Electrical Connector Locking Clip for Arc-Safe Battery Swapping
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Solution Overview
Problem
Existing electrical connectors for electric vehicles face challenges such as long charging times, difficulty in handling, risk of arcing and sparking during disconnection, and potential damage to electronics due to voltage spikes, necessitating a quick and safe battery replacement mechanism.
Innovation Solution
A compact electrical connector with a quick-locking system and controlled interlock mechanism, featuring a locking clip and latching apparatus with a blocking element, which can be actuated electromechanically to ensure safe and reliable connection and disconnection, preventing voltage peaks and arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is added to prevent arcing and sparking during disconnection, then safety and reliability are improved, but device complexity increases
Solution Approach 1:
The locking mechanism is divided into two independent parts: a locking clip with recess for mechanical connection, and a separate latching apparatus with latching element and blocking element. This segmentation allows each component to perform its specific function (mechanical locking vs. controlled unlocking) independently, improving reliability while keeping individual components simple and manageable.
Solution Approach 2:
The blocking element acts as an intermediary component that controls the latching element's movement. It mechanically blocks the latching element in the closed position and removes blockage when retracted, enabling controlled unlocking without requiring complex electronic controls or additional actuating mechanisms.
2Reliability
If a blocking element is added to control the latching element, then protection against voltage spikes and arcing is improved, but installation space requirements increase
Solution Approach 1:
The blocking element is integrated into the existing latching apparatus structure rather than being a completely separate component. It works in conjunction with the latching element and recess to form a compact interlock mechanism, minimizing additional space requirements while providing controlled unlocking protection against voltage spikes and arcing.
Solution Approach 2:
The blocking element is positioned within the latching apparatus structure, nested alongside the latching element and recess. This nested arrangement allows the blocking element to control the latching element's movement without requiring significant additional external space, maintaining a compact overall design.
3Ease of operation
If a latching apparatus with blocking element is implemented, then ease of operation for quick battery swapping is improved, but manufacturing cost increases
Solution Approach 1:
The latching apparatus is designed to be manually operable without requiring external power sources, electronic controls, or complex actuating mechanisms. The blocking element provides mechanical control that enables quick and safe battery swapping through simple manual operation, reducing manufacturing costs associated with electronic control systems while maintaining ease of use.
Data Source
AI summary
An electrical connector, in particular for signal and/or power transmission, preferably for charging electric vehicles or of accumulators of electrical vehicles, has a coupling housing for connection to a corresponding second electrical connector. A locking clip on the coupling housing can be moved from an open position to a closed position. The locking clip has a recess into which a locking element of the second connector can be inserted in the open position of the locking clip, and in the closed position of the locking clip, the locking element is arranged in the recess such that the coupling housing is form-fit and/or force-fit connected to the second connector. A latching apparatus with at least one latching element engages in a latching receptacle of the locking clip in the closed position. An electrically movable locking element is arranged which inhibits movement of the latching element in a locking position.