EV Battery Pack Harness Routing via Straight Air Passages
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Solution Overview
Problem
The existing battery pack structure for electric vehicles faces issues with deteriorated harness wiring workability and durability due to bent harness paths, which disrupt temperature-adjusting air flow and reduce the efficiency of temperature management.
Innovation Solution
The battery pack structure configures clearances within the battery pack case as temperature-adjustment air passages and positions the junction box and battery controller to face these passages, allowing for straight harness wiring along the air passages, thereby improving workability and durability while ensuring smooth air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the junction box and battery controller are connected via a bent harness path in the T-shaped clearance space, then the harness can be routed between components, but the harness-wiring workability deteriorates and harness durability is lowered
Solution Approach 1:
The patent transitions from a two-dimensional bent path routing (through T-shaped clearance) to a three-dimensional straight-line routing by utilizing the depth dimension of the battery pack case. The harness is routed straight from the junction box to the battery controller through the internal space, eliminating the need to follow bent clearance paths and thereby improving both workability and durability.
2Reliability
If the bent harness is wired in the clearances to connect junction box and battery controller, then the components can be connected, but the harness acts as passage resistance and smooth flow of temperature-adjusting air cannot be ensured
Solution Approach 1:
The patent extracts the harness from the temperature-adjustment air passage path by routing it through a separate straight path that does not interfere with air flow. The harness is positioned to run parallel to or alongside the air passage rather than through it, removing the passage resistance effect while maintaining connectivity between components.
3Area of stationary object
If the T-shaped clearance space is used as both junction-box mounting space and harness wiring path, then space utilization is improved, but the harness durability is lowered due to bending requirements
Solution Approach 1:
The patent segments the functional zones within the battery pack case by designating specific regions for different purposes: the T-shaped clearance space is assigned for junction box mounting and air flow, while a separate straight path is created for harness routing. This spatial segmentation allows each zone to fulfill its primary function without compromising the other.
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 configuration enhances harness wiring workability and durability while maintaining smooth temperature-adjusting air flow, ensuring efficient temperature management and adequate battery module mounting space.
Implementation Method 1
clearances, ensured when the battery module is mounted in the internal space of the battery pack case, are configured as temperature-adjustment air passages through which temperature-adjusting air flows
Data Source
AI summary
In a battery pack structure for electric vehicles that a battery module, a junction box, and a battery controller for battery management are mounted in a battery-pack-case internal space, clearances, ensured when the battery module is mounted in the case internal space, are configured as temperature-adjustment air passages through which temperature-adjusting air flows. The junction box and the battery controller are arranged at positions spaced apart from each other and facing one straight passage part of the temperature-adjustment air passages. Furthermore, a weak-electric harness, via which the junction box and the battery controller are connected to each other, is wired along the straight passage part, thus ensuring smooth flow of temperature-adjusting air, while improving both the harness-wiring workability and the harness durability.