Contact-Protected Screw Connector for Safe High-Voltage Assembly
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Solution Overview
Problem
Existing electrical connection methods for high voltage storage devices in electric vehicles lack effective contact protection, particularly during assembly, which can lead to unsafe unplanned contact with voltage-conducting components.
Innovation Solution
A contact-protected screw connection device is designed with a male and female screw connector configuration, featuring protective covers and a connecting sleeve to establish and disconnect an electrically conducting connection safely, ensuring protection against unintended contact while allowing for simple assembly and high current carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective covers are added to cover voltage-conducting components, then contact protection and safety are improved, but device complexity increases
Solution Approach 1:
The protective cover is merged with the connector housing to form an integrated structure. The cover is not a separate component but is formed as part of the housing structure itself, eliminating the need for additional protective components while maintaining contact protection functionality.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support for the connector, guides the mating process, and simultaneously acts as the protective cover that prevents contact with voltage-conducting components. This multi-functionality reduces overall device complexity.
2Reliability
If a female interface is arranged on the cell-facing side and male region on the other connector side, then safety against unplanned contact is improved, but assembly complexity increases
Solution Approach 1:
The housing structure is designed in advance with integrated guiding elements and positioning features that automatically align the male and female connectors during assembly. The protective cover geometry itself serves as a guide, ensuring correct orientation before electrical contact is made.
Solution Approach 2:
The housing structure acts as an intermediary element that mediates between the operator and the electrical contacts. It provides a safe interface for assembly through guiding features and positioning elements, allowing assembly without direct exposure to voltage-conducting components.
3Reliability
If protective covers completely surround the connecting screw head, then contact protection is improved, but accessibility for tightening torque application deteriorates
Solution Approach 1:
The protective cover is segmented with an opening or recess in the region where screwdriver access is needed. This segmentation allows the cover to maintain protection for most of the connecting screw head while providing necessary access for tightening operations.
Solution Approach 2:
The protective cover provides complete coverage in regions where contact protection is critical, while intentionally leaving openings or recesses in specific local areas where screwdriver access is required. This localized differentiation of protection level maintains safety while enabling operation.
Data Source
AI summary
A contact-protected screw-connection has a male screw connector and a female screw connector. The male screw connector has a connecting screw, which extends along a longitudinal axis in a screw direction towards the female screw connector and is screwed into a nut portion of the female screw connector. The connecting screw has a connecting-screw head, and the connecting screw extends along the longitudinal axis through a first electrical conductor. The connecting-screw head is arranged on a side of the first electrical conductor that is directed away from the nut portion. The male screw connector has a first protective cover, which encloses the connecting-screw head at a radial distance therefrom. The female screw connector has a second protective cover. The nut portion extends from a second electrical conductor, in the direction counter to the screw direction towards the first electrical conductor. The second protective cover encloses this region of the nut portion to some extent and at a radial distance therefrom. The nut portion extends from the second electrical conductor as far as a nut-end surface. The nut portion has a nut cap radially enclosing the nut portion to some extent and projecting beyond the nut portion to some extent. The male screw connector has a connecting sleeve that electrically conductively connects the first electrical conductor and the second electrical conductor and encloses the connecting screw at a radial distance therefrom and within the first protective cover. The connecting sleeve projects beyond the first protective cover to some extent in the screw direction.