Battery Array Disconnect Key for Short Circuit Prevention
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Solution Overview
Problem
Electrified vehicle battery arrays are prone to short circuits when their positive and negative terminals are contacted, leading to potential damage and rendering the array unusable, as existing solutions that address short circuits often result in the array being rendered unusable.
Innovation Solution
A disconnect key mechanism that moves between engaged and disengaged positions to either complete or open the electrical conductive path between the battery array's positive and negative terminals, preventing short circuits by keeping the path open when disengaged and allowing activation when engaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery array includes circuitry that ruptures in response to a short circuit, then the short circuit is addressed, but the battery array becomes unusable
Solution Approach 1:
The patent extracts the protective function from permanent circuitry rupture and relocates it to a removable disconnect key. The disconnect key can be taken out (removed) to restore functionality, whereas traditional solutions permanently damage the circuitry. This allows the protective function to be separated from the permanent structure, enabling both protection and continued usability.
Solution Approach 2:
The disconnect key acts as a disposable protective element that can be discarded (removed) when no longer needed. Instead of permanently damaging the battery array circuitry to protect against short circuits, the protective function is achieved through a removable key that can be discarded after serving its protective purpose, allowing the battery array to be recovered and reused.
2Ease of operation
If the disconnect key is used to complete the electrical conductive path, then the battery array can be activated, but short circuit risk increases during assembly and shipping
Solution Approach 1:
The disconnect key is pre-installed in the battery array during manufacturing, establishing the electrical conductive path in advance. However, the key can be removed before shipping and assembly operations, creating a preliminary protective state. This preliminary action (pre-installation) enables easy activation later while allowing the protective removal state to prevent short circuits during handling.
Solution Approach 2:
The disconnect key serves as an intermediary element between the battery terminals. It can be inserted to complete the circuit for activation or removed to prevent short circuits during assembly and shipping. This intermediary component mediates between the need for electrical connectivity and the need for short circuit prevention, allowing transition between states as needed.
Data Source
AI summary
An exemplary array activating assembly includes, among other things a disconnect key moveable back and forth between an engaged and a disengaged position relative to a battery array. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The electrical conductive path is open when the disconnect key is in the disengaged position. An exemplary array activating method includes moving a disconnect key relative to a battery array from a disengaged to an engaged position. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The disconnect key does not complete the electrical conductive path when in the disengaged position.