Screw Contact Power Connector With Retained Screw Interlock Safety

Solution Overview

Problem

Existing power connectors pose a risk of electrocution during maintenance due to the potential for the screw to rest on the counter-connector's first thread after disassembly, causing unintended activation of the interlock circuit and potential damage or injury.

Innovation Solution

The connector features a housing with retention means that hold the screw in a high position after unscrewing, preventing the cover from closing and maintaining an open interlock circuit, thus ensuring the connector remains de-energized during maintenance operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the screw is allowed to rest on the first thread of the counter-connector after unscrewing, then the connector can be quickly reassembled, but the interlock circuit may be unintentionally activated causing electrocution risk

Engineering Contradiction:

Improveassembly speedVSAvoidelectrocution risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The retention means are pre-configured in the housing to automatically hold the screw in a high position after unscrewing. This preliminary mechanical arrangement ensures that before any cover closing action occurs, the screw is already positioned to prevent interlock circuit activation, thus preventing electrocution risk while maintaining quick reassembly capability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The retention means act as an intermediary mechanical element between the screw and the housing. This intermediary structure prevents direct contact between the screw and the first thread of the counter-connector, thereby blocking the harmful signal path that would activate the interlock circuit and cause electrocution

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the cover is closed immediately after unscrewing, then the connector is protected from dust and water, but the screw may accidentally activate the interlock circuit

Engineering Contradiction:

Improveprotection against dust and waterVSAvoidsafety of interlock circuit

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The retention means are pre-configured in the housing to automatically hold the screw in a high position after unscrewing. This preliminary mechanical arrangement ensures that before any cover closing action occurs, the screw is already positioned to prevent interlock circuit activation, thus preventing electrocution risk while maintaining quick reassembly capability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The retention means create a preliminary mechanical constraint that opposes the potential harmful action of the screw contacting the first thread. By pre-positioning the screw in a high position, the system preemptively counteracts the risk of accidental interlock circuit activation that would otherwise occur upon cover closing

Inventive Principle:

Principle #9Preliminary anti-action

3Ease of operation

If the screw is made accessible for easy removal, then maintenance operations are simplified, but the risk of accidental energization increases

Engineering Contradiction:

Improvemaintenance accessibilityVSAvoidaccidental energization

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The connector is segmented into functional zones: the screw remains accessible in the open position for maintenance operations, while the retention means create a distinct mechanical state (high position) that separates the screw from the hazardous interaction zone with the first thread, thus allowing easy removal while preventing accidental energization

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retention means are pre-configured in the housing to automatically hold the screw in a high position after unscrewing. This preliminary mechanical arrangement ensures that before any cover closing action occurs, the screw is already positioned to prevent interlock circuit activation, thus preventing electrocution risk while maintaining quick reassembly capability

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4283790A1Screw contact power connector and method of connecting and disconnecting such a connector

Publication Date: 2023.11.29 APTIV TECHNOLOGIES AG

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

An electrical power connector (2), comprising a housing (4), at least one electrically conductive element (200), a cover (15) and at least one screw (6) for establishing an electrical connection with said electrically conductive element (200). The connector (2) is connected to an interlock circuit. The housing (4) comprises retention means (18) configured to hold the screw (6) in a high position. The cover (15) is configured to occupy at least an open position in which the screw (6) is accessible, and a closed position in which the screw (6) is not accessible. The interlock circuit is open when the cover (15) is in the open position and closed when the cover (15) is in the closed position, The screw (6) prevents the cover (15) from being placed in the closed position when it is in the high position. A method of disconnecting a connector assembly comprising this connector (2).