HV Junction Box Connector Interlock for Terminal Alignment
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Solution Overview
Problem
Existing electrical distribution assemblies for high voltage in hybrid and electrical vehicles face challenges with one-way connections that are difficult to inspect for proper terminal alignment, leading to potential damage and high costs during assembly, as they require destruction for unplugging and can result in incorrect connections if not properly equipped.
Innovation Solution
An electrical distribution assembly with a junction box and connector housing featuring blocking means that prevent connection unless all terminals are correctly aligned, using a combination of rigid and flexible components to ensure proper terminal placement before allowing mating, and a final locking mechanism for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If blocking means are used to prevent connection without proper terminals, then connection safety is improved, but device complexity increases
Solution Approach 1:
The blocking means are positioned in advance within the connector housing to prevent connection before terminals are properly inserted. This preliminary blocking action ensures that connection safety is maintained by preventing improper connections from occurring in the first place, rather than detecting and correcting them after connection attempts.
Solution Approach 2:
The blocking means act as an intermediary element between the connector housing and the junction box, physically preventing contact unless terminals are properly in place. This intermediary mechanism translates the presence or absence of terminals into a mechanical blocking or unblocking state, ensuring safety without requiring complex electronic detection systems.
2Reliability
If one-way connection is implemented for safety, then safety requirements are met, but ease of operation deteriorates
Solution Approach 1:
The connection system transitions from a static one-way design to a dynamic system where the blocking means can move between blocked and unblocked states. This dynamic behavior allows the connector to be initially blocked for safety, then become operable when terminals are properly inserted, and potentially be reset if needed, improving ease of operation while maintaining safety.
Solution Approach 2:
The blocking means are designed to automatically respond to the presence or absence of terminals without requiring external control or manual intervention. The system self-regulates the connection state based on whether proper terminals are in place, eliminating the need for complex control systems while maintaining both safety and operational ease.
3Manufacturing precision
If inspection of terminal alignment is required, then connection accuracy is improved, but productivity decreases
Solution Approach 1:
The patent replaces complex electronic or optical inspection systems with a simple mechanical blocking mechanism. The blocking means physically prevent connection unless terminals are properly aligned and inserted, providing inherent mechanical verification of terminal alignment without requiring separate inspection equipment or procedures.
Solution Approach 2:
The blocking means automatically verify terminal alignment through their mechanical interaction with the terminals. When terminals are properly inserted, they automatically displace the blocking means, allowing connection. This self-verifying mechanism eliminates the need for separate inspection steps, maintaining both precision and productivity.
Data Source
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AI summary
An electrical distribution assembly (10) for the distribution of high voltage in electrical or hybrid vehicles, comprising a junction box (20) having a box housing (22), wherein the box housing (22) comprises a plug portion (30) adapted to receive an electrical connector (100) and the electrical connector (100), having a connector housing (102) comprising a plurality of cavities (110), each adapted to receive and hold a terminal (150), wherein the plug portion (30) comprises a plurality of first blocking means protruding along a mating axis (M) outwards the box housing (22) and wherein each of the plurality of cavities (110) comprises a second blocking means extending along the mating axis (M) along the cavity (110), wherein each of the first blocking means blocks the corresponding second blocking means in a blocked position (B) when the corresponding cavity is empty, thereby preventing movement of the connector housing (102) along the mating axis (M) towards the box housing (22), the assembly further comprising at least one terminal (150) movable from an outward position to an inserted position, wherein each terminal (150) inserted in the cavity (110) relocates the corresponding first blocking means or the corresponding second blocking means, to release the blocking, thereby allowing movement of the connector housing (102) towards the box housing (22), along the mating axis (M).