Connector Assembly Two-Stage Latch HVIL Sequencing
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Solution Overview
Problem
High voltage connectors in electric and hybrid electric vehicles require a high voltage interlock (HVIL) circuit for safety, but existing solutions often necessitate a second connector or lack significant delay during unmating, posing risks and inefficiencies.
Innovation Solution
A connector assembly with a floating latch and flexible latch mechanism that ensures proper sequencing and delay during mating and unmating, preventing damage by maintaining the interlock circuit open until high voltage conductors are securely mated and allowing a controlled discharge during separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second connector is used for HVIL protection, then safety is improved, but device complexity increases
Solution Approach 1:
The patent combines the high voltage connector and HVIL protection circuit into a single integrated unit. The connector housing incorporates both the high voltage contact elements and the HVIL circuit elements, eliminating the need for a separate second connector while maintaining safety functions.
Solution Approach 2:
The single connector assembly performs multiple functions: it provides high voltage power transmission through the conductor elements and simultaneously provides HVIL protection through the integrated circuit elements. This multi-functional design replaces the need for separate dedicated connectors for each function.
2Ease of manufacture
If conventional latch mechanism is used, then manufacturing is simple, but unmating sequence control is insufficient
Solution Approach 1:
The latch mechanism is divided into two independent latches: a first latch that releases the high voltage conductor elements and a second latch that releases the HVIL circuit elements. This segmentation allows each latch to control a specific stage of the unmating sequence, providing reliable sequence control while maintaining manufacturing simplicity through modular design.
Solution Approach 2:
The latch system is designed to dynamically transition between different operational states during the unmating process. The first latch engages and disengages at different stages than the second latch, creating a controlled dynamic sequence that ensures safe disconnection of high voltage before HVIL circuit disconnection.
3Speed
If high voltage conductors are disconnected first, then unmating speed is improved, but damage risk increases
Solution Approach 1:
The latch mechanism is designed so that the first latch releases the high voltage conductor elements before the second latch releases the HVIL circuit elements. This preliminary action sequence ensures that high voltage disconnection occurs first, followed by HVIL circuit disconnection, preventing voltage damage while maintaining efficient unmating speed through the coordinated two-stage process.
Data Source
Figure 1
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AI summary
A connector assembly having an outer housing and a floating latch. The outer housing includes a flexible latch and mates with a header connector subassembly. The floating latch is slidably joined to the outer housing. The floating latch latches onto the outer housing and the header connector subassembly. When the outer housing is moved along a mating direction to mate with the header assembly, the floating latch travels with the outer housing until one of opposite ends of the floating latch couples to the header connector subassembly. After the floating latch is coupled to the header connector subassembly, the outer housing continues to travel along the mating direction relative to the floating latch with the floating latch sliding relative to the outer housing until another one of the opposite ends couples with the flexible latch of the outer housing.