Battery Pack Protrusion Shields Breaker from Foreign Matter

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Solution Overview

Problem

The breaker in existing electric vehicle battery packs is positioned high and is at risk of damage from foreign matter entering the space between the vehicle body and the battery pack, which can transmit shocks and cause damage.

Innovation Solution

The battery pack design features a protrusion formed higher than the dent portion where the accessory is disposed, acting as a protective wall to prevent foreign matter from entering and protecting the breaker.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the breaker is disposed in a high position on the battery pack, then it is easily accessible for maintenance operations, but it becomes vulnerable to damage from foreign matter entering the space between the vehicle body and battery pack

Engineering Contradiction:

Improveaccessibility of breakerVSAvoidforeign matter damage to breaker

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The battery pack upper surface is segmented into different height levels: a first level with the breaker and a second level with a protrusion that extends higher. This segmentation creates a protective barrier while maintaining breaker accessibility, as the breaker remains exposed for maintenance but is shielded from foreign matter by the protrusion structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protrusion acts as an intermediary protective structure between the foreign matter (gravel, stones) and the breaker. It intercepts and blocks foreign matter before it can reach the breaker, while allowing maintenance personnel to access the breaker from above without removing the protrusion.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the breaker is surrounded by boot members for protection, then it is protected from direct contact with foreign matter, but shocks from foreign matter can still be transmitted through the boot members to the breaker

Engineering Contradiction:

Improvebreaker protectionVSAvoidshock transmission to breaker

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The breaker is extracted from the protected interior space and positioned on the upper surface of the battery pack where it is accessible. The protrusion is then added as a separate protective element that blocks foreign matter before it can reach the breaker, eliminating the need for boot members that would transmit shock.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The protrusion provides beforehand protection by blocking foreign matter before it can contact the breaker. This preventive structure stops gravel and stones from entering the space near the breaker, cushioning the breaker from potential impact before the impact can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentEP2454771B1Battery pack

Publication Date: 2021.10.27 NISSAN MOTOR CO LTD

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AI summary

A battery pack (13) is disposed at a lower part of a vehicular body. The battery pack (13) includes: a protrusion (27, 31) protruding in a vehicular upward direction and disposed at an upper face of the battery pack (13), and a dent portion (29) disposed at the upper face of the battery pack (13) and formed lower than the protrusion (27, 31), wherein an accessory (25) is disposed in the dent portion (29).