EV Battery Pack Side Pouch Layout for Connector Routing
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Solution Overview
Problem
Conventional electric vehicle battery packs face space constraints and structural weakening due to internal routing of electrical components, which limits their size and impact resistance.
Innovation Solution
The implementation of external side pouch enclosures on the battery pack frame to house electrical connectors and components, allowing for routing through gaps between the frame and cover without compromising the frame's structural integrity, using materials like plastic or metal for weight savings and electromagnetic interference shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electrical components are routed internally within the battery pack frame, then the battery pack maintains a compact design, but the frame structure is weakened and space constraints are violated
Solution Approach 1:
The patent moves electrical components from the internal three-dimensional space to the external surface of the battery pack frame, utilizing the external dimension for routing. This allows components to be positioned on the frame's outer surface without compromising internal structural integrity, while still maintaining electrical connectivity through strategically placed openings.
Solution Approach 2:
The patent extracts electrical components (connectors, terminals, wires) from the internal battery pack structure and relocates them to external side pouches mounted on the frame's outer surface. This separation allows the frame to maintain its full structural strength while electrical routing is handled externally through dedicated pouch enclosures.
2Ease of operation
If holes are made in the frame sides for component connections, then electrical routing is enabled, but the frame strength is compromised
Solution Approach 1:
The patent introduces side pouches as intermediary structures that attach to the frame's outer surface. These pouches serve as mediators between the frame and electrical components, providing a dedicated enclosure for electrical connections without requiring holes or openings in the frame itself. The pouches can be attached through minimal openings that are then sealed, preserving frame integrity.
Solution Approach 2:
The side pouches are constructed as flexible or semi-rigid enclosures that can be attached to the frame surface. These pouches provide a protective yet adaptable housing for electrical components, allowing routing and connection access without compromising the rigid frame structure underneath.
3Volume of moving object
If battery components are positioned to meet space constraints, then the battery pack fits within vehicle dimensions, but structural rigidity is reduced
Solution Approach 1:
The patent segments the battery pack into distinct functional zones: the central frame structure maintains structural rigidity, while external side pouches accommodate electrical components. This segmentation allows the main frame to be optimized for strength and compact dimensions, while electrical components are housed in separate external enclosures that do not compromise the frame's structural integrity.
Data Source
AI summary
Electric vehicle battery packs with external side enclosures for containing electrical connectors and other components therein. Each enclosure is sized to support various connectors or other components as desired, and may have a number of openings formed to provide interfaces for connecting various electric vehicle systems to the battery pack. The enclosures may be placed at various locations along one or more sides of the battery pack, and connectors may be routed over an upper surface of a battery pack frame or through a gap formed between the pack frame and cover. Enclosures may be made of any material, including plastic for lower weight applications and metal for improved electromagnetic interference shielding.