Vehicle Battery Pack Wiring Assembly in Casing Member
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Solution Overview
Problem
Existing battery packs for vehicles inefficiently utilize internal space, limiting the number of battery modules that can be loaded and resulting in a larger volume, which hinders the development of more compact designs.
Innovation Solution
A wiring assembly is strategically arranged within a casing member that secures the battery pack's rigidity and optimizes spatial efficiency by being inserted in recessed portions or grooves, allowing for increased module density or reduced volume without additional space allocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wiring assembly is arranged outside the casing member, then the wiring assembly is easily accessible for installation and maintenance, but the battery pack volume increases and spatial efficiency decreases
Solution Approach 1:
The wiring assembly is nested inside the casing member, which itself is positioned within the battery pack casing. This nesting arrangement allows the wiring assembly to be housed within the structural framework of the battery pack without increasing external dimensions, thereby reducing overall battery pack volume while maintaining organized wiring layout.
Solution Approach 2:
The casing member is configured with a U-shaped cross-section that creates an internal cavity space. The wiring assembly is arranged within this three-dimensional cavity, utilizing the vertical and lateral dimensions of the U-shape to organize wiring in a compact manner that would not be achievable with simple planar arrangements.
2Volume of moving object
If the wiring assembly is arranged inside the casing member, then the battery pack volume is reduced and spatial efficiency is improved, but the wiring assembly becomes harder to access for installation and maintenance
Solution Approach 1:
The battery pack is segmented into distinct functional zones: the casing member containing the wiring assembly, the battery modules, and the cooling plate. This segmentation allows the wiring assembly to be isolated in its own compartment, making it possible to access wiring components through designated openings or removable sections of the casing member without disturbing other battery components.
Solution Approach 2:
The casing member serves multiple functions: it provides structural support to the battery pack, organizes and protects the wiring assembly, and creates defined spaces for both wiring and battery modules. This multi-functionality reduces the need for separate dedicated wiring trays or channels, thereby saving space while maintaining wiring accessibility through the casing's integrated design.
3Quantity of substance
If more battery modules are loaded in the battery pack, then the energy capacity increases, but the available space for wiring assembly decreases
Solution Approach 1:
The structural support function and wiring housing function are merged into a single casing member component. This integration eliminates the need for separate wiring trays, brackets, or mounting structures, thereby maximizing the use of available space within the battery pack casing and allowing for increased battery module density.
Solution Approach 2:
The U-shaped cross-section of the casing member creates three-dimensional wiring accommodation space that efficiently utilizes vertical and lateral dimensions. This spatial optimization allows wiring to be arranged in a compact volumetric configuration rather than requiring additional planar space, thereby preserving maximum space for battery modules.
Data Source
AI summary
An embodiment battery pack for a vehicle includes a plurality of battery modules disposed in a casing, a casing member provided in the casing to secure rigidity of the casing, and a wiring assembly disposed in the casing member. Another embodiment battery pack for a vehicle includes a plurality of battery modules arranged flatly, a casing surrounding a bottom and lateral sides of the battery modules, a casing member provided lengthwise in the casing along an arranged direction of the battery modules, and a wiring assembly provided in a space defined by a recessed portion recessed inward in a cross-sectional view of the casing member.