Protective Device for Power Electronics Connector Impact Absorption
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Solution Overview
Problem
Conventional protection mechanisms for high voltage electrical connectors in electric vehicles are inadequate during violent frontal impacts, particularly when the inverter is integrated into the engine block, limiting flexibility in power electronics module design and size constraints.
Innovation Solution
A protection device for electrical connectors that integrates into a casing, featuring a face capable of covering the connector and bearing against the casing to absorb impact forces, allowing the connector to move with the engine block while maintaining connection, and includes ribbed profiles for added stiffness and a recess for orthogonal power bus exit to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inverter is integrated into the engine block, then the power electronics module size is reduced, but the connector protection capability during frontal impact deteriorates
Solution Approach 1:
The protective device is designed as a separate component from both the engine block and the connector assembly. It can be independently installed on the engine block to protect the connector, allowing the power electronics module to remain compact while maintaining protection capability through modular addition rather than integrated design
Solution Approach 2:
The protective device acts as an intermediary element between the engine block and the connector. It absorbs and distributes impact forces before they reach the connector, serving as a buffer that enables both compact integration and reliable protection by mediating the mechanical interaction between these components
2Reliability
If the inverter is fixed to the chassis, then the connector protection mechanism functions effectively, but the flexibility in power electronics module design is reduced
Solution Approach 1:
The protection system is segmented into the protective device mounted on the engine block and the connector assembly. This separation eliminates the requirement to fix the entire inverter to the chassis, allowing flexible positioning and design of the power electronics module while maintaining effective connector protection through the dedicated protective device
Solution Approach 2:
The protection function is extracted from the chassis-fixing mechanism and embodied in a standalone protective device. This extraction allows the connector to be protected without constraining the power electronics module design to require chassis attachment, thereby preserving design flexibility while ensuring protection effectiveness
3Reliability
If conventional protection mechanisms are used, then the connector is protected during minor impacts, but the protection is insufficient during violent frontal impacts
Solution Approach 1:
The protective device is pre-installed on the engine block before impact occurs, creating a cushioning barrier in advance. The bearing surfaces are positioned to absorb and distribute impact forces before they reach the connector, providing beforehand protection that maintains effectiveness during violent frontal impacts rather than just minor ones
Solution Approach 2:
The protective device incorporates ribbed profiles and bearing surfaces designed to distribute and absorb high-magnitude impact forces. This composite structural design with reinforced features provides enhanced strength and impact resistance capability while maintaining protection for minor impacts, bridging the gap between conventional and high-performance protection
Data Source
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AI summary
The invention relates to a protective device (DP) for an electrical connector (CHT) of a power electronics module inserted in a casing (CA), said connector (CHT) protruding from one of the faces (FC) of said casing (CA) and being able to connect an electrical supply line (BHT) to said module, characterized in that said device (DP) comprises at least one face (FF) able at least partially to cover said connector (CHT) so as to protect said connector (CHT) between said face (FC) of said casing (CA) and said at least one face (FF) of the device (DP), said device (DP) being able to rest against said casing (CA) when a force (F) in the direction of the casing (CA) is applied to said at least one face (FF) of the device (DP).