Separable High-Voltage Connector Assembly for Mis-Insertion Prevention

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Solution Overview

Problem

Existing low-voltage connectors are unable to operate in high-voltage environments without increasing size, leading to errors from incorrect pin insertions when multiple connectors are used.

Innovation Solution

A separable high-voltage connector assembly that individually separates first pins into multiple small connectors, each with a housing and terminal, and fastens second pins to form a miniaturized assembly with adjusted creepage and clearance, preventing incorrect insertions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple connectors are used to meet high voltage requirements, then voltage capability is improved, but the risk of incorrect insertion increases and device complexity worsens

Engineering Contradiction:

Improvevoltage capabilityVSAvoidconnector configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connector is divided into multiple independent pin units, each with its own housing and terminal. These segmented pins are arranged in specific patterns (e.g., alternating polarity arrangements) to achieve high voltage capability while maintaining a compact, integrated connector structure that prevents incorrect insertion.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If connectors are miniaturized to reduce size, then compactness is improved, but manufacturing precision requirements worsen

Engineering Contradiction:

Improveconnector sizeVSAvoidpin separation and alignment

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The connector is segmented into multiple independent pin units with clearances between them, allowing for compact arrangement while maintaining manufacturability. The segmented design enables precise positioning through individual housing structures and key code features, reducing the overall connector volume while managing manufacturing precision requirements.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If pins are separated individually to form multiple small connectors, then connector size is reduced, but assembly process complexity increases

Engineering Contradiction:

Improveconnector sizeVSAvoidassembly process

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

Multiple separated pin units are merged into a single integrated connector assembly through standardized housing structures and fastening mechanisms. The individual pins are combined with corresponding receptacles to form a unified connector that maintains compact size while simplifying the assembly process through modular design and standardized interfaces.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3629427B1Separable high-voltage connector assembly and manufacturing method therefor

Publication Date: 2025.09.10 LG ENERGY SOLUTION LTD

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AI summary

The present invention relates to a separable high-voltage connector assembly which can miniaturize a size by individually separating each first pin of a connector mounted on a board to form multiple small connectors and simplify a process and prevent an error that connectors are incorrectly inserted into each other by forming an inserting connector through fastening and assembling each of individually separated second pins.