A New Connection Solution for Hybrid Vehicle

Abstract

The trend for passenger vehicle development is to incorporate more and more communication, safety and entertainment features to meet customer’s desires. At the same time, improving vehicle performance and enhancing driver and passenger’s comfort are becoming equally important. All of these have imposed higher and higher pressure on car makers to use smaller connection systems hiding inside a vehicle. For hybrid vehicles, because of the high current and voltage requirements, the requirement of smaller-size connection systems becomes even more challenging as the systems need to meet stricter shielding and sealing needs. This research focuses on the design and the manufacturing process of a connection system for hybrid application. The innovation results in a more flexible design which allows for a streamlined wiring connection system with large-sized cable. The system can work under 300 A, 1000 V electrical conditions with sealing, shielding and pluggable functions which in turn have solved a common problem encountered in hybrid vehicle design. The connection solution combines an inlet connector and a 90° pluggable adaptor with a unique design to reach shielding function. The related technologies include low pressure over molding process, ferrule crimping and round spring contact.

F2012-H09-002