Battery Pack Safety Switch with Cover-Actuated Circuit Disconnection
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Solution Overview
Problem
Existing battery packs face safety issues due to the complexity of maintaining consumable components like fuses, which can lead to electric shocks or exposure of high-voltage components, potentially causing fires or explosions if not properly disconnected or reinstalled during maintenance.
Innovation Solution
A battery pack design featuring a safety switch with a cover body that controls the connection/disconnection of the built-in circuit, ensuring the pack is only operational when sealed and preventing accidental exposure of high-voltage components by using a safety switch with elastic contacts and a reset member to manage the connection state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a maintenance window is designed for accessing consumable components, then maintenance accessibility is improved, but safety risks increase due to potential electric shock and exposure of high-voltage components
Solution Approach 1:
The safety switch is activated in advance before opening the maintenance window, automatically disconnecting the built-in circuit from the power source. This preliminary disconnection action prevents electric shock and exposure of high-voltage components during maintenance operations.
Solution Approach 2:
The safety switch acts as an intermediary mechanism between the maintenance window opening action and the built-in circuit. It mediates the connection state, ensuring that the circuit is disconnected before maintenance access is granted, thereby eliminating direct exposure to high-voltage components.
2Ease of operation
If the cover of the casing is removed for maintenance, then access to consumable components is achieved, but the sealing interface between upper and lower casings may fail
Solution Approach 1:
The maintenance window is segmented from the main casing structure, allowing selective opening of only the maintenance window rather than removing the entire cover. This segmentation enables maintenance access while preserving the sealing integrity of the main casing and its sealing interface.
Solution Approach 2:
The maintenance window is extracted as a separate, independently operable component from the main casing. This extraction allows the maintenance window to be opened for component access while the main casing remains closed and sealed, preventing damage to the sealing interface.
3Reliability
If the safety switch is automatically triggered by cover removal, then safety is improved, but the complexity of the device increases
Solution Approach 1:
The safety switch activation mechanism is merged with the maintenance window opening action. The same mechanical motion that opens the maintenance window also triggers the safety switch, combining two functions into one integrated mechanism and avoiding additional complex components.
Solution Approach 2:
The maintenance window opening action serves multiple functions: it provides access to consumable components and simultaneously activates the safety switch to disconnect the built-in circuit. This multi-functionality reduces the need for separate safety mechanisms and simplifies the overall device structure.
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
This design simplifies maintenance by ensuring the battery pack is only operational when sealed, preventing safety accidents related to seal failures and improper disconnection during maintenance, thus enhancing safety performance.
Implementation Method 1
the movable contact is elastic such that the movable contact is moved between the first position and the second position by its own elastic force
Implementation Method 2
the safety switch further includes a reset member, which is coupled to the movable contact such that movable contact is moved between the first position and the second position by a reset deformation of the reset member
Data Source
AI summary
The disclosure relates to a battery pack, comprising a casing; a built-in circuit disposed inside the casing; a consumable component disposed inside the casing and connected in series to the built-in circuit, wherein an opening corresponding to the consumable component is provided on the casing; a safety switch disposed inside the casing, wherein an on/off of the safety switch controls a connection/disconnection of the built-in circuit; and a cover body disposed corresponding to the opening, wherein the cover body has a first state in which the cover body is capped at the opening, so that the safety switch is switched on and the built-in circuit is connected, and a second state in which the cover body is detached from the opening, so that the safety switch is switched off and the built-in circuit is disconnected.