Staged Release Electrical Connector Assembly
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Solution Overview
Problem
Existing electrical connector assemblies do not adequately delay the disconnection process, particularly in high voltage applications, which can lead to unsafe conditions due to the rapid separation of high voltage terminals.
Innovation Solution
The electrical connector assembly incorporates a staged release mechanism with a connector position assurance system that includes stop tabs and blocks, allowing the first connector to separate from the second in multiple steps, introducing a time delay between the separation of secondary and primary electrical terminals, thus ensuring the high voltage interlock loop has time to open before the high voltage circuit is disconnected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector position assurance allows rapid separation of connectors, then the ease of operation is improved, but the safety is worsened due to rapid disconnection of high voltage terminals
Solution Approach 1:
The connector separation process is divided into multiple discrete stages through the staged release mechanism. The connector position assurance includes multiple stop tabs (first stop tab, second stop tab) that create distinct separation phases, forcing the connectors to separate in controlled increments rather than all at once. This segmentation of the separation process maintains operational ease while ensuring safety by preventing rapid simultaneous disconnection of all terminals.
Solution Approach 2:
The staged release mechanism performs preliminary actions by sequentially separating different terminal groups before complete disconnection. The first stop tab separates secondary terminals (interlock loop) before the first connector is fully separated from the second connector, and the second stop tab provides an additional separation phase. This preliminary separation of circuits ensures that high voltage interlock loops open before high voltage terminals, maintaining safety while allowing operational flexibility.
2Device complexity
If the connector position assurance is simplified without staged release, then the device complexity is reduced, but the safety is worsened due to inability to control separation timing
Solution Approach 1:
The staged release mechanism employs a nested structure where multiple stop tabs are integrated within the connector position assurance body. The first stop tab, second stop tab, and various blocks are nested within the CPA housing, creating a compact multi-functional component. This nesting approach provides complex staged separation functionality without proportionally increasing external complexity, maintaining safety while managing device complexity through efficient spatial arrangement.
Solution Approach 2:
The connector position assurance serves multiple functions simultaneously: it provides positional confirmation, enables staged release through multiple stop tabs, and controls separation timing through the interaction of blocks and tabs. The CPA base and arms work together to provide both assurance functionality and staged release mechanism in a single integrated component, reducing overall device complexity while maintaining safety through multi-functional design.
Data Source
AI summary
An electrical connector assembly includes a first connector including a first electrical terminal and a second connector including a second electrical terminal. The first connector and the second connector are movable from a mated position toward an unmated position. The second connector includes a first block, a second block, and a third block. The electrical connector assembly also includes a connector position assurance that is movable between an assurance position and a pre-lock position. The connector position assurance includes a stop tab. The first block is positioned to engage the stop tab when the connector position assurance is located in the pre-lock position. The second block is positioned to engage the stop tab when the first connector is located a first distance from the second connector. The third block is positioned to engage the stop tab when the first connector is located a second distance from the second connector.