Pivotable Isolating Flap for EV Battery High Voltage Safety
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Solution Overview
Problem
Existing battery systems for electric vehicles lack effective and simple methods for protecting users from high voltage components while allowing accessible maintenance, with current touch protection elements being complex, error-prone, and prone to accidental removal or loss.
Innovation Solution
A battery system incorporating a pivotably mounted isolating flap that blocks access to high voltage components by default but pivots into an access position when sufficient force is applied, allowing tool-based access while preventing accidental contact, and automatically returning to the blocking position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a removable touch protection element is used to allow maintenance access, then ease of operation is improved, but reliability deteriorates due to accidental removal or loss
Solution Approach 1:
A tool receptacle with a precisely fitting tool serves as an intermediary mechanism. The tool must be intentionally inserted into the receptacle to release the isolating flap, providing a controlled intermediate step between the protected state and the accessible state. This prevents accidental removal while enabling deliberate maintenance access.
Solution Approach 2:
The isolating flap system is self-latching and automatically returns to its protective blocking position after use. The tool receptacle is self-contained, and the flap automatically seals the opening when the tool is removed, eliminating the need for manual reattachment and ensuring continuous protection without user intervention.
2Reliability
If a fixed touch protection element is used, then reliability is improved, but ease of operation deteriorates due to complex removal procedures
Solution Approach 1:
The isolating flap transitions from a static fixed element to a dynamic component that can pivot between a blocking position (providing protection) and an access position (allowing maintenance). This dynamic behavior enables the system to adapt between its protective function and its accessibility function as needed.
Solution Approach 2:
The touch protection system is segmented into modular components: the isolating flap, the tool receptacle, and the hinge mechanism. This segmentation allows the flap to be independently actuated by the tool while remaining connected to the housing, enabling controlled access without compromising the overall structural integrity or protection.
3Device complexity
If a simple cover is used for protection, then device complexity is reduced, but manufacturing precision deteriorates due to IP rating requirements
Solution Approach 1:
The isolating flap is implemented as a flexible, resilient element that can deform to create effective seals. This flexibility allows the flap to conform to the sealing surfaces and maintain IP65 protection even with simpler construction, avoiding the need for complex rigid sealing mechanisms while still achieving the required manufacturing precision.
Data Source
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AI summary
The present disclosure refers to a battery system for an electric vehicle, the battery system comprising at least one high voltage component and a touch protection element for protecting a user from accidentally contacting the high voltage component, wherein the touch protection element comprises a pivotably mounted isolating flap (12), the isolating flap (12) being pivotable between a blocking position where it blocks access to the at least one high voltage component and an access position where it allows access to the at least one high voltage component, wherein the isolating flap (12) is adapted such that if a sufficient force is applied to the isolating flap (12) in the blocking position, the isolating flap (12) pivots into the access position towards the high voltage component.