Vehicle Inverter Interface Assembly with Spring-Loaded Clips
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Solution Overview
Problem
Existing interface assemblies for vehicle inverters face challenges in achieving optimal coupling between direct current connectors, communication media, and interfaces, leading to potential slippage and electrical coupling interruptions.
Innovation Solution
The proposed interface assembly includes a housing with busbars, a communication medium, and spring-loaded clips that provide secure electrical coupling between the busbars and the communication medium, ensuring stable and efficient transfer of electric current and information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupling methods are used between direct current connectors, communication medium, and interface, then the device complexity is reduced, but the reliability of electrical coupling deteriorates due to slippage and interruptions
Solution Approach 1:
The patent combines the direct current connectors, communication medium, and interface into a single integrated interface assembly. The housing unifies these components, and the clips simultaneously secure both electrical and communication connections, eliminating slippage between separate components while maintaining manageable complexity through functional integration.
Solution Approach 2:
The spring-loaded clips act as intermediary elements between the busbars and the communication medium/interface. These clips provide a reliable mechanical and electrical connection, mediating the coupling between power and communication components while preventing slippage and ensuring stable contact.
2Stability of the object's composition
If secure coupling is achieved between busbars and communication medium, then the stability of electrical connection is improved, but the manufacturing complexity increases due to spring-loaded clips
Solution Approach 1:
The spring-loaded clips are designed to self-adjust and self-secure during assembly. The spring mechanism automatically provides the necessary contact pressure when the clips are installed, eliminating the need for additional fastening steps or complex adjustment procedures, thereby maintaining ease of manufacture while ensuring stable connections.
Solution Approach 2:
The spring-loaded clips introduce a dynamic element to the otherwise static electrical connection. The spring mechanism allows for thermal expansion and contraction while maintaining stable contact pressure, accommodating manufacturing tolerances and operational variations without requiring complex rigid fixation systems.
3Loss of energy
If optimal coupling is provided between connectors and communication medium, then the loss of electrical current is reduced, but the device complexity increases
Solution Approach 1:
By integrating the power connection and communication medium coupling into a single unified assembly, the patent minimizes the number of connection interfaces where electrical current could be lost. The merged structure reduces contact resistance and eliminates energy losses associated with multiple separate coupling points, while the complexity remains manageable through functional consolidation.
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
This configuration enhances the performance and longevity of the interface assembly by reducing slippage and ensuring reliable communication and power delivery to vehicle systems, improving the overall efficiency of the inverter assembly.
Implementation Method 1
The plurality of clips are spring loaded against a respective one of the plurality of busbars
Data Source
AI summary
An interface assembly for an inverter of a vehicle includes an interface, a plurality of busbars, a communication medium, and a clip. The interface is for communicating with one or more vehicle systems outside of the interface assembly. The plurality of busbars are configured to receive and transport electric current. The communication medium is electrically coupled between the plurality of busbars and the interface. The communication medium is configured to provide information to the interface based at least in part on the electric current transported by the plurality of busbars. The clip assembly is electrically coupled between the plurality of busbars and the communication medium.