Rotating Metal Cover for EV High-Voltage Cable Collision Protection

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Solution Overview

Problem

In electric vehicles with high-voltage cables disposed in the interior, there is a risk of exposure during collisions due to impact forces, which can lead to cable breakage and potential hazards.

Innovation Solution

A structure comprising a console box with a metal cover that rotates relative to a console bracket, covering the high-voltage cable and its connections, and is secured with a bolt to prevent accidental removal, thereby protecting the cable from external forces and breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the high-voltage cable is disposed in the vehicle interior, then the cable is accessible for connection, but the cable may be exposed to the vehicle interior during collision due to impact forces

Engineering Contradiction:

Improvecable accessibilityVSAvoidcable protection during collision

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The metal cover is rotatably attached to the console bracket, allowing it to rotate when subjected to impact forces during collision. This dynamic attachment enables the cover to move with the cable rather than rigidly constraining it, preventing cable breakage while maintaining coverage protection

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The protective structure is divided into separate components: the console box, console bracket, and metal cover. This segmentation allows the metal cover to independently rotate and absorb impact forces while the console bracket remains fixed to the floor tunnel, providing both accessibility and protection

Inventive Principle:

Principle #1Segmentation

2Strength

If the metal cover is rigidly fixed to the console bracket, then the high-voltage cable is well protected, but the metal cover may break under large impact forces during collision

Engineering Contradiction:

Improvecable protectionVSAvoidimpact force during collision

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The rotatable attachment allows the metal cover to dynamically respond to impact forces by rotating rather than breaking. This converts the rigid protective structure into a flexible one that can absorb collision energy while maintaining cable coverage

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rotatable attachment mechanism pre-prepares the metal cover to absorb impact forces through rotation. Before collision occurs, the cover is already positioned to rotate and cushion the impact, preventing breakage rather than relying on post-collision repair

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of operation

If the metal cover is easily removable, then the occupant can access the high-voltage cable, but the cable connection portion may be accidentally touched

Engineering Contradiction:

Improvecable accessibilityVSAvoidaccidental contact hazard

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The metal cover acts as an intermediary barrier between the occupant and the high-voltage cable connection portion. It provides controlled access through tool-secured fastening rather than direct exposure, mediating between safety and accessibility needs

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250206242A1Electric vehicle

Publication Date: 2025.06.26 TOYOTA JIDOSHA KK

AI summary

An electric vehicle comprising: a high-voltage cable routed in a vehicle interior, a console box for accommodating the high-voltage cable; a console bracket for connecting the console box and an upper surface of a floor tunnel; and a metal cover disposed inside the console box and covering an upper portion of the high-voltage cable, wherein the metal cover is rotatably attached to the console bracket.