Battery Case Dent Portion for High-Voltage Cable Routing
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Solution Overview
Problem
Existing techniques for mounting batteries on electric vehicles face challenges in connecting high-voltage cables due to spatial constraints and the difficulty of bending thick cables, which can lead to damage or inadequate installation.
Innovation Solution
A structure featuring a battery case with a dent portion on its side surface, containing a concave side wall with a cable hole that allows high-voltage cables to be installed, maintaining a distance from the side member based on the cable diameter, enabling efficient routing and preventing damage during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick high-voltage cables are used to carry 300V, then the cable outer diameter increases, but the cable becomes difficult to bend and may be damaged
Solution Approach 1:
The patent pre-forms a dent portion with a cable hole on the battery case before cable installation. This preliminary structural preparation guides the thick cable through a predetermined path with appropriate bending radius, eliminating the need to bend thick cables sharply during installation and preventing cable damage while ensuring proper routing.
Solution Approach 2:
The dent portion acts as an intermediary structure between the battery case and the thick cable. It provides a transition zone with a cable hole that has a specific bending radius, allowing the rigid thick cable to be installed without direct sharp bending, thus protecting the cable while maintaining structural integrity.
2Volume of moving object
If the cable hole is positioned close to the battery case, then space utilization improves, but the thick cable cannot be properly routed without damage
Solution Approach 1:
The patent creates a localized dent portion with a specific geometric structure on the battery case surface. This local modification provides an optimized cable routing path with appropriate bending radius exactly where the cable passes through, while the rest of the battery case maintains its original compact structure for space efficiency.
Solution Approach 2:
The dent portion with cable hole is pre-formed on the battery case with a bending radius designed based on the cable outer diameter. This preliminary structural preparation ensures that when thick cables are installed, they follow a safe bending path that prevents damage, eliminating the need for excessive spacing between the battery case and body members.
Data Source
AI summary
A structure for mounting a battery onto an electric vehicle comprises: a high-voltage cable, which is disposed between at least one of first body members of the vehicle and a battery case containing a battery, connecting the battery and an external device disposed outside of the battery case; and a dent portion being formed on a side surface of the battery case faces to the first body member. The dent portion includes a concave side wall, which faces the first body member, having a cable hole portion through which the high-voltage cable is installed. The concave side wall is kept at a distance from the first body member defined based on a diameter of the high-voltage cable.