Movable Terminals in EV Service Disconnects

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Solution Overview

Problem

Existing manual service disconnects for high voltage circuits in electric vehicles face challenges in maintaining consistent component positioning and accommodating variations in size during manufacturing, which can affect the reliability of interrupting current flow during maintenance.

Innovation Solution

The design incorporates a terminal housing with movable terminals and flexible bus bars, allowing independent movement of terminals and ensuring secure connections through guide attachments and retaining mechanisms, ensuring reliable current interruption while accommodating size variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If rigid fixed-position terminals are used, then manufacturing precision can be maintained, but adaptability to size variations and space constraints is reduced

Engineering Contradiction:

Improveadaptability to size variationsVSAvoidcomponent positioning consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies the dynamics principle by making terminals movable rather than fixed. Each terminal is retained in the terminal housing for movement relative to the housing, allowing them to adjust their positions dynamically. This resolves the contradiction by enabling adaptability to size variations while maintaining manufacturing precision through controlled movement within defined ranges.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the positional parameter of terminals from fixed to variable. By allowing terminals to move within the terminal housing while maintaining their electrical connection through flexible bus bars, the system can adapt to different component sizes and spacing variations without compromising manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If movable terminals with independent adjustment are used, then adaptability to manufacturing variations is improved, but device complexity increases

Engineering Contradiction:

Improveadjustability of terminalsVSAvoidterminal retention mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the terminal retention and positioning functions into a single terminal housing structure. The housing simultaneously retains multiple movable terminals and provides the movement constraint, eliminating the need for separate complex retention mechanisms for each terminal and reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal housing serves multiple functions: it retains all terminals, allows their independent movement, provides guide openings for alignment, and maintains structural integrity. This multi-functionality reduces the need for additional components and simplifies the overall device design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If flexible bus bars are used to connect movable terminals, then adaptability to position changes is improved, but connection stability may be compromised

Engineering Contradiction:

Improveflexibility of connectionsVSAvoidconnection stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent uses flexible bus bars to connect movable terminals, allowing the connections to adapt to position changes while maintaining electrical continuity. The flexible nature of the bus bars enables them to accommodate terminal movement without compromising connection stability, as they can bend and flex within defined limits while maintaining reliable electrical contact.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS11394158B1Electrical connector with adjustable terminals

Publication Date: 2022.07.19 LEAR CORP

AI summary

An electrical connector includes a terminal housing. A first terminal is retained in the terminal housing for movement relative to the terminal housing. A second terminal is also retained in the terminal housing for movement relative to the terminal housing. A flexible bus bar is connected to the first terminal and to the second terminal. The first terminal is able to be moved independently of the second terminal.