Battery Mounting Structure Insulating Sheet Rear Collision Protection
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Solution Overview
Problem
Existing battery mounting structures in vehicles fail to adequately prevent short-circuiting of electric power terminals during rear collisions, as the metal flange of the rear pillar can contact and short-circuit the battery terminals, and existing insulation methods are insufficient to prevent this.
Innovation Solution
A battery mounting structure that includes an insulating sheet attached to the battery cover, positioned between the electric power terminal and the metal flange of the rear pillar, which deflects and deforms to prevent direct contact and rupture, ensuring reliable protection against short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal cover made of insulating material is used to cover the electric power terminal, then short-circuiting is prevented under normal conditions, but the terminal cover may be detached due to impact during rear collision, causing short-circuiting
Solution Approach 1:
The patent introduces a rubber sheet as an intermediary element positioned between the metal flange and the electric power terminal. This rubber sheet acts as a mediator that absorbs impact energy and prevents direct contact between the metal flange and terminal, even when the terminal cover is detached during rear collision
Solution Approach 2:
The rubber sheet is pre-installed between the metal flange and the electric power terminal to provide cushioning protection before any collision occurs. This beforehand cushioning ensures that when impact occurs, the rubber sheet is already in position to absorb the energy and prevent short-circuiting
2Reliability
If the insulating sheet is made rigid to effectively block contact between the flange and terminal, then short-circuiting is prevented, but the insulating sheet may rupture under impact force
Solution Approach 1:
The patent changes the material parameter of the insulating sheet from rigid to flexible by specifying it as made of rubber. This parameter change allows the sheet to deform and absorb impact energy without rupturing, while still maintaining its insulating properties to prevent short-circuiting
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively prevents short-circuiting of the electric power terminal during rear collisions by using an insulating sheet that deflects and deforms to absorb the impact, reducing the risk of electrical contact and terminal damage.
Implementation Method 1
the insulating sheet may be able to deflect in a direction toward a side of the first electric power terminal following movement of the flange when the insulating sheet is pushed by the flange
Implementation Method 2
the insulating sheet can deform following the flange, and rupturing of the insulating sheet can be effectively prevented
Data Source
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AI summary
A battery mounting structure has a battery (22) that is placed in a luggage space and that has a positive electric power terminal (32) which protrudes upward near a rear end of the battery (22), a battery cover (24) that covers at least a part of the battery (22), a rear pillar that is placed at a boundary between a side surface and a back surface of the vehicle and that has a flange (14) which protrudes to a front side, and an insulating sheet (28) that is attached to the battery cover (24) so as to be positioned between the positive electric power terminal (32) and the flange (14).