CPA Element Connector Preventing Electrical Arcing
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Solution Overview
Problem
Existing electrical connector assemblies for hybrid and electric vehicles do not ensure safe power flow, as power can inadvertently pass through during incorrect or incomplete mating, posing risks of electrical arcing and damage.
Innovation Solution
The electrical connector assembly features six-contact connectors with a shunt contact pair and a CPA element that ensures power flows only upon correct and complete mating, using a sealing system and retaining members to prevent arcing and facilitate safe connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If connectors are designed with multiple contacts for high current and voltage transmission, then power transmission capability is improved, but the risk of electrical arcing and injury during incorrect mating increases
Solution Approach 1:
The CPA element performs preliminary verification of correct connector mating before enabling power transmission. The visual indicator provides advance confirmation to the operator that mating is correct, preventing premature energization and subsequent arcing hazards
Solution Approach 2:
The CPA element acts as an intermediary safety mechanism between the mechanical connection and electrical power transmission. It mediates by verifying connection integrity and controlling the timing of power enablement, ensuring that power is transmitted only after correct mating is confirmed
2Productivity
If power flows through connectors during mating operations, then operational efficiency is improved, but safety risks during incorrect or incomplete mating increase
Solution Approach 1:
The visual indicator system performs preliminary verification of correct mating status before power transmission begins. This preliminary check ensures that mating is complete and correct, maintaining safety while enabling efficient power transfer once verified
Solution Approach 2:
The CPA element provides visual feedback to the operator regarding the status of connector mating. This feedback mechanism ensures that power flows only when correct mating is confirmed, balancing operational efficiency with safety by preventing premature energization
3Reliability
If a safety system with CPA element and visual indicator is added, then user safety is improved, but device complexity increases
Solution Approach 1:
The CPA element serves multiple functions simultaneously: it provides mechanical verification of correct mating, drives the visual indicator, and controls power transmission enablement. By consolidating these functions into a single component, the design minimizes the increase in overall system complexity while maximizing safety benefits
Solution Approach 2:
The patent merges the safety verification mechanism, visual indication system, and power control function into an integrated CPA element assembly. This consolidation reduces the number of separate components needed, thereby limiting the increase in device complexity while achieving comprehensive safety
Data Source
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AI summary
An electrical connector assembly comprising a first connector having a first casing and a first contact and a second contact, and a second connector having a second casing and a first and a second contact, in which the first and second connectors are adapted to selectively mate and unmate along a mating axis (XX) respectively between an unassembled condition and an assembled condition to electrically connect the first contacts together, the second contacts together, wherein the second connector supports a CPA element carrying one of the contacts, and wherein, in the unassembled condition, the CPA element abuts against an abutment surface borne by one of the first and second connector, thereby preventing movement of the CPA element relative to the second connector between a safety position and an active position, and wherein, in the assembled condition, the CPA element does not abut against said abutment surface so as to be movable relative to the second connector between said safety position and said active position, so as to connect the contact carried by the CPA element with the corresponding contact of the first connector.