Power Terminal Spring Clip Stabilization for EV Connectors
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Solution Overview
Problem
Existing electrical connectors for high power applications, such as in electric or hybrid electric vehicles, face issues with insufficient overtravel for staggered separation of high voltage interlock and high voltage circuits, leading to increased cost and complexity, as well as degradation of spring beams due to vibration and wear, which affects stability and requires higher normal force that can cause wear at the mating interface.
Innovation Solution
A power terminal design with a terminal body having a terminating portion, a mating portion, and a base, coupled with a spring clip that includes cantilevered and stabilization contact springs to provide enhanced contact normal force and stability, allowing for reliable and cost-effective electrical connections, and a family of electrical connectors that can be adapted for different orientations and terminations using a limited number of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If higher normal force spring beams are used to compensate for stability problems due to vibration and wear, then stability is improved, but wear of the plating at the mating interface increases over time
Solution Approach 1:
The patent changes the material parameter by using beryllium copper alloy instead of conventional spring beam materials. This alloy provides superior elasticity and vibration resistance, allowing the spring beam to maintain stable contact force without excessive wear. The material parameter change resolves the contradiction by providing both the needed stability and reduced wear simultaneously.
Solution Approach 2:
The patent employs composite construction by combining beryllium copper alloy with specific plating materials (such as gold or palladium) on the contact surfaces. This composite approach allows the base material to provide structural stability and vibration resistance while the plated surface layer protects against wear, thus resolving the contradiction between stability and wear prevention.
2Reliability
If a separate HVIL connector is provided that is unmated prior to unmating the high voltage connector, then the high voltage interlock circuit can be properly controlled, but cost and complexity of the system increase
Solution Approach 1:
The patent merges the HVIL circuit functionality directly into the power terminal structure. The spring beam itself serves dual purposes: providing electrical connection for high voltage power transmission and containing the HVIL circuit elements. This integration eliminates the need for a separate HVIL connector, reducing system complexity while maintaining proper high voltage interlock control.
Solution Approach 2:
The power terminal is designed with multi-functionality, where the same component structure serves both high voltage power connection and HVIL circuit functions. The spring beam and its associated elements perform multiple roles including electrical conduction, mechanical retention, and interlock circuit operation, thereby eliminating the need for separate dedicated components and reducing overall system complexity.
3Adaptability or versatility
If there are many different arrangements for the electrical connectors to accommodate different vehicle applications, then adaptability is improved, but manufacturing cost and part supply cost increase
Solution Approach 1:
The patent designs the power terminal with universal features that allow it to function in multiple connector arrangements. The spring beam structure and contact geometry are designed to accommodate different orientations and mounting configurations without requiring different terminal designs. This universality allows a single terminal design to serve multiple vehicle applications, reducing manufacturing complexity and part supply costs while maintaining adaptability.
Solution Approach 2:
The spring beam provides dynamic adaptability through its elastic properties, allowing the terminal to accommodate variations in assembly tolerances, thermal expansion, and mechanical stress in different vehicle installations. This dynamic characteristic enables a single terminal design to function reliably across multiple connector arrangements and vehicle platforms without requiring custom designs for each application.
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
The solution provides reliable and cost-effective electrical connections by enhancing the contact normal force and stability of power terminals, reducing the need for multiple connector designs and part supplies, while maintaining the integrity of high power circuits during mating and unmating.
Implementation Method 1
The spring clip includes at least one stabilization contact spring spring biased against and electrically connected to at least one of the first plate or the second plate and configured to be spring biased against and electrically connected to the tab terminal. The stabilization contact spring provides a greater contact normal force against the tab terminal than the cantilevered contact spring.
Data Source
AI summary
A power terminal includes a terminal body having a mating portion including plates with a mating space therebetween. A spring clip is coupled to the mating portion and includes inner spring plates extending along the plates in the mating space with a slot therebetween. The inner spring plates directly engage and electrically connect to the terminal body and to a tab terminal received in the slot. The spring clip includes at least one cantilevered contact spring configured to be spring biased against and electrically connected to the tab terminal. The spring clip includes at least one stabilization contact spring spring biased against and electrically connected to the corresponding plate and configured to be spring biased against and electrically connected to the tab terminal. The stabilization contact spring provides a greater contact normal force against the tab terminal than the cantilevered contact spring.