Electrical Connector Back Cover Sealing With HVIL Closure Feedback
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Solution Overview
Problem
Existing electrical connectors for high voltage systems lack effective mechanisms for ensuring secure connections and safe operation, particularly in ensuring the back cover is properly closed to prevent electrical hazards.
Innovation Solution
The electrical connector system incorporates a base with a housing for cable reception, a back cover with a seal securement flange and elastomeric seal for closure assurance, and a high voltage interlock system using HVIL pads and pins to indicate back cover closure and prevent high voltage exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a back cover is used to close the electrical connector, then protection against moisture and debris is improved, but the risk of improper closure and electrical hazards increases
Solution Approach 1:
The seal is pre-installed on the back cover's seal securement flange, positioned to engage with the housing before the back cover is closed. This preliminary positioning ensures that when the back cover is installed, the seal is already in the correct location to provide immediate protection against moisture and debris, while the pre-positioned seal works together with the closure mechanism to ensure proper closure.
Solution Approach 2:
The electrical connection between the HVIL pad on the back cover and the HVIL pin on the housing provides feedback about the closure status. When the back cover is properly closed, the seal compresses and brings the HVIL pad into contact with the HVIL pin, creating an electrical circuit that confirms proper closure. This feedback mechanism ensures reliability by providing a verifiable indication that the protective back cover is correctly installed.
2Object-affected harmful factors
If a sealing mechanism is added to secure the back cover, then protection against environmental factors is improved, but device complexity increases
Solution Approach 1:
The seal serves multiple functions simultaneously: it provides environmental protection by sealing between the back cover and housing, and it acts as a mechanical indicator for the closure status by compressing when the back cover is properly installed. This merging of sealing and indication functions into a single component reduces overall device complexity while maintaining effective environmental protection.
Solution Approach 2:
The seal securement flange with the attached seal is designed to perform multiple roles: securing the back cover to the housing, providing environmental sealing, and enabling the HVIL electrical connection to indicate proper closure. This multi-functional design eliminates the need for separate components for each function, thereby reducing device complexity while achieving comprehensive protection.
3Reliability
If an HVIL system is implemented to indicate back cover closure, then safety is improved, but device complexity increases
Solution Approach 1:
The HVIL indication system is integrated into the sealing mechanism itself. The HVIL pad is positioned on the back cover to contact the HVIL pin on the housing when the seal compresses during proper closure. This merging of the safety indication system with the sealing mechanism eliminates the need for a separate, complex interlock system while maintaining reliable safety indication.
Solution Approach 2:
The seal acts as an intermediary element that translates the mechanical action of closing the back cover into an electrical signal. When the back cover is closed, the seal compresses and mediates the contact between the HVIL pad and HVIL pin, converting the mechanical closure state into an electrical indication that can be monitored by the control system, thereby simplifying the overall interlock system.
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 ensures reliable and secure electrical connections by maintaining the back cover in a closed position, preventing moisture and debris ingress, and providing a low voltage indicator for safe operation.
Implementation Method 1
the seal configured to be elastically compressed between the seal securement flange and the second perimeter wall when the back cover is in the closed position
Data Source
AI summary
An electrical connector system that has a base, a back cover, and a seal. The base has a housing that includes a first perimeter wall and a second perimeter wall spaced from the first perimeter wall. The first perimeter wall defines a first opening. The second perimeter wall defines a second opening. The back cover includes a plate configured to be secured against the second perimeter wall to cover the second opening and a seal securement flange that is configured to fit within the second perimeter wall when the back cover is in a closed position relative to the base. The seal extends around a perimeter of the seal securement flange, is retained by and movable with the back cover, and is configured to be elastically compressed between the seal securement flange and an inner surface of the second perimeter wall when the back cover is in the closed position.