EV Traction Battery Pack Layout With Open Routing Channel
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Solution Overview
Problem
Conventional electrified vehicle traction battery packs often have inefficient internal layouts, leading to increased weight and cost due to suboptimal arrangement of battery components, which can hinder performance and driving range.
Innovation Solution
The battery pack design includes an enclosure assembly with strategically arranged battery arrays, a battery internal structure, and routing of coolant and wiring lines within an open channel to maximize internal component volume without increasing the overall footprint, utilizing a rigid cross-member for structural support and thermal management with heat exchanger plates and thermal interface materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery components are arranged in a conventional layout, then the battery pack can be assembled, but the internal component volume is not maximized leading to increased weight and cost
Solution Approach 1:
The patent applies dimensional optimization by arranging battery arrays, coolant lines, and wiring in a three-dimensional configuration that充分利用 the vertical and lateral space within the enclosure. The battery arrays are positioned at different heights and depths, with coolant lines routed through channels between arrays, maximizing volumetric efficiency without increasing the external footprint of the battery pack.
Solution Approach 2:
The patent implements nesting by routing coolant lines and wiring harnesses through channels formed between battery arrays, effectively placing conduits within the interstices of the battery configuration. This nested arrangement allows multiple components to occupy overlapping spatial envelopes, increasing internal component volume utilization while maintaining a compact overall structure.
2Volume of moving object
If battery components are arranged in a conventional layout, then the battery pack can be assembled, but the internal component volume is not maximized leading to increased cost
Solution Approach 1:
The patent applies dimensional optimization by arranging battery arrays, coolant lines, and wiring in a three-dimensional configuration that充分利用 the vertical and lateral space within the enclosure. The battery arrays are positioned at different heights and depths, with coolant lines routed through channels between arrays, maximizing volumetric efficiency without increasing the external footprint of the battery pack.
Solution Approach 2:
The patent implements multi-functionality by designing the battery array arrangement to simultaneously serve multiple purposes: structural support, thermal management pathways, and electrical routing channels. The same spatial configuration that maximizes energy density also provides inherent pathways for coolant flow and wiring, eliminating the need for separate structural frameworks and reducing manufacturing complexity.
3Quantity of substance
If more battery arrays are added to increase capacity, then the energy storage increases, but the internal layout becomes less efficient and footprint increases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional configuration, stacking battery arrays vertically and positioning them at different depths within the enclosure. This allows additional battery capacity to be added by utilizing the vertical dimension and available depth, rather than expanding the horizontal footprint. Coolant lines and wiring are similarly routed through the third dimension, maintaining compactness.
Solution Approach 2:
The patent implements nesting by routing coolant lines and wiring harnesses through channels formed between battery arrays, effectively placing conduits within the interstices of the battery configuration. This nested arrangement allows multiple components to occupy overlapping spatial envelopes, increasing internal component volume utilization while maintaining a compact overall structure.
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
This design enhances packaging efficiency, reduces weight and cost, and improves the performance and driving range of electrified vehicles by optimizing the internal layout of battery components.
Implementation Method 1
a heat exchanger plate positioned against a floor of the tray... The first row of battery arrays is positioned in proximity to the heat exchanger plate
Implementation Method 2
a coolant line routed within the open channel... connected to the first and second ports of the heat exchanger plates
Implementation Method 3
a thermal interface material (TIM) is disposed between the first and third battery arrays and the first heat exchanger plate
Data Source
AI summary
This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include an enclosure assembly that houses one or more battery arrays. The battery arrays may be efficiently arranged relative to one another inside the enclosure assembly to establish an open channel within the enclosure assembly. Coolant lines and/or wiring lines may be positioned within and/or routed through the open channel in order to maximize battery internal component volume without increasing the overall footprint of the enclosure assembly.