Battery Pack Controller Nesting and Wire Folding
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Solution Overview
Problem
Existing battery packs face challenges in compact design and efficient electrical connectivity between battery cells, with limited space for components like controllers and circuit boards, which affects their overall size and functionality.
Innovation Solution
A battery pack design featuring a support plate with bus bars connecting battery cells, a cover with a controller inside, and a circuit board connected to the cells via a connection wire with a folding portion that allows for space-efficient arrangement and easy replacement, along with support ribs for secure fixation and venting mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the controller and circuit board are arranged in traditional configurations, then the battery pack can function properly, but the overall size increases and space utilization decreases
Solution Approach 1:
The controller is placed inside the cover, creating a nested arrangement where one component (controller) is housed within another structure (cover). This nesting approach reduces the overall footprint of the battery pack by utilizing internal spaces that would otherwise be empty, thereby solving the contradiction between compact size and functional completeness.
Solution Approach 2:
The connection wire is configured with a folding portion that extends in multiple directions rather than a straight line, utilizing three-dimensional space efficiently. This dimensional arrangement allows the wire to connect components without increasing the planar footprint, addressing the size-reduction goal while maintaining connectivity functionality.
2Reliability
If the connection wire is made rigid for stable connection, then electrical connectivity is reliable, but the wire cannot adapt to space constraints and component positioning
Solution Approach 1:
The connection wire transitions from a rigid structure to a dynamic, flexible configuration with folding portions. This allows the wire to adapt its shape and position according to the available space and component locations, while maintaining reliable electrical connectivity. The flexibility enables the wire to accommodate various arrangements without compromising connection stability.
3Area of stationary object
If components are tightly packed to reduce size, then space utilization improves, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
The battery pack is divided into distinct functional modules: the cover containing the controller, the support plate with circuit board, and the connection wire linking them. This segmentation allows each module to be manufactured and positioned independently, reducing the precision requirements for overall assembly while achieving compact integration. The modular approach simplifies manufacturing compared to tightly integrated monolithic designs.
Data Source
AI summary
A battery pack includes a plurality of battery cells; a support plate on the plurality of battery cells and having a plurality of bus bars electrically connecting the plurality of battery cells to one another; a cover over the support plate; a controller on an inner side of the cover; and a circuit board on one side of the support plate to be connected to the plurality of battery cells, the circuit board having a connection wire extending toward the cover and being connected to the controller.