Multi-Stage Latching Sequence for HVIL Connector Assembly
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Solution Overview
Problem
High voltage connector assemblies in electric vehicles face challenges in integrating high voltage interlock protection without requiring a second connector and do not provide sufficient delay during the unmating sequence, risking damage to components and users.
Innovation Solution
The connector assembly incorporates a housing with power supply and interlock circuit contacts, a lever subassembly, and a lever latch or slide bar to control the mating and unmating sequence, ensuring the interlock circuit is decoupled before the power supply, and introducing a delay to prevent damage during unmating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second connector is used to integrate HVIL protection circuit, then safety protection is improved, but device complexity increases
Solution Approach 1:
The patent combines the HVIL protection circuit and power supply connection into a single connector assembly. The interlock contacts and power contacts are integrated within the same connector housing, allowing both safety protection and power transmission functions to be achieved without requiring a second separate connector. This merging approach maintains reliability while reducing device complexity.
2Productivity
If unmating sequence is accelerated, then productivity is improved, but harmful factors increase due to insufficient discharge time
Solution Approach 1:
The patent implements a controlled unmating sequence where the interlock contacts are designed to disconnect before the power contacts. This preliminary action ensures that the electrical connection is safely interrupted first, allowing capacitive components to discharge before the physical separation occurs. The lever subassembly mechanically enforces this sequence, preventing simultaneous disconnection that could cause damage.
3Ease of operation
If interlock contacts are decoupled after power contacts, then ease of operation is improved, but harmful factors increase due to potential damage
Solution Approach 1:
The patent inverts the conventional unmating sequence by designing the lever subassembly and latch mechanism to automatically disconnect the interlock contacts before the power contacts. This inversion ensures safety by interrupting the control circuit first, preventing damage from sudden power interruption during disconnection. The mechanical design enforces this reverse sequence automatically during the unmating operation.
Data Source
AI summary
A connector assembly includes a housing, a power supply contact, an interlock circuit contact, a lever subassembly and a lever latch. The lever subassembly is pivotally coupled to the housing and includes a handle and a gripping end that engages the mating connector to move the housing relative to the mating connector when the handle is rotated. The handle is rotated to sequentially decouple the interlock circuit contact from the mating interlock contact prior to unmating the power supply contact from the mating power contact. The lever latch is coupled with the housing and prevents unmating of the power supply contact from the mating power contact before separation of the interlock circuit contact and the mating interlock contact before the power supply contact is decoupled from the mating power contact and after the interlock circuit contact is decoupled from the mating interlock contact by blocking rotation of the lever subassembly.