High Power Connector Locking Element for External Terminal Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly and electrical connection of high power connectors in power electronic apparatuses, such as those in electric or hybrid vehicles, are complex due to the need for access openings and long wirings, leading to increased production costs and complexity.
Innovation Solution
A high power connector with a conductive element and a locking element made of insulating material, allowing for easy insertion and locking on the cover, along with sealing and fixing means, simplifies the assembly and connection process by enabling the connector to be accessible from outside the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are fixed to the cover and connected to internal electronics after container closing, then electrical connection is achieved, but assembly complexity increases and access openings are required
Solution Approach 1:
The connector is pre-assembled with the cover before the container is closed. The conductive element is inserted through the opening in the cover and electrically connected to the power electronic circuit during the initial assembly phase, eliminating the need for subsequent complex wiring operations through access openings.
Solution Approach 2:
The cover serves multiple functions: it closes the container hermetically and simultaneously provides the structural base for mounting the connector. The opening in the cover is designed to accommodate both the sealing function and the electrical connection function, integrating two separate requirements into a single component.
2Reliability
If access openings and long wirings are used for connector connection, then electrical connection is achieved, but production costs increase
Solution Approach 1:
The connector assembly is extracted as a separate pre-assembled unit from the main container assembly process. By preparing the connector with its conductive element and terminal independently before final installation, the manufacturing process eliminates the need for costly access openings and long wiring operations, reducing overall production costs.
3Ease of operation
If connectors are accessible from outside the container, then connection ease is improved, but container structure becomes more complex
Solution Approach 1:
The connector mounting structure is merged with the container cover. The opening in the cover and the mounting features for the connector are integrated into the cover's design, eliminating the need for separate access openings, doors, or closing mechanisms. This unified approach provides external accessibility while maintaining container structural simplicity.
Data Source
AI summary
The high power connector (1) comprises an electricity conductive element (2) of substantially elongated conformation and provided with a first end portion electrically connectable to a power electronic circuit (C) of a power electronic apparatus (A) and with a second end portion provided with an electrical connection terminal (3), the conductive element (2) being insertable inside a through opening (E) made on the cover (D) with said terminal (3) facing outwards, wherein the connector (1) comprises a locking element (4) made of an electrically insulating material that can be coupled with the conductive element (2) and fixable to the outer surface of the cover (D).