Interlock Bypass Connector for High-Voltage Continuity Testing

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Solution Overview

Problem

Existing high voltage connector systems in electrified vehicles require multiple types of male connectors to maintain continuity in the high voltage interlock loop during testing, leading to inefficiency and high costs due to the need for extensive storage and maintenance of various connector styles.

Innovation Solution

A standalone high voltage interlock bypass connector, featuring a U-shaped wire with a handle, allows for closing the interlock circuit without mating the male connector, ensuring continuity and visibility of the connection for diagnostic purposes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple different male high voltage connectors are stocked for various female connector types, then the high voltage interlock circuit can be maintained during testing, but storage space requirements increase and operational efficiency decreases

Engineering Contradiction:

Improvehigh voltage interlock circuit continuityVSAvoidconnector management efficiency

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The invention extracts the interlock pin function from the male connector body, creating a separate bypass connector that only contains the interlock pins. This allows the interlock circuit to be completed independently from the main high voltage connection, eliminating the need to stock multiple male connector variants.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The bypass connector is segmented into distinct functional components: a handle for user operation, insulation material for safety, and interlock pins for circuit completion. This segmentation allows the interlock function to be performed separately from the main connector assembly.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple different male high voltage connectors are maintained in stock, then all female connector types can be tested, but storage costs and maintenance requirements increase

Engineering Contradiction:

Improvecompatibility with various female connectorsVSAvoidnumber of connectors to stock

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The bypass connector is designed as a universal component that can be used with any female high voltage connector type. The interlock pins are configured to mate with standard interlock pin receiving wells found in various female connectors, making the bypass connector adaptable to different connector styles without requiring multiple variants.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The bypass connector acts as an intermediary device that mediates between the test equipment and the female connector. It provides a standardized interface for completing the interlock circuit during testing, eliminating the need to have specialized male connectors for each female connector type.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Difficulty of detecting and measuring

If the bypass connector uses a transparent handle, then the connected end of the U-shaped wire is visible for diagnostics, but the handle material requirements become more specific

Engineering Contradiction:

Improvevisibility of connection statusVSAvoidhandle material selection

Core Design Contradiction:

Difficulty of detecting and measuringVSEase of manufacture

Solution Approach 1:

The handle is made transparent or translucent, allowing visual detection of the connected end of the U-shaped wire inside. This transparency provides diagnostic information about the connector's internal state without requiring disassembly, making the connection status visible to operators.

Inventive Principle:

Principle #32Color changes

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

Enables efficient and cost-effective testing of high voltage systems by eliminating the need for multiple male connectors, reducing storage and maintenance costs while ensuring reliable circuit closure and diagnostic visibility.

Implementation Method 1

The handle is configured to provide insulation from a voltage carried by the metal pin

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS12592515B2High voltage interlock bypass connector

Publication Date: 2026.03.31 FCA US LLC

AI summary

A high voltage interlock bypass connector for use with a female high voltage connector having an interlock is provided and includes a metal connector pin having a substantially U-shape with a connected end and a pair of terminal ends; and a handle formed around and enclosing the connected end of the connector pin opposite the terminal ends such that the terminal ends extend beyond the handle. The handle is configured to provide insulation from a voltage carried by the metal pin and is transparent such that the connected end of the metal pin enclosed by the handle is visible within the handle. The interlock bypass connector is configured to be inserted into the interlock to complete a high voltage interlock circuit without having to connect a corresponding male high voltage connector having integrated interlock pins.