  141  carry the same polarity. A terminal  124  (which may be the positive terminal) forms a square ring inside of a terminal  125  (which may be the negative terminal), which is also a square ring and is concentric about the terminal  124 . 
     The concentric terminals  124  and  125  allow the bus bars  140  and  141  to always mate to the same terminal—and therefore carry the same charge—regardless of cable takeoff direction  20 A,  20 B,  20 C, or  20 D selected. In the embodiment shown in  FIG. 4 , the bus bar  140  always contacts the terminal  124  and the bus bar  141  always contacts the terminal  125 . Connector blades  142  and  143  connect bus bars  140  and  141 , respectively, to the cable connectors (not shown). Therefore, respective cable ports  18  and  19  (not shown) always carry the same polarity. 
     Referring now to  FIG. 5 , there is shown another embodiment of an input member  222  and bus bars  240  and  241  usable within the scope of the claimed invention. A central terminal  224  is surrounded by a concentric terminal  225 . Like the terminals  124  and  125  of  FIG. 4 , the configuration of the terminals  224  and  225  allows the bus bars  240  and  241  to always mate to a respective one of the terminals  224  and  225 , such that polarity of the cable ports  18  and  19  (not shown in  FIG. 5 ) and cables (not shown) is not dependant upon the cable takeoff direction  20 A- 20 D selected. 
     Similar to the input members  22  and  112  of  FIGS. 1-3  and  4 , respectively, the square ring configuration of the input member  222  allows for the adjustable connecting member (of which, only the bus bars  240  and  241  of the connecting member are shown in  FIG. 5 ) to be selectively mated to the electrical module  14  in one of four positions, at ninety degree intervals. Connector blades  242  and  243  facilitate communication between the bus bars  240  and  241 , respectively, and the cable connectors  12  (not shown in  FIG. 5 ).  FIG. 5  also shows the bus bars  240  and  241  oriented to provide the cable takeoff direction  20 B. 
     Referring now to  FIG. 6 , there is shown another embodiment of an input member  322  and bus bars  340  and  341  usable within the scope of the claimed invention. In this embodiment, a central terminal  324  is surrounded by a concentric, circular terminal  325 . The concentric terminals  324  and  325  allow the connecting member (of which, only the bus bars  340  and  341  are shown in  FIG. 6 ) to mate to the input member  322  in multiple positions without changing the polarity of the bus bars  340  and  341 . 
     Because the input member  322  is configured with concentric, circular terminals  324  and  325 , the bus bars  340  and  341  (and the remainder of the connecting member, not shown) may be mated to the input member  322  in infinite positions. This differs from the square-shaped terminals  24 ,  25 ,  124 ,  125 ,  224 , and  225 ; which require connecting member positions separated by ninety degree intervals for consistent surface area of the contact between the terminals  24 ,  25 ,  124 ,  125 ,  224 , and  225  and bus bars  40 ,  41 ,  140 ,  141 ,  240 , and  241 . 
     The terminals  324  and  325  provide substantially equal contact with the bus bars  340  and  341  regardless of the angular orientation of the bus bars about an axis  338  at the center of the terminals  324  and  325 . Therefore, while  FIG. 6  shows the bus bars  340  and  341  generally oriented to provide a cable takeoff direction substantially similar to takeoff direction  20 B, any direction in between (and inclusive of) cable takeoff directions  20 A- 20 D is possible with the structure shown in this embodiment. Connector blades  342  and  343  may be provided to communicate with the cable connectors  12  (not shown in  FIG. 6 ). 
     In the embodiments shown in  FIGS. 1-6 , the adapter  10  is a two-phase adapter configured for cable connectors  12  having structure for two cables (not shown). However, some electrical modules  14  may require three-phase adapters for three-cable cable connectors. These embodiments may be used to carry direct current with a ground connection (in addition to positive and negative); may be used for alternating current with live, neutral, and ground connections; or may be used for another three-phase connection (in which the phases may be nominally referred to as U, V, and W). 
       FIG. 7  shows a three-phase embodiment of an input member  422 . In the embodiment shown, an outer square ring terminal  425  surrounds, and is concentric with, an inner square ring terminal  424 . The input member  422  also includes a third, central terminal  450  located inside of the concentric square ring terminals  424  and  425 . 
     Terminals  424 ,  425 , and  450  are concentric about an axis  438 . Therefore, the polarity of the connections is not dependent on connecting member position. Regardless of the cable takeoff direction  20 A- 20 D, a bus bar  441  communicates with the terminal  425 , a bus bar  440  communicates with the terminal  424 , and a third bus bar  452  communicates with the third terminal  450 . 
     Similar to the embodiments shown in  FIGS. 1-6 , the bus bars  440  and  441  are configured with connector blades  442  and  443 , respectively, to communicate with the cable connectors (not shown). Additionally, the third bus bar  452  has connector blades  454  to communicate with a third cable on the cable connectors. 
     Those having ordinary skill in the art will recognize that, in addition to high-voltage cable connections, the variable direction cable connector adapter  10  may be used for connection of electrical modules sending commands or signals over the connected cables. For example, each of the three terminals  424 ,  425 , and  450  of the three-phase input member  422  shown in  FIG. 7  may be configured to receive or output a unique signal. An adaptor allowing multiple cable takeoff directions may also reduce cable length, bend radius, and installation difficulty for electrical modules configured for signal communication. Similarly, by adding additional concentric terminals and associated bus bars, more than three signals (or high-voltage phases) could be communicated to a cable connector having more than three cables. 
     While the best modes and other embodiments for carrying out the claimed invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.