HVAC High-Voltage Connector Segmentation for EV Heating
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Solution Overview
Problem
Electric and hybrid vehicles lack waste heat from internal combustion engines for air heating, necessitating high-voltage electric heaters that require complex and costly high-voltage connections in motor vehicle air conditioning systems, complicating assembly and increasing manufacturing costs.
Innovation Solution
A motor vehicle air conditioning system design featuring a recessed plug for high-voltage connections at the end wall, allowing for easy assembly by plugging in a mating connector from the engine compartment, with an optional mechanical attachment and waste heat dissipation through the recess, simplifying the electrical connection to the high-voltage source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a high-voltage electric heater is used to heat air in electric and hybrid vehicles, then heating function is achieved, but assembly complexity and manufacturing cost increase due to complex high-voltage connections
Solution Approach 1:
The high-voltage connection system is segmented into separate components: a connector attached to the air conditioning housing and a mating connector in the engine compartment. This segmentation allows the air conditioning system to be assembled and tested independently before final vehicle assembly, reducing overall assembly complexity while maintaining the necessary high-voltage connection functionality for the electric heater.
2Use of energy by moving object
If a high-voltage electric heater is used to heat air in electric and hybrid vehicles, then heating function is achieved, but assembly effort and time increase due to complex high-voltage connections
Solution Approach 1:
The connector for the high-voltage connection is pre-attached to the air conditioning housing during air conditioning system assembly, before the system is installed in the vehicle. This preliminary action allows the air conditioning system to be prepared in advance, so that during final vehicle assembly, only the mating connector needs to be connected, significantly reducing assembly time and effort while enabling the electric heater functionality.
3Use of energy by moving object
If a high-voltage electric heater is used to heat air in electric and hybrid vehicles, then heating function is achieved, but manufacturing cost increases due to complex high-voltage connections
Solution Approach 1:
The high-voltage connection system is divided into separate connector components that can be manufactured and attached to the air conditioning housing independently. This segmentation enables standardized mass production of the connector assembly, reducing per-unit manufacturing costs compared to integrating complex high-voltage connections into the main housing structure, while still providing the necessary heating function through the electric heater.
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
This design simplifies and secures the high-voltage connection to the electric heating device, reducing assembly effort and costs while ensuring reliable operation and efficient heat dissipation, making the system more affordable and efficient.
Implementation Method 1
The PTC heating elements 4 consist of materials that have an electrical resistance and can conduct electricity better at low temperatures than at higher temperatures. The electrical resistance thus increases with increasing temperature, so that overheating of the PTC heating elements 4 can be prevented
Implementation Method 2
waste heat from the control and/or regulation unit 10 can be dissipated directly through the recess 16 from the housing wall 22 and the cooling fins 18 into the engine compartment 14 by thermal radiation and thermal convection
Implementation Method 3
waste heat from the control and/or regulation unit 10 can be dissipated directly through the recess 16 from the housing wall 22 and the cooling fins 18 into the engine compartment 14 by thermal radiation and thermal convection
Data Source
Figure 1
AI summary
In a motor vehicle air conditioning system (1), particularly for an electric or hybrid vehicle, comprising a housing (2), preferably at least one air duct (13), preferably a blower (12) for circulating air, and at least one high-voltage electric heating element (3), the electric heating element (3) should be easily and safely connected to a high-voltage source (9) with minimal installation effort. This objective is achieved by arranging a high-voltage connector (5) with at least one electrical contact element (7) in the area of an end wall (15) of a motor vehicle, and by using the connector (5) to electrically connect the electric heating element (3) to the high-voltage power source (9).