Battery Disconnect Relay Layout With Integrated Arc Magnet Control
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Solution Overview
Problem
Conventional battery disconnect units (BDUs) with multiple relays suffer from poor assemblability and increased component count, leading to deteriorated workability and price competitiveness due to complex electrical connections and mounting requirements.
Innovation Solution
A battery disconnect apparatus with a lower case featuring individual mounting spaces for relays and a circuit board, utilizing a permanent magnet to control arcs and simplify electrical connections, allowing direct coupling of relays to a circuit board without additional fixing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple relays are mounted in a separate case with individual spaces, then each relay can be individually accommodated, but the number of components increases and assemblability deteriorates
Solution Approach 1:
The patent combines multiple relay mounting spaces into a single integrated case structure. The lower case includes a first mounting space for multiple relays, eliminating the need for separate cases for each relay. This merging approach reduces the total number of components while maintaining individual relay accommodation, directly improving assemblability and reducing component count.
Solution Approach 2:
The lower case serves multiple functions: it provides structural support, contains multiple relay mounting spaces, and integrates the circuit board mounting function. By making the case multi-functional, the patent eliminates the need for separate mounting structures and fixing members, thereby reducing component count and simplifying assembly.
2Reliability
If additional fixing members are used to mount relays, then relay mounting is secured, but the number of components increases and assembly complexity increases
Solution Approach 1:
The fixing members are integrated into the case structure itself rather than being separate components. The case includes built-in fixing structures that directly secure the relays, eliminating the need for additional standalone fixing members. This integration maintains mounting stability while reducing the total component count.
Solution Approach 2:
The case structure provides its own fixing capability through integrated fixing members, making the system self-sufficient. The relays are secured by the case's inherent structure without requiring external fixing components, thereby reducing component count while maintaining mounting reliability.
3Ease of operation
If cable connections are used for electrical connection, then relay operation is enabled, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The circuit board is integrated directly into the case structure, combining the electrical connection function with the structural housing. This integration eliminates the need for separate cable connections between relays and external control circuits, as the circuit board provides direct electrical pathways. The result is simplified assembly and improved productivity while maintaining full electrical connection capability.
4Reliability
If multiple separate cases are used, then each component is protected, but air flow obstruction increases and temperature management becomes difficult
Solution Approach 1:
Multiple relay mounting spaces are combined into a single case with a unified structure. This integration creates open spaces and pathways within the case that facilitate air flow between relays and to external environments. The unified case design maintains component protection while improving heat dissipation and temperature management compared to multiple separate cases.
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
Simplifies assembly, improves work productivity, ensures electrical connection stability, and reduces obstruction of air flow, thereby enhancing product reliability and minimizing temperature-related issues.
Implementation Method 1
a permanent magnet arranged in each of the plurality of upper mounting spaces to be able to control an arc generated from the relay
Data Source
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AI summary
A battery disconnect apparatus is disclosed. The battery disconnect apparatus according to an aspect of the present invention may include: a lower case, of which the top portion is open and which includes mounting spaces arranged along a first axial direction, which is a lengthwise direction; a plurality of relays, each mounted in one of the mounting spaces; an upper case, which is coupled to the lower case so as to cover the open top portions of the mounting spaces and includes a plurality of upper mounting spaces at positions corresponding to the plurality of relays on an one-to-one basis; and a permanent magnet disposed in each of the plurality of upper mounting spaces to control an arc generated from the relays.