Battery Insulation Protector for EV Service Safety
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Solution Overview
Problem
High-voltage batteries in eco-friendly vehicles, such as hybrid and electric vehicles, pose safety risks during servicing due to the difficulty in mounting a service plug in airtight casings and high production costs, which can lead to increased accident possibilities.
Innovation Solution
A battery system design featuring a plurality of battery modules between upper and lower casings, connected by busbars and an intermediate busbar with a fuse, where the electrical connection can be blocked using an insulation protector and service cover, eliminating the need for a conventional service plug.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a service plug is used to block electrical connection in high-voltage battery, then safety during servicing is improved, but production cost increases and mounting in airtight casing becomes difficult
Solution Approach 1:
The battery system is divided into modular units with battery modules that can be independently serviced. The electrical connection blocking function is segmented into the insulation protector component that can be independently installed and removed, allowing servicing without complex service plugs.
Solution Approach 2:
The insulation protector is extracted as a separate, removable component from the battery system. This allows the blocking function to be implemented without integrating a complex service plug into the airtight casing, reducing mounting difficulty and production cost while maintaining safety.
2Ease of manufacture
If service plug is omitted to reduce production cost, then manufacturing expense decreases, but possibility of safety accident increases
Solution Approach 1:
The insulation protector is designed as an inexpensive, simple component that can be easily manufactured and replaced. This provides adequate safety protection without the high cost of service plugs, accepting that the simpler component may need replacement but achieving cost-effectiveness.
Solution Approach 2:
The insulation protector acts as an intermediary component between the battery modules and servicing operations. It provides the necessary electrical isolation function at low cost, mediating between safety requirements and manufacturing constraints.
3Temperature
If airtight casing is used for water cooling, then cooling efficiency is improved, but mounting service plug becomes difficult
Solution Approach 1:
The service plug function is extracted and replaced by the insulation protector that interfaces with the battery module terminals externally. This allows the airtight casing to remain sealed for efficient water cooling while the blocking function is performed outside the casing boundary.
Solution Approach 2:
The electrical connection blocking function is copied from the service plug concept to the insulation protector implementation. The insulation protector replicates the safety function of a service plug but with a simpler structure that does not require penetration of the airtight casing.
Data Source
AI summary
Disclosed is a battery system, including: a plurality of battery modules provided in a space formed between an upper casing and a lower casing; connection busbars respectively connected to terminals of the battery modules; an intermediate busbar connected to the connection busbars such that the connection busbars are electrically connected to each other; and an insulation protector provided with opposite end portions attached to the upper casing, and with a holding portion placed below the intermediate busbar at a position between the opposite end portions.