Decoupled Shroud for 48V Leadframe Orientation
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Solution Overview
Problem
Current 48 Volt leadframes are vehicle-specific, requiring significant re-tooling for different applications, which increases complexity and cost, while also posing safety risks due to high voltage requirements in hybrid and electric vehicles.
Innovation Solution
A connector system that decouples the shroud from the leadframe, allowing for orientation in any direction with minimal tooling changes, featuring alignment features and connecting mechanisms that enable secure attachment without reconfiguring the entire tooling setup, thus accommodating multiple vehicle configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leadframes are designed to be vehicle-specific with fixed connector orientations, then connection reliability is improved, but device complexity and re-tooling requirements increase
Solution Approach 1:
The connector system is divided into two separable components: the leadframe and the shroud. The shroud can be removed and reattached in different orientations, allowing the same leadframe to serve multiple vehicle configurations without requiring different tooling setups.
Solution Approach 2:
The shroud is designed with removable attachment features that allow it to be dynamically repositioned between different orientations. This dynamic reconfigurability enables a single leadframe design to accommodate multiple vehicle applications while maintaining reliable electrical connections.
2Adaptability or versatility
If leadframes are customized for each vehicle application, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The leadframe is designed as a universal base component that can be used across multiple vehicle applications. The shroud's ability to be reoriented allows a single universal leadframe design to adapt to different vehicle configurations, eliminating the need for costly vehicle-specific customizations.
Solution Approach 2:
The shroud is pre-equipped with alignment features and attachment mechanisms that enable it to be repositioned in different orientations. This preliminary design of reconfigurable features allows the same component to serve multiple purposes without requiring additional manufacturing steps for each application.
3Power
If high voltage systems are implemented for improved power output, then power capability is improved, but safety risks increase
Solution Approach 1:
The high voltage connector system is segmented into separable components with defined interfaces. This segmentation allows for controlled connection and disconnection procedures, reducing the risk of accidental contact with live electrical components during assembly or maintenance.
Solution Approach 2:
The shroud acts as an intermediary component between the leadframe and external connections. It provides a protective barrier and defined interface that reduces the risk of accidental contact with high voltage elements, thereby mitigating safety risks while maintaining power output capability.
Data Source
AI summary
A shroud configured to connect a leadframe to a battery system for a hybrid motor vehicle is provided. The shroud is removably attachable to the leadframe. The shroud has at least one shroud alignment feature, the shroud being removably attached to the leadframe in a predetermined orientation wherein the shroud alignment feature is aligned with a complimentary leadframe alignment feature. The shroud may include a hollow cylindrical portion and at least one connecting feature configured to attach the shroud to the leadframe. The shroud may be provided as part of a connector system that includes the leadframe. In this case, the leadframe is configured to provide an electrical and mechanical connection between a power inverter and the battery system of the electric motor. The leadframe includes at least one leadframe alignment feature that is aligned with the shroud alignment feature.