Bifurcated Connector Assembly for High Voltage Interlock
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Solution Overview
Problem
Existing high voltage connectors lack a flexible solution for closing interlock circuits without being fixed as header connectors and require multiple connectors for each high voltage interlock circuit, posing safety and operational challenges in high voltage applications.
Innovation Solution
A connector assembly with a housing featuring bifurcated cavities for current carrying and interlock conductors, allowing for the closure of an interlock circuit when the interlock conductor mates with a shunt, enabling safe transfer of high voltage current without the need for a fixed header connector and accommodating various high voltage interlock connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed header connector is used to close the interlock circuit, then the interlock circuit can be reliably closed, but the connector lacks flexibility and must be mounted on the exterior of the device
Solution Approach 1:
The connector assembly integrates both interlock circuit closure and current transfer functions into a single component. The housing contains both interlock conductors and current carrying conductors, allowing the same connector to perform multiple functions that previously required separate header connector and plug connector components.
2Reliability
If multiple separate connectors are used for each high voltage interlock circuit, then each interlock circuit can be independently managed, but the device complexity and number of components increases
Solution Approach 1:
The patent combines multiple separate connectors into a single integrated connector assembly. The housing contains both interlock conductors and current carrying conductors that work together to close both the interlock circuit and the high voltage power supply circuit simultaneously, reducing the total number of connectors required.
Solution Approach 2:
The connector assembly performs multiple functions: it closes the interlock circuit through its interlock conductors, transfers high voltage current through its current carrying conductors, and provides mechanical coupling between connectors. This multi-functionality eliminates the need for separate dedicated interlock connectors and power connectors.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A connector assembly includes a housing (102), a current carrying conductor (332, 334), and an interlock conductor (308, 310). The housing has a cavity (700) that receives conductive members and a shunt of a first connector. The cavity is bifurcated into a conductor channel (704) and an interlock channel (702) that receives a conductive member of a second connector. The current carrying conductor (332, 334) is in the housing and extends through the conductor channel (704) and into the cavity (700). The interlock conductor (308, 310) is in the housing and extends through the interlock channel (702) and into the cavity (700). The interlock conductor (308, 310) closes an interlock circuit when the interlock conductor mates the shunt of the first connector with the conductive member of the second connector. The current carrying conductors (332, 334) mate to the conductive members of the first connector to begin transferring electric current through the current carrying conductor when the interlock circuit is closed.