Insulated Electrical Connector for Visible HV Disconnection
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Solution Overview
Problem
Existing electrical connectors in vehicles, particularly in high-voltage subsystems, pose a safety risk as busbars remain connected and under power when the screw is released, posing a danger to service technicians.
Innovation Solution
An electrical connector with an electrically conductive bushing, an insulating insulation element, and an electrically insulated screw with a displaceable contact element that ensures a safe interruption of current flow when the screw is released, allowing visual confirmation of disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw is used to clamp busbars to a bushing, then electrical connection is established, but the busbars remain under power and connected even after the screw is released
Solution Approach 1:
The contact element is segmented from the screw head by introducing a contact element that can move independently on the screw. This segmentation allows the contact element to be carried away with the screw when released, ensuring complete disconnection of the electrical circuit between busbars, thereby eliminating the electrical hazard while maintaining reliable connection during operation
Solution Approach 2:
The contact element acts as an intermediary between the screw and the busbar contact. It is displaceably arranged on the screw and carries the contact surface that interfaces with the bushing. This intermediary ensures that when the screw is released, the contact element is also removed from the contact area, providing safe interruption of electrical flow
2Object-affected harmful factors
If the screw head is electrically insulated, then safety to touch is improved, but the ability to visually confirm disconnection is reduced
Solution Approach 1:
The contact element is provided with a surface region that serves as a contact surface with the bushing and is visible from the outside. This visual feature allows service technicians to confirm disconnection by observing the position or presence of the contact element, while the electrically insulated screw head maintains safety to touch
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 connector provides a safe and reliable means to interrupt electrical connections, ensuring the connector is safe to touch and visibly indicates disconnection, reducing the risk of electrical hazards.
Implementation Method 1
an electrically insulating insulation element which surrounds the bushing laterally
Implementation Method 2
a screw which can be plugged into the bushing and has at least one electrically insulated screw head
Data Source
AI summary
An electrical connector bas an electrically conductive sleeve with a surface region provided as a contact area to a first electrical line, an electrically insulating insulation element which laterally surrounds the sleeve, an electrically insulated screw which can be inserted into the sleeve and has at least one electrically insulated screw head, and a contact element which is displaceably and captively arranged on the screw and has a surface region provided as a contact area to a second electrical line. The contact element and the sleeve make electrical contact when the screw is tightened. A vehicle, in particular an electric vehicle, includes the electrical conductor.