Insulated HV Connector Sleeve for Compact Finger-Safe Mating
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Solution Overview
Problem
Existing electrical connectors for high-voltage applications in electric vehicles face issues with protection pin damage, increased length requirements, complex assembly, and specific insulation needs, leading to safety and usability concerns.
Innovation Solution
An electrical connector with a connector housing made from bent sheet metal or reinforced plastic, featuring a planar contact with an insulative sleeve that prevents finger contact and reduces mechanical loading, allowing for a form-fit connection without additional insulation, and a snap connection mechanism for improved assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the protection pin is attached to a tip of an affixing element, then mechanical connection is achieved, but the length of the connection required in mating direction is increased
Solution Approach 1:
The protective function is shifted from the longitudinal axis (mating direction) to the radial dimension through the insulative collar. This dimensional change allows protection without extending the connection length in the critical mating direction, enabling compact connector designs suitable for confined spaces.
2Reliability
If specific affixing elements with insulation are used to attach protection pin, then protection is provided, but the module connector requires specific affixing elements which include insulation
Solution Approach 1:
The insulation requirement is extracted from the affixing element and transferred to dedicated protective components (insulative collar and protection cap). This extraction allows the use of simple, versatile affixing elements like standard screws without insulation, while maintaining protection through the specialized collar and cap components.
Solution Approach 2:
The insulative collar serves multiple functions: providing finger protection, enabling the use of non-insulated affixing elements, and serving as a structural component. This multi-functionality increases adaptability while maintaining protection, allowing various affixing element types to be used interchangeably.
3Ease of manufacture
If the protection pin is attached to affixing element, then mechanical connection is achieved, but the assembly sequence is complicated to perform by a worker
Solution Approach 1:
The insulative collar and protection cap are designed as pre-formed components that can be independently manufactured and prepared before final assembly. This preliminary preparation simplifies the assembly sequence, allowing workers to install components in a straightforward sequence without complex intermediate steps involving protection pin attachment.
Data Source
AI summary
An electrical connector includes a connector housing configured for mating with a corresponding counter-connector. Further, the electrical connector has an electrical contacting means arranged in the connector housing and configured for electrically contacting with the electrical conductor. The electrical contacting means is further configured for establishing an electrical contact with the counter-connector. Moreover, the electrical connector includes an insulative sleeve attachable to the electrical contacting means. The insulative sleeve is shaped to prevent a finger of a human from touching the electrical contacting means.