Mid-tray Enclosure for EV Battery Packaging Density
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Solution Overview
Problem
The limited space within electrified vehicles for battery pack packaging poses a challenge in achieving high packaging density and ease of assembly, as conventional battery pack enclosures struggle to efficiently house multiple internal components such as the battery electric control module, bussed electrical center, wiring, and I/O connectors.
Innovation Solution
The use of a mid-tray within the battery pack enclosure assembly, made of expanded polymer-based materials, secures internal components like the bussed electrical center, battery electric control module, wiring harness, and I/O connectors, allowing for a nested assembly that increases packaging efficiency and simplifies the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional battery pack enclosures are used, then assembly is simpler, but packaging density is insufficient
Solution Approach 1:
The enclosure assembly is divided into multiple functional components: a tray for battery cells, a mid-tray for electrical components, and a cover. This segmentation allows each component to be optimized for its specific function while collectively achieving high packaging density.
Solution Approach 2:
The mid-tray is nested within the tray structure, and electrical components are nested within the mid-tray. This nested arrangement maximizes space utilization by placing components within existing structural voids rather than adding external attachments.
2Adaptability or versatility
If multiple internal components are housed inside the enclosure, then functionality is improved, but assembly complexity increases
Solution Approach 1:
Multiple electrical components (BECM, BEC, wiring harness, I/O connectors) are merged into a single integrated electrical subassembly housed within the mid-tray. This consolidation reduces the number of separate assembly operations required while maintaining full functionality.
Solution Approach 2:
The mid-tray serves as an intermediary structure that organizes and secures multiple electrical components. By providing dedicated pockets and channels within the mid-tray, it simplifies the arrangement and assembly of complex electrical subcomponents.
3Volume of moving object
If limited vehicle space is utilized for battery pack, then vehicle size is reduced, but packaging efficiency must be maximized
Solution Approach 1:
The enclosure assembly utilizes vertical stacking with the mid-tray positioned between the battery cell tray and the cover. This three-dimensional arrangement maximizes volume utilization within the constrained vehicle space by efficiently distributing components across multiple levels.
Solution Approach 2:
The mid-tray is constructed from expanded polymer material that provides structural containment while minimizing material volume. This allows the enclosure to achieve high packaging efficiency without excessive structural mass.
4Reliability
If expanded polymer material is used for mid-tray, then energy absorption and electrical insulation are improved, but structural rigidity may be reduced
Solution Approach 1:
The enclosure assembly combines expanded polymer material for the mid-tray (providing energy absorption and electrical insulation) with solid polymer or metal for the tray and cover (providing structural rigidity). This composite approach allows each material to contribute its superior properties to the overall structure.
Data Source
AI summary
A battery pack includes a battery array and an enclosure assembly housing the battery array. The enclosure assembly includes a tray, a cover, and a mid-tray. A plurality of internal components are secured within the mid-tray to establish an electrical subassembly within the enclosure assembly.