High Voltage Connector Arc Prevention via Plating Part
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Solution Overview
Problem
High-voltage connectors in electric vehicles experience arc discharges during terminal insertion and separation, particularly at 42V power systems, posing safety risks due to high discharge voltages.
Innovation Solution
A high-voltage connector design featuring a first connector with an open circuit terminal and a second connector with a holder and elastic member, forming a closed loop to prevent arc occurrence by ensuring continuous contact and using a conductive plating part integrated with the female terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-voltage connector uses a separate complex structure for fixing terminals, then terminal contact reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the terminal fixing function with the connector housing itself. The housing includes integrated fixing protrusions that engage with corresponding recesses in the terminal, eliminating the need for separate fixing structures. This merging approach maintains reliable terminal contact while reducing overall device complexity.
Solution Approach 2:
The connector housing performs its own terminal fixing function through integrated structural features. The fixing protrusions and recesses are built into the housing design, allowing it to secure terminals without requiring additional dedicated fixing components. This self-service approach simplifies the overall connector structure.
2Stability of the object's composition
If a high-voltage connector uses traditional terminal fixation methods, then terminal stability is improved, but manufacturing complexity increases
Solution Approach 1:
The terminal fixation features are merged into the housing manufacturing process. The fixing protrusions and recesses are formed as integral parts of the housing during molding or machining, eliminating the need for separate fixation components and assembly steps. This reduces manufacturing complexity while ensuring terminal stability.
Solution Approach 2:
The housing structure provides its own terminal fixation capability through built-in geometric features. These features are created during the housing manufacturing process itself, requiring no additional parts or assembly operations. This self-service approach simplifies manufacturing while maintaining terminal stability.
3Device complexity
If a high-voltage connector uses simple terminal contact design, then device complexity is reduced, but arc discharge risk increases
Solution Approach 1:
The patent introduces a plating part as an intermediary element between the terminal contact surfaces. This plating layer provides enhanced electrical conductivity and arc resistance, reducing arc discharge risk. The plating part is integrated into the simple connector design, maintaining low complexity while effectively mitigating the harmful arc discharge effect.
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
The design effectively prevents arc discharges by maintaining electrical contact and reducing the need for a separate complex structure for terminal fixation, enhancing safety and reducing costs.
Implementation Method 1
a second connector that includes an elastic member configured to support the holder in an inserted state of the first connector, and configured to provide an abutting connection between the plating part and the open circuit terminal
Implementation Method 2
a plating part which is electrically in contact with the open circuit terminal of the first connector may be formed
Data Source
AI summary
A high-voltage connector for a vehicle is provided. The high-voltage connector includes a first connector having an open circuit terminal configured to transmit an electrical signal in one direction. Additionally, a second connector is provided and includes a plating part which is electrically in contact with the open circuit terminal of the first connector.