Battery Pack Horizontal Stacking for Compact Design
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Solution Overview
Problem
Conventional battery packs for hybrid and electric vehicles are bulky and complex, with upright battery cell arrangements leading to mechanical strength issues and complicated wiring, which hinder the achievement of a slim and compact design and increase manufacturing process complexity.
Innovation Solution
A battery pack design featuring vertically and horizontally stacked battery modules with bus bars and sensing wires, connected via a connector with insulation and power/sensing terminals, and thermally conductive barriers, allowing for a slim and compact form factor while simplifying the manufacturing process by sequential coupling of modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery cells are positioned upright in a housing, then mechanical strength is secured, but the battery pack becomes bulky and wiring becomes complicated
Solution Approach 1:
The patent transitions from traditional upright positioning to horizontal stacking of battery cells in multiple layers. This dimensional change allows the cells to be arranged in a compact horizontal configuration within the housing, reducing the overall battery pack volume while maintaining structural integrity through the layered arrangement and reinforcement members.
2Strength
If battery cells are positioned upright, then mechanical strength is secured, but wiring complexity increases
Solution Approach 1:
By arranging battery cells horizontally in stacked layers rather than upright, the patent simplifies the wiring architecture. The horizontal arrangement allows for more straightforward connection paths between cells and reduces the complexity of bus bar and sensing wire routing compared to upright configurations.
3Strength
If multiple reinforcement members are attached to the housing, then mechanical strength is improved, but the battery pack cannot achieve a slim and compact design
Solution Approach 1:
The horizontal stacking arrangement allows reinforcement members to be integrated within the layered structure of the battery cells, rather than requiring external attachments to an upright housing. This enables mechanical strengthening while maintaining a compact, slim profile.
4Ease of manufacture
If conventional manufacturing process is used with upright cells, then assembly is straightforward, but manufacturing efficiency decreases due to process complexity
Solution Approach 1:
The patent divides the battery pack into modular horizontal layers of stacked cells, each layer functioning as an independent unit. This segmentation allows for standardized manufacturing of individual layers that can be efficiently assembled into the complete battery pack, improving overall manufacturing efficiency despite the horizontal configuration.
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 design results in a more efficient manufacturing process and a slim, compact battery pack with improved mechanical strength and reduced wiring complexity, enhancing both performance and production efficiency.
Implementation Method 1
barriers, which are electrically insulating and thermally conductive, are further disposed between the plurality of battery cells stacked in a vertical or horizontal direction
Data Source
AI summary
A slim and compact battery pack is provided. The battery pack includes a battery module including a plurality of battery cells stacked in vertical and horizontal directions, and a plurality of bus bars electrically coupled to the plurality of battery cells; and a connector including an insulation body connected to the battery module, and power terminals formed in the insulation body and electrically coupled to a group of the plurality of bus bars.