Battery Pack Junction Compartment for External Cell Layer Connections
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Solution Overview
Problem
Battery packs in electric vehicles face challenges related to space utilization, development and manufacturing costs, assembly complexity, and maintenance difficulties due to the need for internal electrical connections between battery cell layers.
Innovation Solution
A battery pack design with a battery junction compartment outside the casing that houses electrical connection arrangements, allowing for external connection of battery cell layers, facilitating simpler assembly, maintenance, and space optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connection arrangements are placed inside the casing to connect battery cell layers, then reliable electrical connection is achieved, but space utilization inside the casing is reduced and assembly/maintenance complexity increases
Solution Approach 1:
The battery pack is divided into two functional segments: the casing containing battery cells and the separate battery junction compartment containing electrical connection arrangements. This segmentation allows the connection system to be isolated from the cell housing, maximizing space utilization while maintaining connection reliability through dedicated connection space in the junction compartment.
Solution Approach 2:
The battery junction compartment acts as an intermediary structure between the battery cell layers. It provides a dedicated space with electrical connection arrangements that mediate the connection between cells, eliminating the need for connections inside the casing and optimizing both space utilization and connection reliability.
2Device complexity
If electrical connection arrangements are placed inside the casing, then compact structure is achieved, but manufacturing and assembly costs increase and maintenance becomes difficult
Solution Approach 1:
By segmenting the battery pack into a casing unit and a separate battery junction compartment unit, each can be manufactured and assembled independently. The battery junction compartment with its electrical connection arrangements can be pre-assembled and tested separately, then integrated with the battery cells, significantly simplifying manufacturing and assembly processes.
Solution Approach 2:
The electrical connection arrangements are extracted from the casing and placed in the separate battery junction compartment. This extraction simplifies the casing design and manufacturing, while the extracted connection system can be independently assembled, tested, and maintained without affecting the battery cells.
3Device complexity
If electrical connection arrangements are inside the casing, then integrated design is achieved, but accessibility for maintenance and repair is reduced
Solution Approach 1:
The electrical connection arrangements are taken out of the casing and housed in the separate battery junction compartment, which is accessible from the outside of the vehicle. This extraction maintains design integration through the unified battery pack structure while dramatically improving maintenance accessibility, as technicians can service the connection arrangements without disassembling the battery cells or casing.
4Quantity of substance
If more battery cells are arranged inside the casing to increase operational range, then energy capacity increases, but internal space for electrical connections is reduced
Solution Approach 1:
The battery pack is segmented into the casing for battery cells and a separate battery junction compartment for electrical connections. This segmentation allows maximum number of battery cells to be arranged inside the casing for increased energy capacity, while the electrical connection space is provided in the external junction compartment, eliminating the space conflict.
Solution Approach 2:
The electrical connection system is moved from the internal three-dimensional space of the casing to an external dimension via the battery junction compartment. This dimensional relocation allows unlimited expansion of battery cell quantity inside the casing without compromising connection space, as connections are established externally.
Data Source
AI summary
A battery pack is disclosed configured to provide electricity to an electric propulsion motor of a vehicle. The battery pack comprises at least two layers of battery cells arranged inside a casing, and a battery junction compartment arranged outside of the casing. The battery junction compartment comprises a number of electrical connection arrangements electrically connecting battery cells of the at least two layers of battery cells. The present disclosure further relates to a vehicle comprising an electric propulsion motor and a battery pack configured to provide electricity to the electric propulsion motor.