High-Voltage Housing Sealant Ejection for Collision Insulation Coverage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-voltage devices in vehicles face challenges in ensuring complete coverage of insulating sealant distribution during collisions, leading to potential short circuits and electric leaks due to incomplete sealant spread.
Innovation Solution
A high-voltage device with an ejection member that sprays insulating sealant in a mist or foam state using a gas flow, activated by a control device upon impact detection, ensuring wide and effective coverage within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating sealant is filled in a hollow portion of the housing and ejected by internal pressure increase during collision, then the sealant can be deployed to insulate damaged areas, but the sealant may not spread to all corners of the housing interior, leaving parts of the high-voltage device exposed
Solution Approach 1:
The patent changes the physical state parameters of the insulating sealant by converting it from liquid/gel form to foam form through chemical reaction (mixing isocyanate and polyol components). This phase change enables the sealant to expand and fill the entire housing interior, reaching all corners and surfaces that liquid injection cannot achieve, thereby improving both insulation reliability and distribution uniformity
Solution Approach 2:
The patent utilizes phase transition by storing the insulating sealant as liquid components (isocyanate and polyol) in the hollow portion, which upon collision-induced mixing, undergo chemical reaction to form foam. This phase transition from liquid to foam allows the sealant to expand and uniformly distribute throughout the housing, ensuring complete coverage of the high-voltage device
2Reliability
If a large amount of insulating sealant is prepared in liquid or gel form to ensure complete coverage, then all areas can be covered, but the device mass increases significantly
Solution Approach 1:
The patent changes the density parameter of the insulating sealant by converting it from liquid/gel form to foam form. The foam structure has much lower density than liquid or gel, allowing the same volume of insulation material to weigh significantly less. This enables complete coverage of the housing interior while minimizing the mass of the insulating sealant, thus reducing overall device mass
Solution Approach 2:
The patent employs asymmetric density distribution by using foam material that has low density in the expanded state. The foam structure provides sufficient insulation volume and coverage while maintaining minimal mass, creating an asymmetric relationship between volume and weight that favors lightweight design without compromising insulation coverage
3Productivity
If the housing structure is designed to generate high internal pressure during collision to eject sealant, then the sealant can be forced out, but the sealant may not achieve uniform distribution and complete coverage
Solution Approach 1:
The patent utilizes phase transition from liquid to foam during the ejection process. As the liquid sealant components mix and react, they expand into foam, which naturally distributes more uniformly throughout the available space compared to liquid injection. This phase transition occurs simultaneously with the collision-induced ejection, ensuring both rapid deployment and uniform distribution throughout the housing interior
Solution Approach 2:
The patent employs a dynamic system where the insulating sealant transitions from a static liquid/gel state during normal operation to an active foam-expanding state during collision. This dynamic response allows the sealant to adapt its physical properties based on the operational condition, achieving rapid ejection and uniform distribution only when needed during impact events
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 solution effectively prevents short circuits and electric leaks by ensuring comprehensive sealant distribution, reducing the mass of the device, and utilizing a moisture-curable resin for rapid adhesion and coverage.
Implementation Method 1
an ejection member for ejecting an insulating sealant inside the housing in a mist state or a foam state with a gas flow
Implementation Method 2
the insulating sealant is configured to include a moisture-curable resin carrier
Data Source
AI summary
A high-voltage device used in a vehicle includes a high-voltage device body, a housing that houses the high-voltage device body, an ejection member, and a control device. The ejection member is configured to eject the insulating sealant into the housing in a mist or foam form with a gas flow. The control device is configured to activate the ejection member when a predetermined impact force on the vehicle is detected.