High-Voltage Battery Voltage Sensing Connector With Heat-Expanding Isolation
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Solution Overview
Problem
Conventional safety connectors for high-voltage batteries require a large installation height and anti-vibration structures, making it difficult to install additional features due to the embedded fuse and anti-vibration components, which can lead to safety issues during vehicle repairs.
Innovation Solution
A connector system with a foam pad that expands in response to heat, blocking heat transfer and disconnecting the transmission wire from the voltage sensing portion to prevent electrical shocks, featuring a cover with a hinge and clip portions for easy maintenance and protection against foreign matter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse is embedded in the safety connector, then safety protection is provided, but the installation height increases and peripheral space is narrowed
Solution Approach 1:
The patent extracts the fuse from the connector housing and places it in a separate location, allowing the connector to be lower-profile while maintaining fuse protection functionality. The fuse remains accessible for replacement but no longer increases the connector's installation height.
Solution Approach 2:
The patent repositions the fuse from a vertical arrangement (increasing height) to a horizontal or lateral arrangement within the connector assembly, utilizing space in other dimensions to maintain safety functionality without increasing the critical installation height dimension.
2Stability of the object's composition
If an anti-vibration structure is provided to absorb vibrations, then vibration protection is improved, but the peripheral space is narrowed making it difficult to install additional structures
Solution Approach 1:
The patent applies vibration damping features selectively at specific locations within the connector where vibrations are most problematic, rather than providing comprehensive vibration protection throughout the entire structure. This localized approach reduces the overall peripheral space required while maintaining essential vibration protection.
Solution Approach 2:
The patent uses composite construction combining rigid structural components with integrated vibration-damping materials, achieving vibration protection through material properties rather than requiring separate anti-vibration structures that would consume additional peripheral space.
3Area of stationary object
If the connector structure is compact to reduce installation space, then space utilization is improved, but heat dissipation capability is reduced
Solution Approach 1:
The patent introduces heat dissipation fins or thermal pathways as intermediary structures between the internal components and the external environment, enabling efficient heat transfer from the compact internal components to the surrounding air without requiring a larger overall connector structure.
Solution Approach 2:
The patent incorporates thin heat-dissipating surfaces or thermal interface materials that provide large surface area for heat transfer within a compact volume, allowing the connector to maintain a small installation footprint while effectively managing heat dissipation.
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
The foam pad effectively disconnects the transmission wire and connector when heat is generated, preventing heat transfer to the voltage sensing portion or battery, enhancing safety and reducing the risk of electrical shocks during vehicle repairs.
Implementation Method 1
a foam pad disposed inside the cover, formed of a material, a volume of which increases when heat is transferred thereto, and configured to expand, when the heat is transferred thereto
Implementation Method 2
configured to expand, when the heat is transferred thereto, to prevent the heat from being transferred to the voltage sensing portion or the battery
Data Source
AI summary
An apparatus for detecting a voltage of a high-voltage battery, may include a voltage sensing portion configured to detect a voltage of the high-voltage battery; a transmission wire connected to the voltage sensing portion to transmit the voltage of the battery, detected by the voltage sensing portion, to the outside of the apparatus; a cover of covering a position in which the voltage sensing portion is connected to the transmission wire; and a foam pad, which is disposed inside the cover, is formed of a material, a volume of which increases when heat is transferred thereto, and when heat is generated, expands to prevent the heat from being transferred to the voltage sensing portion or the battery or to release a connection between the transmission wire and the voltage sensing portion.