Insulated Pry Tool for High-Voltage Battery Pack Covers
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Solution Overview
Problem
Mechanical tools used to open covers in electric or electronic systems, such as lithium ion battery systems, pose a risk of electrical contact and damage to sensitive components due to the lack of safety features, particularly in ensuring the pry bar does not inadvertently contact live terminals or deteriorate the sealing quality of the housing.
Innovation Solution
A prying tool with a pry bar and fulcrum design that includes pivotally mounted pins and slots to prevent deep insertion and apply force in a controlled manner, combined with a clamp for secure attachment to a surface, ensuring electrical isolation and preventing unintended contact or damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pry bar is used to open battery pack covers, then the opening operation can be performed, but there is a high risk of electrical contact with live terminals and damage to sensitive components
Solution Approach 1:
The patent introduces an intermediary device - a specialized pry tool with electrically insulating body and controlled engagement mechanism - that mediates between the operator and the battery pack. This intermediary prevents direct contact between metal tools and live electrical terminals, eliminating the harmful electrical contact risk while still enabling the cover opening function
Solution Approach 2:
The pry tool is segmented into distinct functional zones: an electrically insulating body portion, a controlled engagement portion with teeth, and a handle. This segmentation allows the tool to provide electrical isolation while maintaining mechanical leverage capability, resolving the contradiction between safety and operational effectiveness
2Force
If a metal tool is used to manipulate the housing, then the prying operation can be performed with sufficient force, but the likelihood of damaging sensitive components and deteriorating sealing quality increases
Solution Approach 1:
The pry tool applies force locally at specific engagement points on the battery pack housing rather than distributing force indiscriminately. The teeth on the pry tool engage with corresponding features on the housing, concentrating the prying force at controlled locations away from sensitive electronic components and sealing surfaces, thus enabling effective force application without component damage
Solution Approach 2:
The specially designed pry tool acts as an intermediary that transfers prying force from the operator to the housing in a controlled manner. The tool's structure distributes and directs the applied force to appropriate structural points on the housing, preventing force transmission to sensitive components while maintaining sufficient prying capability
3Ease of operation
If the pry bar is inserted deeply into the battery pack to leverage the cover, then greater mechanical advantage is achieved, but the risk of contacting live terminals and damaging internal components increases
Solution Approach 1:
The pry tool changes the dimension of engagement by utilizing the external surface of the battery pack housing rather than requiring deep internal insertion. The teeth engage with external housing features, providing mechanical advantage through leverage on the housing structure itself, eliminating the need to insert the tool deep into the battery pack interior where live terminals are located
Data Source
AI summary
A prying tool comprises: a pry bar comprising a load tip at a distal end and a handle at a proximate end, the pry bar having a pair of pins extending on opposing sides thereof; a body through which the pry bar extends, the body forming a pair of pivot points for the respective pins, and a slot extending away from each of the pivot points; and a clamp that is attached to the body and configured for securing the prying tool by clamping a base of the body to a surface.