Power Connector Overheating Detection via Passive Interlock Shorting
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Solution Overview
Problem
High electrical currents in electric and hybrid motor vehicles can cause overheating in connectors, existing solutions like temperature probes are costly and do not effectively prevent continued use after overheating detection, posing safety risks.
Innovation Solution
An electrical connector design that uses a low-voltage line for both interlock control and shielding, incorporating an insulating element with a melting temperature that deforms to create a short circuit upon overheating, signaling overheating through voltage modification and potentially interrupting power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature probes (thermocouples) are integrated in the connectors to detect overheating, then overheating detection capability is improved, but manufacturing cost and device complexity increase due to additional electronic circuits required for measurement and interpretation
Solution Approach 1:
The patent merges the overheating detection function with the existing interlock control circuit by using the same low-voltage electrical line for both interlock control and temperature detection. The conductive component serves dual purposes: controlling the interlock circuit and detecting overheating through voltage modification when the insulating element deforms.
Solution Approach 2:
The low-voltage electrical line is designed to perform multiple functions: it serves as both an interlock control line and a temperature detection line. The conductive component and insulating element combination provides universal functionality for both safety control and thermal monitoring without requiring separate dedicated detection components.
2Reliability
If temperature probes or fuses are integrated in the connector to indicate overheating, then overheating indication is improved, but safety is worsened because the connector can continue to be used after overheating detection
Solution Approach 1:
The patent implements preliminary anti-action by designing the interlock control circuit to automatically disconnect power supply when overheating is detected. The conductive component establishes an electrical connection that modifies the voltage signal, triggering the interlock circuit to prevent continued operation before damage can occur, rather than merely indicating the problem.
Solution Approach 2:
The system implements feedback through the interlock control circuit that continuously monitors the voltage on the low-voltage electrical line. When the insulating element deforms due to overheating, the conductive component changes the electrical connection, creating a voltage modification that feeds back to the interlock circuit, which then automatically disconnects the power supply.
3Reliability
If dedicated detection components are added to the connector for overheating detection, then detection reliability is improved, but ease of manufacture is worsened due to additional assembly steps and installation complexity
Solution Approach 1:
The patent combines the detection function with existing connector components rather than adding separate dedicated detection components. The conductive component and insulating element are integrated into the existing structure, utilizing the same low-voltage electrical line already present for interlock control, thereby avoiding additional assembly steps.
Solution Approach 2:
The low-voltage electrical line and conductive component serve multiple functions: they are part of the existing interlock control system and simultaneously provide overheating detection. This multi-functionality eliminates the need for separate dedicated detection components and their associated assembly procedures.
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
This design provides a cost-effective and reliable method for detecting overheating without adding dedicated detection components, ensuring safety by automatically taking the connector out of service upon overheating, with the deformation of the insulating element being an irreversible event requiring replacement.
Implementation Method 1
the insulating element consists of a material having a melting temperature less than or equal to the melting temperature of at least one of the materials forming the housing
Implementation Method 2
Following this deformation, the electrically conductive element establishes an electrical connection between the first conductive component and the second conductive component
Implementation Method 3
The shielding element makes it possible to at least partially screen the electromagnetic waves produced by the flow of high currents in the cables and the contacts housed in the connector housing
Data Source
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AI summary
Electrical connector comprising a detection device (110) for detecting potential overheating, which comprises an electrically conductive element (160) and an electrically insulating element (170) inserted between the electrically conductive element (160) and a low-voltage line. The electrically conductive element (160) exerts an elastic force on the insulating element (170). For example, the electrically conductive element (160) is a spring. In the event of overheating, the insulating element (170) deforms under the pressure of the electrically conductive element (160) and enables an electrical connection between two low-voltage lines. The overheating is detected as a consequence of the electrical design of this connection between the low-voltage lines.