Battery Pack Internal Wiring Channel Design
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Solution Overview
Problem
Electrified vehicles face challenges in efficiently packaging high voltage traction battery packs and routing high voltage wiring harnesses, often requiring external routing and electromagnetic shielding, which increases weight and cost.
Innovation Solution
The proposed solution involves an enclosure assembly with an open channel within the battery pack for routing high voltage wiring harnesses internally, eliminating the need for external routing and electromagnetic shielding, and optimizing the arrangement of battery arrays and heat exchanger plates for efficient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high voltage wiring harnesses are routed externally around the battery pack, then installation and maintenance become easier, but vehicle weight increases and packaging efficiency decreases
Solution Approach 1:
The wiring harness is merged with the battery pack structure by routing it through an internal channel formed between battery arrays and heat exchanger plates. This integration eliminates the need for separate external routing, reducing vehicle weight while maintaining serviceability through accessible connection points at the battery pack exterior.
Solution Approach 2:
The wiring harness is nested within the battery pack's internal structure, specifically through the channel formed between battery arrays and heat exchanger plates. This nesting approach allows the harness to be contained within the battery pack volume, improving packaging efficiency and reducing overall vehicle weight.
2Object-affected harmful factors
If electromagnetic shielding is added around external wiring harnesses, then electromagnetic interference is reduced, but vehicle cost and weight increase
Solution Approach 1:
The metal enclosure and internal channel structure, which could be seen as constraints, are converted into beneficial electromagnetic shielding elements. The metallic battery pack structure itself provides the shielding against electromagnetic interference, eliminating the need for additional shielding materials and reducing vehicle cost.
Solution Approach 2:
The structural enclosure and electromagnetic shielding functions are merged into a single component - the metal battery pack enclosure with internal channels. This multi-functionality eliminates the need for separate shielding materials, reducing both cost and weight while maintaining electromagnetic compatibility.
3Temperature
If battery arrays are arranged with maximum spacing for thermal management, then heat dissipation improves, but packaging efficiency and power density decrease
Solution Approach 1:
Heat exchanger plates are introduced as intermediary components between battery arrays, serving dual functions: they provide thermal management by conducting heat away from batteries while simultaneously creating structured spacing that allows efficient wiring harness routing. This mediator approach enables closer battery arrangement without compromising thermal management.
Solution Approach 2:
Thermal management is applied locally at specific interfaces between battery arrays through heat exchanger plates, rather than requiring uniform spacing throughout. This localized approach allows batteries to be positioned closer together in regions without heat exchangers, improving power density while maintaining effective heat dissipation where needed.
4Volume of stationary object
If wiring harnesses are routed through internal channels within the battery pack, then packaging efficiency and weight are improved, but installation complexity and manufacturing precision requirements increase
Solution Approach 1:
The internal channel is segmented into discrete sections between battery arrays and heat exchanger plates, with connection points accessible at the battery pack exterior. This segmentation allows for modular assembly and tolerance accumulation, reducing the impact of manufacturing precision variations while maintaining effective internal routing.
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 by eliminating the need for external wiring and shielding, while maintaining effective power distribution to electric machines in all-wheel, rear-wheel, and front-wheel drive vehicles.
Implementation Method 1
a first row of battery arrays positioned in proximity to the heat exchanger plate
Data Source
AI summary
This disclosure details exemplary electrical architectural layouts for distributing high voltage power within electrified vehicles. An exemplary battery pack associated with an electrical architectural layout of an electrified vehicle 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. A high voltage wiring harness may be routed through an interior of the battery pack within the open channel. The exemplary electrical architectural layouts of this disclosure may be employed within all-wheel drive, rear-wheel drive, or front-wheel drive electrified vehicles.