Plug Connector Shock Hazard Protection Design
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Solution Overview
Problem
Existing plug connectors for motor vehicle inverters lack effective shock hazard protection, particularly in environments with high voltages and currents, and are prone to accidental contact due to exposed contact elements.
Innovation Solution
A plug connector design featuring dome-like shock hazard protection bodies and a plastic tip at the contact region, which project beyond the contact elements to prevent contact with a test finger or human finger, combined with a locking mechanism and pivotable protective flap for enhanced safety and guidance during connection/disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If contact elements are exposed for direct connection, then ease of operation is improved, but shock hazard protection deteriorates
Solution Approach 1:
The contact element is segmented into a contact region and a non-contact region, with the non-contact region extending beyond the contact region to form a protective protrusion. This segmentation allows the connector to provide both connection functionality and shock hazard protection simultaneously.
Solution Approach 2:
The non-contact region acts as an intermediary protective element between the exposed contact elements and potential contact by fingers or tools. It provides a physical barrier that prevents direct contact with live electrical components while allowing the connection process to proceed.
2Object-affected harmful factors
If shock hazard protection bodies are added, then shock hazard protection is improved, but device complexity increases
Solution Approach 1:
The non-contact region is merged with the contact element itself, forming an integrated structure. This eliminates the need for separate protection components and reduces overall device complexity while maintaining effective shock hazard protection.
Solution Approach 2:
The non-contact region serves multiple functions: it provides shock hazard protection, guides the insertion process, and maintains structural integrity. This multi-functionality reduces the need for additional components and simplifies the overall device design.
3Ease of operation
If contact elements are exposed for direct contact, then ease of operation is improved, but reliability deteriorates
Solution Approach 1:
The non-contact region performs preliminary protective action by extending beyond the contact region before connection occurs. It pre-establishes a safety barrier that prevents accidental contact during the connection process, ensuring operating safety before the actual electrical connection is made.
Solution Approach 2:
The non-contact region provides beforehand cushioning by creating a physical buffer zone that prevents direct contact with live contact elements. This protective cushioning is in place before any potential harmful contact can occur, ensuring reliability and operating safety.
Data Source
AI summary
A plug-side first electrical plug connector has at least two flat electrical contact elements arranged in parallel extending in a housing of the connector in the insertion direction of the connector for accommodating socket-side second plug connector in the direction of an opening of the housing. A plastic tip is formed on one end of a contact region of the contact elements, and at least one dome-like shock hazard protection element is provided in the housing, extending in the insertion direction adjacent to the contact elements and protrudes beyond the contact region of the contact elements. The plug connector is suitable for a motor vehicle inverter to supply power to an auxiliary unit of the motor vehicle, and provides shock hazard protection of the contact elements for a human finger and/or reliable operating security is provided.