Integrated Connector Protection Circuitry
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Solution Overview
Problem
Existing vehicle connector systems face challenges with over-current and over-voltage protection, reliability issues with fuses, and the need for complex remote junction boxes, which can lead to malfunctioning brake lights and increased complexity.
Innovation Solution
A single connector system incorporating a plug subassembly, sensor connector subassembly, and a circuit board with PTC devices, relay switches, Zener diodes, metal oxide varistors, and a microcontroller for integrated over-current and over-voltage protection, fault detection, and interlock functionality, eliminating the need for remote modules and unreliable fuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fuses and relays are used in remote junction boxes for over-current and over-voltage protection, then protection functionality is provided, but device complexity and mounting space requirements increase
Solution Approach 1:
The patent combines multiple protection functions (over-current protection via PTC device, over-voltage protection via Zener diode, fault detection via microcontroller, and connection verification) into a single integrated connector assembly, eliminating the need for separate remote junction boxes with multiple discrete fuses and relays
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: it provides electrical connection, over-current protection, over-voltage protection, fault detection, and connection status verification, making a single component perform the roles of previously separate protection devices
2Reliability
If fuses are used in brake light circuits for over-current protection, then current protection is provided, but the brake light may become inoperative without driver awareness
Solution Approach 1:
The microcontroller continuously monitors the circuit status and provides feedback to the driver through an indicator light when a fault condition is detected, such as when the PTC device restricts current due to over-current or when the brake light circuit experiences a fault
Solution Approach 2:
The patent replaces the passive mechanical fuse system with an active electronic protection system using PTC devices and microcontroller-based monitoring, which can detect and communicate fault conditions rather than simply opening the circuit
3Ease of manufacture
If simple pin connections are used for power transfer in connectors, then ease of manufacture is maintained, but integrated protection and fault detection capabilities are lost
Solution Approach 1:
The patent integrates passive connection elements with active protection circuitry within a single connector housing, combining the simplicity of pin connections with the functionality of protection devices without requiring separate assemblies
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
The system provides automatic resettable protection against over-current and over-voltage, detects faults, and ensures proper connection, reducing the risk of brake light malfunctions and simplifying installation by integrating multiple functions into a single connector assembly.
Implementation Method 1
The circuit board may include at least one positive temperature coefficient (PTC) device electrically connected between an activation switch and a load. The PTC(s) restricts current from flowing to the relay switch when current at the current through the PTC(s) exceeds a current threshold.
Implementation Method 2
The circuit board may also include a Zener diode connected to a relay coil. The Zener diode is configured to allow current to pass to the relay coil when the Zener diode experiences a breakdown voltage, thereby energizing the relay coil to move the relay switch from a closed to an open position.
Implementation Method 3
The circuit board may also include a metal oxide varistor (MOV) electrically connected between the relay switch and the load (and to ground).
Data Source
AI summary
A system configured to protect a load within a vehicle includes a plug subassembly and a sensor connector subassembly. The sensor connector subassembly is selectively connectable to the plug subassembly. A circuit board is secured within the sensor connector subassembly. The circuit board includes at least one positive temperature coefficient (PTC) device electrically connected between an activation switch and a load. The circuit board includes at least one circuit to protect against over-voltage or over-current to the load, detect a fault condition of the load, and determine whether the plug subassembly is connected to the sensor connector subassembly.