Spring-Loaded HV Connector for Stable Vehicle Power Contacts
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Solution Overview
Problem
High-voltage on-board power systems in vehicles require connectors that ensure stable and electrically flawless connections with low contact resistance and high mechanical stability, especially under dynamic loads, which existing connectors often fail to achieve due to high currents and varying voltages.
Innovation Solution
The on-board power system connector features a housing with spring-mounted connection parts made from conductive materials, such as copper or aluminum, with a metallic coating, and a compression spring mechanism that maintains contact pressure between sleeve-shaped receptacles and rod-shaped plug-in elements, ensuring stable and low-resistance connections even in dynamic environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors are used for high-voltage on-board power systems, then the connector structure is simple, but the connection stability and electrical reliability are insufficient under high currents and dynamic loads
Solution Approach 1:
The connection part is designed to be movable along the longitudinal axis within the housing part, allowing it to adapt dynamically to mechanical stresses and maintain optimal contact pressure under varying load conditions, thereby improving connection stability without requiring an overly complex fixed structure
Solution Approach 2:
The connector utilizes spring force to dynamically adjust the contact pressure parameter between connection parts, ensuring maintained electrical contact under high currents and dynamic loads while keeping the overall structure relatively simple
2Reliability
If large-area contact surfaces are used to reduce contact resistance, then the electrical reliability improves, but the connector size and complexity increase
Solution Approach 1:
The connection part features localized large-area contact surfaces specifically at the contact regions with the housing part, while other portions of the connector maintain compact dimensions. This concentrates the electrical contact area where needed without unnecessarily increasing overall connector volume
Solution Approach 2:
The movable connection part can translate along the longitudinal axis to optimize the contact surface area dynamically, ensuring adequate electrical contact area is achieved without requiring a permanently oversized connector structure
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 design provides a stable, electrically reliable connection with reduced ohmic losses and enhanced mechanical stability, capable of handling high currents and dynamic loads, thus meeting the demands of high-voltage on-board power systems.
Implementation Method 1
the first connection part is spring-mounted in the first housing part along the longitudinal axis by a spring element... the spring element is thus compressed in the connected state, causing a permanent spring force to act on the connection between the two connection parts
Data Source
AI summary
On-board power supply connector, in particular for high-voltage on-board power supplies, comprising, a first connection part arranged in a first housing part, the first housing part having a longitudinal extension along a longitudinal axis and having an end-face opening, and the first connection part being mounted in the first housing part such that it can move along the longitudinal axis, a second connection part arranged in a second housing part, the second housing part having a longitudinal extension along a longitudinal axis and having an end-face opening, characterized in that, in the connected state of the connector, a fastening lever which can be pivoted about an axis perpendicular to the longitudinal axis is arranged on one of the housing parts and, in the connected state of the connector, engages with a fastening means on the other housing part, wherein, in the connected state of the connector, the longitudinal axes of the first and second housing parts extend collinearly and the second housing part is fixed relative to the first housing part at least in the longitudinal direction and the second connection part is in mechanical contact with the first connection part, characterized in that the first connection part is resiliently mounted in the first housing part along the longitudinal axis by a spring element.