Vehicle Contactor Reducing Continuous Charge Distribution
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Solution Overview
Problem
The existing electrical distribution systems in vehicles face challenges with high costs due to large, costly wiring for high amperage requirements and increased risk of fire and accidental contact due to continuous charge distribution, necessitating multiple protective covers.
Innovation Solution
A contactor device with a housing, switch, and power terminals that can be electrically coupled and decoupled, reducing continuous charge distribution by directly attaching one terminal to the battery and coupling the other to a starter through a wire, with insulative covers and a fused accessory terminal for safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a battery and starter contactor are separated by a greater distance, then the electrical circuit can be more flexible in layout, but the continuous charge distribution within the vehicle increases
Solution Approach 1:
The patent extracts the continuous charge distribution problem by introducing a disconnect switch that isolates the battery terminal from the starter circuit when not in use. This removes the harmful continuous charge from the system, allowing greater layout flexibility without the fire hazard associated with continuous charge distribution.
Solution Approach 2:
The disconnect switch acts as an intermediary device between the battery and starter contactor. It controls the electrical connection, allowing the system to have flexible layout while preventing continuous charge distribution by opening the circuit when the engine is not being started.
2Reliability
If a protective cover is added to shield against incidental contact with continuously live terminals, then safety against accidental contact is improved, but device complexity and installation cost increase
Solution Approach 1:
The patent removes the need for multiple protective covers by extracting the continuous charge hazard through the disconnect switch. By isolating the battery terminal, the system eliminates the fire risk and reduces the number of protective covers needed to just one at the battery, simplifying the overall system.
3Reliability
If heavy-duty wiring is used to deliver high amperage from battery to starter contactor, then the required starting amperage is reliably delivered, but manufacturing cost and installation labor increase
Solution Approach 1:
The disconnect switch enables periodic action by closing the circuit only during the brief period when the starter motor needs high amperage to crank the engine. After starting, the switch opens, stopping the high amperage flow. This intermittent operation allows for less expensive wiring compared to continuous high-amperage delivery.
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 reduces manufacturing costs, installation labor, and enhances safety by minimizing continuous charge distribution, eliminating the need for heavy-duty wiring and multiple protective covers, while ensuring reliable electrical connectivity.
Implementation Method 1
The switch is capable of electrically conductively coupling the first power terminal to the second power terminal
Implementation Method 2
a first electrically insulative cover is provided, which is selectively engageable with the housing to at least partially surround one of the power terminals
Data Source
AI summary
Provided is a device mounted contactor and a method of reducing continuous charge distribution, especially in a vehicle. The contactor includes a housing, and a plurality of power terminals. The device may further include a conductance shield and support structure extending from the housing. Situated at least partially in the housing is a switch, which is capable of electrically coupling at least two of the plurality of power terminals. One or more electrically insulative covers may be provided. The contactor may also provide a fused accessory terminal, which is electrically coupled to one of the power terminals through a fuse. A method according to the present invention reduces continuous electrical charge distribution in an electrical circuit by mechanically attaching a first contactor power terminal to a battery terminal and electrically coupling a second contactor power terminal to a circuit, which may include a vehicle starter.