Battery Pack Connector Shutter Mechanism for Safe Power Supply
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Solution Overview
Problem
Existing battery packs for electric vehicles with high output voltage pose a risk of electric shock and short circuit due to the need for manual operation of covers, which can be hazardous, especially when wet, and require complex mechanisms for opening and closing the connector terminals.
Innovation Solution
A battery pack design featuring a shutter mechanism operated by a shutter-opening rod within the electrical apparatus' loading cavity, which automatically opens and closes the connector terminal windows, preventing foreign material ingress and ensuring safe connection without direct hand intervention, maintaining a simple and reliable structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover is provided to close the connector opening when not in use, then safety against electric shock and short circuit is improved, but the complexity of the opening and closing mechanism increases
Solution Approach 1:
The connector opening is divided into multiple terminal windows (first terminal window, second terminal window, third terminal window) that can be opened and closed independently or in groups. The shutter mechanism is segmented into multiple shutters (first shutter, second shutter, third shutter) corresponding to different terminal windows, allowing selective coverage of high-voltage terminals while maintaining access to low-voltage terminals.
Solution Approach 2:
The shutter mechanism transforms from a static cover to a dynamic system that can change its state based on operational requirements. The shutters can be moved between open and closed positions by the shutter-opening rod, allowing the connector to adapt between safety mode (closed) and operational mode (open) without requiring manual intervention.
2Reliability
If the entire connector opening is covered by a single cover, then comprehensive protection is improved, but the mechanism to open and close the cover becomes more complex
Solution Approach 1:
The single cover concept is replaced by multiple shutters (first shutter for first terminal window, second shutter for second terminal window, third shutter for third terminal window) that can be independently controlled. This segmentation allows each shutter to be opened or closed based on the specific connection requirements for different terminals, reducing the complexity of controlling a single large cover.
Solution Approach 2:
Different terminal windows receive different levels of protection based on their voltage requirements. High-voltage terminals (first and second terminal windows) are equipped with shutters for automatic protection, while the third terminal window may have different protection requirements. This local differentiation allows comprehensive protection where needed without unnecessarily complicating the mechanism for all terminals.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The battery pack has a connector 3 attached to a case 2 housing a plurality of batteries 11 that can be charged. The connector 3 has a plurality of terminal windows 33, 33' opened in a row in a connecting plane 3X on the insertion-side of the battery pack and exposed from the case 2. A shutter mechanism 4 is provided that is opened by a shutter-opening rod 56, and the shutter mechanism 4 opens and closes one part of the plurality of terminal windows 33, 33' in the connector 3. When the battery pack is not loaded in the loading cavity 51 and the shutter-opening rod 56 is not inserted, the shutter mechanism 4 closes-off connector terminal windows 33'. When the battery pack is loaded in the loading cavity 51 and the shutter-opening rod 56 is inserted, the shutter mechanism 4 opens the connector terminal windows 33'.