Integrated Endplate Connector for EV Battery Packs
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Solution Overview
Problem
Existing electrified vehicle battery systems face challenges in maximizing driving range and managing impact energy due to the size and packaging requirements of connection modules, which increase the overall system size and complexity.
Innovation Solution
The integration of an endplate with electrical connectors directly into the battery pack frame, featuring an inner and outer wall with a connector interface and extending connectors, reduces the need for separate connector modules and cables, allowing for a more compact and efficient battery system design while providing improved thermal integrity and simplified maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connection modules are used to connect battery modules to controllers, then electrical connectivity is achieved, but the overall system size and complexity increase
Solution Approach 1:
The patent combines the connector and the endplate into a single integrated component. The connector is formed as part of the endplate structure, eliminating the need for separate connection modules and reducing system complexity while maintaining electrical connectivity between battery modules and controllers.
Solution Approach 2:
The endplate serves multiple functions: it provides structural support for the battery module, acts as a connector for electrical connections, and serves as a mounting surface for controllers. This multi-functionality reduces the number of separate components needed in the system.
2Reliability
If separate connection modules are used to connect battery modules, then electrical connections are established, but the vertical height and horizontal footprint increase
Solution Approach 1:
By merging the connector with the endplate, the patent eliminates the additional space required for separate connection modules. The integrated design allows electrical connections to be made within the existing endplate footprint, reducing the overall horizontal space required for battery module connections.
3Reliability
If multiple separate components are used for battery connections, then connectivity is achieved, but maintenance complexity increases
Solution Approach 1:
The integrated endplate-connector design reduces the number of separate components that need to be inspected, removed, and reinstalled during maintenance. The single-piece construction simplifies troubleshooting and repair procedures while maintaining reliable electrical connectivity.
Data Source
AI summary
An integrated endplate for a battery pack includes an inner wall and an outer wall. The outer wall has a first side adjacent to the inner wall and a second side opposite the first side. The outer wall includes a connector interface protruding from the second side and defining at least one aperture therethrough. The integrated endplate further includes at least one electrical connector extending between the inner wall and the outer wall to the at least one aperture of the connector interface.