Battery Protection System With Removable Coating and Segmented Control
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Solution Overview
Problem
Existing battery protection systems for motor vehicles are difficult to maintain, occupy significant space, and require complex design to ensure compatibility between the relay and on-board computer, limiting flexibility and efficiency in battery management and diagnostics.
Innovation Solution
A battery protection system with a casing containing a switch, signal input means, and a control board that allows independent configuration of battery management and diagnostic functions without relying on the on-board computer, using a removable coating for easy maintenance and a bistable relay with heat management to ensure reliability and compact assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a relay is connected to a remote on-board computer for battery control functions, then battery management capability is improved, but device complexity increases due to parallel design requirements and compatibility constraints
Solution Approach 1:
The patent divides the battery protection system into two independent parts: a standalone control board with all necessary control and diagnostic functions, and a separate relay component. This segmentation eliminates the need for parallel design between relay and on-board computer, as the control board independently handles all battery management tasks while maintaining signal-level compatibility with existing vehicle systems.
Solution Approach 2:
The patent extracts the control functions from the remote on-board computer and consolidates them into a dedicated control board integrated with the relay. This extraction allows the system to maintain battery management capability while reducing design complexity, as the control board is designed as a self-contained unit with all necessary functions.
2Device complexity
If known battery protection systems are designed with integrated components, then structural simplicity is improved, but ease of repair deteriorates due to difficulty in maintaining and replacing individual components
Solution Approach 1:
The patent segments the internal components (control board, relay, terminals) into independently accessible units within the housing. The removable coating allows these components to be accessed and replaced individually without destroying the entire system, combining structural simplicity with ease of maintenance.
Solution Approach 2:
The patent introduces dynamic accessibility through the removable coating, which can be removed and reapplied. This allows the system to transition from a permanently sealed state to an accessible state for maintenance, and back to a sealed state after repair, maintaining both structural integrity and maintenance ease.
3Reliability
If known battery protection systems use fixed sealed enclosures, then protective sealing is improved, but adaptability deteriorates due to inability to modify or reconfigure components
Solution Approach 1:
The patent replaces the fixed sealed enclosure with a dynamic sealing system using removable coating. This allows the enclosure to transition between sealed and accessible states, enabling component modification and reconfiguration while maintaining protective sealing when needed, thus achieving both reliability and adaptability.
Solution Approach 2:
The patent changes the parameter of seal permanence from fixed to variable. The removable coating allows the sealing state to be changed on demand, enabling the system to adapt between protected and accessible configurations as needed for different operational requirements.
4Volume of moving object
If control components are placed close together for compact assembly, then volume is reduced, but temperature increases due to heat generation from switching components
Solution Approach 1:
The patent applies local quality by creating a thermal gradient within the compact housing. The control board is positioned in the cooler region away from the hot portion of the relay, while the relay occupies the hot region. This spatial differentiation of thermal zones allows compact assembly while protecting temperature-sensitive components.
Solution Approach 2:
The patent introduces thermal management as an intermediary consideration in the layout design. The housing structure acts as a thermal mediator, directing heat away from the control board while maintaining compact overall dimensions, thus resolving the conflict between volume reduction and temperature control.
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
Enables flexible and efficient battery management and diagnostics, reduces space requirements, and simplifies maintenance by decoupling the control board from the on-board computer, ensuring compatibility through signal-level compatibility and using a removable coating for component replacement without system disruption.
Implementation Method 1
The removable coating, such as a hot melt adhesive, provides a seal and means that one or more components in the enclosure can be removed and/or replaced for maintenance purposes
Implementation Method 2
the housing has an opening adjacent to the switching means. This allows easy evacuation of the heat generated by the switching means
Implementation Method 3
said switching means have, in operation, a hot portion and a cold portion, said control card being arranged adjacent to said cold portion, at a distance from said hot portion. Thus the control card is not or only slightly subjected to the heat generated by the hot portion
Data Source
Figure 1
Figure 2
AI summary
An input signal connector (20) is attached to the case (12) to receive several signals from the control unit. A control board (22) is mounted in the case and connected between relay (14) and connector to control the operation of relay as a function of several signals received from connector. A removable coating is provided for covering the relay, terminals (16,18) and control board in the case.