Battery Unit Junction Box Inclined Bracket Collision Protection
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Solution Overview
Problem
Existing battery units in vehicles, particularly in Hybrid Electrical Vehicles (HEVs) and Electric Vehicles (EVs), face challenges in protecting critical components from collision damage, as the electric junction boxes are often crushed during side collisions, compromising the integrity of the power transmission system and control components.
Innovation Solution
A battery unit design featuring a first electric junction box along the side surface of the battery and a second electric junction box held by an inclined bracket, which changes posture during a side collision, reducing the likelihood of collision load being transferred to the first electric junction box or battery, thereby protecting critical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric junction box is accommodated in a case with the battery to prevent destruction of important components, then the protection of important components is improved, but the electric junction box may still be crushed under large collision loads
Solution Approach 1:
The electric junction box is segmented from the battery by introducing a partition wall, creating separate accommodation spaces. This segmentation allows the junction box to be protected from direct collision loads that affect the battery, while maintaining the overall integrated structure for space efficiency.
Solution Approach 2:
A partition wall is introduced as an intermediary structure between the battery and the electric junction box. This partition wall serves as a mediator that isolates the important components in the junction box from the collision loads that primarily affect the battery, preventing direct transmission of harmful forces.
2Device complexity
If the bracket holding the second electric junction box is arranged horizontally, then the structure is simple, but the side collision load is more likely to be input to the first electric junction box or battery
Solution Approach 1:
The bracket holding the second electric junction box is designed with an inclined configuration rather than a horizontal arrangement. This asymmetric design creates a geometric relationship that redirects collision loads away from the first electric junction box and battery, utilizing the inclined angle to deflect impact forces.
Solution Approach 2:
The bracket is configured to hold the second electric junction box in a different spatial dimension (inclined position) rather than aligning it horizontally with the first junction box. This dimensional change in positioning creates a staggered arrangement that prevents direct load transmission paths during side collisions.
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 secures a compression stroke during a vehicle side collision, preventing damage to important components in the first electric junction box while allowing the second circuit breaker to be destroyed, ensuring continued power supply to the battery and electric devices, and reduces the number of parts required for holding the junction boxes and cooling fan.
Implementation Method 1
the posture of the second electric junction box changes from an inclined attitude to a vertical attitude due to the deformation of the bracket
Data Source
AI summary
A battery unit mounted on a vehicle, includes: a battery; a first electric junction box electrically connected to the battery; a second electric junction box electrically connected to the battery; and a case accommodating the battery, the first electric junction box, and the second electric junction box. The battery, the first electric junction box, and the second electric junction box are arranged in this order in a vehicle width direction. The first electric junction box is disposed along a side surface of one side of the battery in the vehicle width direction. The second electric junction box is held by a bracket which is inclined upward or downward, as the second electric junction box is separated from the first electric junction box in the vehicle width direction.