Connector Device Partial Locking Mechanism for EV Safety

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Solution Overview

Problem

In connector devices for electric vehicles, there is a risk of arc discharge and electrical shock when connectors are separated, as residual electric charges can remain on terminals, posing a safety hazard due to the lack of a sufficient delay in power supply cutoff.

Innovation Solution

A partial locking mechanism is implemented, where the nut and bolt are loosened to disengage, preventing further separation until a specified force is applied, allowing a delay for electric charges to dissipate, and the interlock circuit is turned off to ensure a safe cut-off state before complete separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If the connectors are separated immediately after the interlock circuit is turned off, then the separation operation is fast and simple, but residual electric charges remain on the terminals causing electrical shock hazard

Engineering Contradiction:
Improveseparation timeVSAvoidelectrical shock hazard
Core Design Contradiction:
Loss of timeVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a delay mechanism that waits for a predetermined period after the interlock circuit is turned off before allowing complete connector separation. This preliminary waiting period enables residual electric charges to dissipate naturally, eliminating the electrical shock hazard before the operator handles the separated connector. The delay mechanism is implemented through a locking mechanism that maintains partial engagement during this critical dissipation period.

Inventive Principle:
Principle #10Preliminary action

2Object-affected harmful factors

If a delay mechanism is introduced to allow charge dissipation, then electrical shock hazard is eliminated, but the separation operation time increases

Engineering Contradiction:
Improveelectrical shock hazardVSAvoidseparation operation time
Core Design Contradiction:
Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent implements a partial locking mechanism that provides intermediate engagement positions between the fully connected and fully separated states. Instead of requiring complete separation for disconnection, the locking mechanism allows the connector to be held in a partially engaged state where the electrical connection is already cut off but physical separation is prevented. This partial action approach eliminates the harmful electrical shock risk without requiring a long delay period, thus minimizing the time loss.

Inventive Principle:
Principle #16Partial or excessive action

3Ease of operation

If the connector is completely separated to expose the connecting surface, then the connector can be easily removed, but the exposed male terminals pose electrical shock risk to operators

Engineering Contradiction:
Improveconnector removalVSAvoidelectrical shock risk
Core Design Contradiction:
Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a locking mechanism as an intermediary element between the electrical connection and physical separation. This locking mechanism acts as a mediator that controls the separation process: it allows the electrical connection to be cut off first (turning off the interlock circuit), then maintains a partial physical engagement during the charge dissipation period, and only after the delay expires does it permit complete separation. This intermediary control ensures that exposed terminals never occur during the critical dissipation period, eliminating electrical shock risk while maintaining ease of operation through clear mechanical states.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentEP2624372B1Connector device and assembling method therefor
Publication Date: 2018.03.21 SUMITOMO WIRING SYSTEMS LTD
  • EP2624372B1 patent drawingFigure 1
  • EP2624372B1 patent drawingFigure 2
  • EP2624372B1 patent drawingFigure 3

AI summary

An object of the present invention is to enable two connectors to be separated only after the elapse of a delay time after a power supply circuit is cut off. Two connectors 20, 40 are separated until an initially connected state is reached by rotating a nut 70 in a loosening direction to release the nut 70 from a threadably engaged state in a properly connected state of the two connectors 20, 40, and an interlock circuit is turned off during this time to set a power supply circuit to a cut-off state. A partial locking mechanism 80 for preventing any further separation by locking the power-supply side connector 40 when the power-supply side connector 40 is separated up to an initial connection position and enabling the power-supply side connector 40 to be completely separated when a specified force or larger is applied to the power-supply side connector 40 is provided between the two connectors 20,40.