Electrical Connector with Exploding Driver for Collision Safety
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Solution Overview
Problem
In vehicles, the connection between the battery and electrical systems poses a risk of explosion during collisions, potentially igniting leaked fuel and causing secondary accidents due to the continuous electrical connection.
Innovation Solution
An electrical connector design featuring a lower body, upper body, and cover with protrusions, grooves, and a driver that explodes to disconnect the terminal from the metal holder, preventing reconnection and blocking explosion pressure, thereby preventing power transmission to electronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery is always connected to electrical systems through wires, then power supply reliability is improved, but collision safety deteriorates due to explosion risk
Solution Approach 1:
The driver is pre-installed in the electrical connector to automatically disconnect the terminal from the metal holder upon collision, preventing power transmission before an explosion can occur. This preliminary protective action resolves the contradiction by maintaining normal connection during operation while automatically isolating the circuit when collision is detected.
Solution Approach 2:
The driver acts as an intermediary component between the terminal and metal holder, providing automatic disconnection functionality. This mediator enables the system to transition from a permanently connected state to an isolated state during collisions, resolving the safety-reliability contradiction.
2Object-affected harmful factors
If the driver explodes to disconnect the terminal, then collision safety is improved by preventing power transmission, but device complexity increases
Solution Approach 1:
The driver is integrated within the electrical connector housing, merging the disconnection function with the existing connector structure. This reduces overall device complexity by combining multiple functions (connection, disconnection, protection) into a single integrated component rather than separate assemblies.
Solution Approach 2:
The driver automatically activates upon collision without requiring external control systems, enabling self-service protection. This self-activating mechanism reduces complexity by eliminating the need for sensors, control circuits, or manual intervention to trigger the disconnection function.
3Strength
If the cover is tightly fitted to the upper body, then structural strength is improved, but explosion pressure containment worsens
Solution Approach 1:
The cover is divided into a fixed portion and a movable portion, allowing the movable part to deform under explosion pressure while the fixed portion maintains structural integrity. This segmentation enables the structure to absorb pressure through controlled deformation rather than rigid resistance, resolving the strength-pressure contradiction.
Solution Approach 2:
The movable cover portion is designed to deform as a predetermined safety mechanism, absorbing explosion pressure through controlled deformation before it can cause damage. This beforehand cushioning design allows the structure to withstand pressure events while maintaining overall integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively disconnects the electrical connection upon collision, preventing secondary accidents by ensuring the metal holder remains separated from the terminal and blocking explosion pressure, thus preventing power transmission to electronic devices.
Implementation Method 1
a driver between the terminal holes in the lower body... an exploding operation of the driver with respect to the lower body, thereby disconnecting the terminal from the metal holder
Data Source
AI summary
An electrical connector includes a lower body with terminal holes, an inflator between the terminal holes in the lower body, an upper body, and a cover, The upper body is on the lower body and includes an opening corresponding to at least one of the terminal holes and a pair of metal holders electrically connected to each other. The cover covers the upper body and includes an end portion coupled to the lower body. An inner surface of the cover faces a top surface of the upper body and includes a space that is separated from the top surface.