Power Connector CPA Lock for Tool-Only Unmating
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Solution Overview
Problem
Existing power connector systems for motor vehicles face issues with unauthorized disconnection under high voltage, accidental button pressing, and lack of robustness, especially in the steps of assembly and maintenance, which can lead to safety concerns and damage.
Innovation Solution
A connector assembly with a 'connection position assurance' (CPA) lock that can only be unlocked with a tool, ensuring secure mating and disconnection processes, and is designed to be more robust and user-friendly, eliminating the need for supplementary actuation buttons and interlock lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a push button is provided for unlocking the connector, then ease of operation is improved, but reliability deteriorates due to unauthorized pressing and lack of protection
Solution Approach 1:
A protective cover is introduced as an intermediary element between the user and the unlocking mechanism. The cover must be removed before the push button can be accessed, creating a protective barrier that prevents unauthorized or accidental pressing while maintaining ease of operation through simple cover removal
Solution Approach 2:
The unlocking mechanism is segmented into two distinct parts: a removable protective cover and the underlying push button. This segmentation allows the system to provide both protection (through the cover) and ease of operation (through the button), resolving the contradiction between these two requirements
2Reliability
If a supplementary actuator with interlock line is provided for high voltage safety, then safety is improved, but device complexity increases
Solution Approach 1:
The protective cover is merged with the existing housing structure, integrating the safety function into the current design rather than adding a separate supplementary actuator. This combination maintains safety functionality while avoiding the complexity of additional interlock lines and actuators
Solution Approach 2:
The protective cover serves multiple functions: it protects the push button from unauthorized access, provides visual indication of connection status, and integrates with the housing structure. This multi-functionality achieves safety requirements without requiring separate supplementary safety systems
3Reliability
If a visible lock is provided for CPA system, then reliability is improved, but ease of operation deteriorates due to accidental pressing
Solution Approach 1:
The protective cover acts as an intermediary that must be deliberately removed before the push button can be accessed. This creates a intentional action barrier that prevents accidental pressing while maintaining the visible lock function for reliability indication
Solution Approach 2:
The protective cover is positioned specifically over the push button area, providing localized protection where it is most needed. The cover's placement and design allow it to protect against accidental pressing while maintaining the visible indication of the locked state
Data Source
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AI summary
Disclosure relates to an electrical power connector (2) and connector assembly(1), preferably including a sliding mate assist member (11). Connector comprises a "connection position assurance", or "CPA", which locks a mate assist member. CPA lock (12) can be locked only when mating is completed, then preventing any unmating. Unlocked position of CPA lock extends out of a masking fixed part (121), accessible there for pushing by human finger until hidden by said masking part in locked position. There, CPA is only accessible with a thin tool (129) for driving it out toward unlocked position. CPA locking member may thus be locked with finger only, while it cannot be unlocked without a tool; thus same is true for mate assist member movement and hence for connection and disconnection. Method for using connector is also disclosed, where connector is supplied unconnected in engaged position before being opened then mated without a tool.