Crash-Release Connector Structure for EV High-Voltage Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing connection structures in electric vehicles fail to prevent heat generation in battery cells due to short circuits in high-voltage circuits when the electronic device is crushed, as fuses are difficult to implement due to size and mountability constraints.

Innovation Solution

A connection structure that includes a release member within the housing of the electronic device, which physically disconnects the female connector from the male connector using a load input during crushing, preventing short circuits by mechanically releasing the connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fuse is used to prevent short circuit, then electrical safety is improved, but device complexity and mountability worsen due to size constraints

Engineering Contradiction:

Improveelectrical safetyVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the safety function from the electronic device by providing a separate release member that physically disconnects the connector. Instead of using a fuse within the device, the release member is configured to pull the male connector away from the female connector, thereby removing the electrical connection and preventing short circuits externally.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The release member acts as an intermediary mechanism between the crushing force and the connector. When the housing is crushed, the release member translates this mechanical force into a pulling action on the male connector, mediating the protection function without requiring complex internal circuitry or fuses within the electronic device.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the electronic device is crushed, then compactness is improved, but heat generation from short circuit worsens

Engineering Contradiction:

Improvehousing volumeVSAvoidheat generation

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent implements preliminary anti-action by pre-configuring the release member to automatically activate when crushing occurs. The release member is positioned and sized so that when the housing volume decreases due to crushing, the release member is pushed and pulls the male connector away from the female connector before a short circuit can generate harmful heat.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent converts the harmful crushing force into a beneficial protective action. The crushing force that would normally cause short circuits and heat generation is instead harnessed to push the release member, which in turn pulls the connectors apart to prevent the short circuit, thereby transforming the harmful input into a safety mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If a release member is added to mechanically disconnect connectors, then safety against short circuit is improved, but device complexity worsens

Engineering Contradiction:

Improveshort circuit protectionVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the release member with the housing structure, integrating the safety function into the existing housing rather than adding a separate complex disconnection mechanism. The release member is provided in the housing and utilizes the housing's structural elements, thereby achieving short circuit protection without significantly increasing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The release member is designed to automatically activate and perform the disconnection function without external control systems. When the housing is crushed, the release member self-activates by being pushed and automatically pulls the male connector away from the female connector, providing self-service protection without requiring additional sensors, controllers, or complex actuation mechanisms.

Inventive Principle:

Principle #25Self-service

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

Prevents heat generation in battery cells by physically disconnecting the high-voltage circuit from the battery module, ensuring safety even when the electronic device is crushed.

Implementation Method 1

the release member, when a load in the direction to release the connection is input from the housing, moves in the direction for releasing the connection of the second connector and apply a load to the second connector so as to release the connection with the first connector

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS20250210916A1Connection structure

Publication Date: 2025.06.26 TOYOTA JIDOSHA KK

AI summary

A connection structure in which an electronic device and a battery are electrically connected via a connector, the connector including a first connector provided on a side of the electronic device connected to the high voltage circuit, and a second connector provided on a side of the battery module connected to the first connector. Further, the electronic device includes a release member, which relatively moves towards a direction to release the connection of the second connector with respect to the base, and the release member, when a load in the direction to release the connection is input from the housing, moves in the direction for releasing the connection of the second connector and apply a load to the second connector so as to release the connection with the first connector.