Battery Case Chamfers Protect Cables From Structural Forces
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Solution Overview
Problem
In motor-driven vehicles, structural members can exert constrained forces on cables and connectors during collisions, compromising their durability.
Innovation Solution
A battery case with a tray having chamfers at the intersections of its sides, allowing cables to pass through chamfered holes, creating triangular spaces that prevent structural members from exerting forces on the cables, enhancing durability and facilitating sealing and cable layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables and connectors are provided on the battery case, then electrical connection between battery and devices is enabled, but durability is reduced when structural members exert constrained forces during collision
Solution Approach 1:
The chamfer is formed on the battery case in advance at the position where cables pass through. This preliminary geometric feature creates a triangular space between the cable and the battery case wall, which prevents structural members from directly contacting and constraining the cables during collision, thereby protecting cable durability before the harmful event occurs
Solution Approach 2:
The chamfer structure acts as an intermediary element between the cable and the external environment. It creates a protective triangular space that mediates the interaction between structural members and cables, preventing direct force transmission to the cables while maintaining the electrical connection function
2Reliability
If cables are routed through the battery case, then electrical connection is achieved, but sealing becomes difficult at cable entry points
Solution Approach 1:
The chamfer is formed on the battery case in advance at the cable passage position. This preliminary structure provides a suitable mounting surface for sealing members, making it easier to install and ensure effective sealing at cable entry points without compromising sealing performance
3Ease of operation
If a rectangular battery case is used, then manufacturing is simple, but cable routing flexibility is limited
Solution Approach 1:
The battery case maintains a simple rectangular overall structure for easy manufacturing, but locally incorporates chamfers at specific corners where cables need to pass. This local modification provides cable routing flexibility and creates protective triangular spaces without significantly increasing overall structural complexity
Solution Approach 2:
The chamfer is formed in advance on the battery case at cable passage positions. This preliminary geometric feature simultaneously achieves two goals: improving cable layout flexibility by creating smooth transition zones and maintaining structural simplicity by using basic machining operations
Data Source
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AI summary
There is provided a battery case which is advantageous in enhancing durability of cables or connectors which are arranged inside and outside the battery case. When a motor-driven vehicle 10 comes into collision, in case where structural members such as an engine 14 or a fuel tank 16 existing adjacent to a battery case 40 are displaced so as to approach a tray 50, shorter outer peripheral edges 5602 are butted against these structural members, and shorter side walls 5802 are also butted against the structural members. Therefore, triangular spaces S are secured between the structural members and the tray 50. As the results, it is possible to prevent the structural members from exerting constrained forces on the cables or the connectors, and durability of the cables and connectors can be advantageously enhanced.