Interlock Connector Assembly With Final-Latch Circuit Switching
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Solution Overview
Problem
Existing connector assemblies in high-voltage automotive applications risk premature or incorrect activation of the interlock circuit due to incomplete interlocking, leading to potential accidents or reduced reliability.
Innovation Solution
A connector assembly design where the housing interlock element integrates a switching element that only contacts the interlock circuit contacts when fully latched, ensuring electrical power transmission is protected and only activated when the assembly is fully locked, eliminating the need for additional state checks and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the interlock circuit is closed early during connector assembly, then the switching system can be activated, but safety is compromised due to premature power transmission
Solution Approach 1:
The mechanical interlocking action is performed preliminarily to bring the connector components into position, but the electrical interlock circuit closing is delayed until the final latched position is achieved. This preliminary mechanical positioning followed by conditional electrical activation ensures safety while maintaining assembly efficiency.
Solution Approach 2:
The housing interlock element serves as an intermediary mechanism that mechanically connects the plug connector and mating plug connector, while its position also controls the electrical interlock circuit. This intermediary element ensures that electrical power transmission is only enabled when mechanical interlocking is complete and secure.
2Ease of operation
If the housing interlock element is made movable between pre-latched and final latched positions, then assembly flexibility is improved, but device complexity increases
Solution Approach 1:
The housing interlock element combines multiple functions into a single component: it provides mechanical interlocking, defines assembly positions (pre-latched and final latched), and controls the electrical interlock circuit. This merging of functions reduces the need for separate mechanisms while maintaining operational flexibility.
Solution Approach 2:
The housing interlock element is designed as a multi-functional component that simultaneously performs mechanical locking, position indication, and electrical circuit control. This universal element simplifies the overall device structure by eliminating the need for separate mechanisms for each function.
3Reliability
If the switching element is integrated in the housing interlock element, then the interlock circuit function is connected to mechanical locking, but manufacturing complexity increases
Solution Approach 1:
The switching element is integrated directly into the housing interlock element, merging the electrical switching function with the mechanical interlocking component. This integration ensures that the interlock circuit can only close when the mechanical locking is complete, improving reliability while the integrated design actually simplifies manufacturing by reducing the number of separate parts and assembly steps.
Data Source
Figure 1A~1B
Figure 1C
Figure 2A
AI summary
The invention relates to a connector assembly (1) of an electrical plug connector (100) and a mating plug connector (200), wherein the electrical plug connector (100) comprises a connector housing (101) and a housing interlock element (109) for securing the assembly connection of the connector housing (101) to the mating plug connector (200), wherein the housing interlock element (109) is movable with respect to the connector housing (101) between a pre-latched position and a final latched position, wherein the mating plug connector (200) comprises a receiving element (211) for the housing interlock element (109). The housing interlock element (109) has a switching element (131) which is configured and arranged such that the contacting of the two electrical contacts (219a, 219b) takes place only when the housing locking element (109) is in the final latched position.