Battery Pack Crossbeam Signal Conversion for Higher Cell Density
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Solution Overview
Problem
Existing battery packs in electric vehicles lack efficient integration of structural components and signal routing, leading to redundant structures, reduced energy density, and compromised crashworthiness due to traditional routing limitations and cell swelling issues.
Innovation Solution
A battery pack design featuring two longitudinal sill members interconnected by transverse members, with integrated analog-to-digital converters within the rear transverse beam, allowing for efficient signal conversion and pass-through while maintaining structural integrity to withstand cell swelling forces, and utilizing compression members to enhance volumetric efficiency and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional routing options are used for signal lines, then signal routing is simple, but pack energy density is reduced and structural performance is compromised
Solution Approach 1:
The patent integrates the analog-to-digital converter directly into the rear transverse beam structure, merging the conversion function with the structural component. This eliminates the need for separate routing paths and reduces the space required for signal lines, thereby increasing pack energy density while maintaining structural integrity.
Solution Approach 2:
The rear transverse beam serves multiple functions: it provides structural support, houses the analog-to-digital converter, and routes signal lines. This multi-functionality reduces the need for separate components and routing paths, improving pack energy density without compromising structural performance.
2Adaptability or versatility
If more conversion units are placed inside the battery pack, then signal conversion capability is improved, but cell volume is reduced
Solution Approach 1:
The analog-to-digital converter is integrated into the rear transverse beam, combining the conversion function with an existing structural component. This eliminates the need for separate conversion units inside the battery pack, preserving cell volume while maintaining signal conversion capability.
Solution Approach 2:
The converter is placed in the rear transverse beam, utilizing the structural space in the depth direction rather than occupying horizontal space within the battery pack. This dimensional relocation preserves cell volume while providing conversion functionality.
3Strength
If the rear transverse beam is made stronger to withstand cell swelling, then beam integrity is improved, but volumetric efficiency is reduced
Solution Approach 1:
The analog-to-digital converter is integrated into the rear transverse beam, allowing the beam to serve both structural and electronic functions. This integration enables the beam to be optimized for strength without requiring additional separate components that would reduce volumetric efficiency.
Solution Approach 2:
The rear transverse beam provides structural support to withstand cell swelling while simultaneously housing the analog-to-digital converter. This multi-functionality maximizes the utility of the beam structure, maintaining beam integrity while preserving volumetric efficiency.
4Strength
If cells are packed closer to vehicle center of gravity, then polar moment of inertia is reduced and crashworthiness is improved, but signal routing becomes more difficult
Solution Approach 1:
The analog-to-digital converter is integrated into the rear transverse beam, merging signal conversion functionality with the structural framework. This integration simplifies signal routing from cells packed near the center of gravity, as the converter is accessible through the beam structure without requiring complex external routing paths.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present disclosure relates to a battery pack 4 for use in an electric vehicle having two longitudinal sill members 6,7 extending in a length direction, interconnected at a front side by front and rear transverse members 15,21, a number of rectangular battery cells 9 being placed between the sill members, the front transverse member and the rear transverse member, the cells being mutually adjacent in the length direction. The battery pack has at least a chamber 31, 31' integrated in the rear transverse beam, said chamber being configured to accommodate an analog-to-digital converter.