Parallel Wiring Circuit for High Voltage Connectors

Solution Overview

Problem

High voltage electrical connection systems in electric and hybrid electric vehicles face challenges with heat dissipation and weight reduction due to the use of thick, stiff copper wires, which are inefficient and heavy.

Innovation Solution

A high voltage connector system that divides high voltage electric currents into sub-currents using multiple smaller terminals and wires, allowing for better heat dissipation and easier implementation by using smaller parallel wires and terminals, which can replace thicker single wires and provide higher current transfer capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If thick copper wires are used to handle high voltage and current, then current transfer capability is improved, but weight increases and heat dissipation becomes inefficient

Engineering Contradiction:

Improvecurrent transfer capabilityVSAvoidwire weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The patent divides a single thick wire into multiple smaller parallel wires. Each smaller wire carries a portion of the total current, collectively achieving the required current transfer capability while reducing overall weight and improving heat dissipation through increased surface area.

Inventive Principle:

Principle #1Segmentation

2Power

If thick copper wires are used to handle high voltage and current, then current transfer capability is improved, but heat dissipation efficiency deteriorates

Engineering Contradiction:

Improvecurrent transfer capabilityVSAvoidheat dissipation efficiency

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent divides a single thick wire into multiple smaller parallel wires. Each smaller wire carries a portion of the total current, collectively achieving the required current transfer capability while reducing overall weight and improving heat dissipation through increased surface area.

Inventive Principle:

Principle #1Segmentation

3Power

If thick stiff wires are used for high current applications, then current transfer capability is improved, but ease of integration and handling deteriorates

Engineering Contradiction:

Improvecurrent transfer capabilityVSAvoidease of integration

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The patent divides a single thick wire into multiple smaller parallel wires. Each smaller wire carries a portion of the total current, collectively achieving the required current transfer capability while reducing overall weight and improving heat dissipation through increased surface area.

Inventive Principle:

Principle #1Segmentation

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 solution enables improved heat dissipation and weight reduction by using smaller parallel wires and terminals, allowing for higher current transfer without significant temperature rise, and facilitates easier integration in vehicles by simplifying the handling of smaller wires.

Implementation Method 1

The first header includes a first plurality of header terminals that are electrically connected together such that the first high voltage electric current is divided into a plurality of sub-currents

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

The second header has a second plurality of header terminals that are electrically connected together such that the plurality of sub-currents are joined together to reform the first high voltage electric current

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 3

The first connector has a first plurality of connector terminals such that each connector terminal in the first plurality of connector terminals electrically contacts a header terminal in the first plurality of header terminals

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS8408944B1Scalable connection system for parallel wiring circuits

Publication Date: 2013.04.02 LEAR CORP

AI summary

A high voltage connector system includes a first header for connection to a first electronic device, a first connector that connects to the first header, a second header that connects to a second electronic device, a second connector that connects to the second header, and a plurality of wires connecting the first connector and the second connector. The first header includes a first plurality of header terminals that are electrically connected together such that a high voltage electric current is divided into a plurality of sub-currents. The second header has a second plurality of header terminals that are electrically connected together such that the plurality of sub-currents are joined together to reform the first high voltage electric current.