Modular EV Battery Pack Wiring With Daisy-Chain Connections

Solution Overview

Problem

Existing scalable battery pack designs for electric vehicles face challenges such as increased complexity and cost due to numerous electrical and fluid connections, which complicate routing and assembly, and result in inefficient use of space and reduced energy density.

Innovation Solution

A modular and scalable battery pack system is proposed, where multiple battery packs are arranged in different configurations to optimize power and range, with a centralized or distributed thermal management system, and electrical connections made in a daisy chain arrangement to reduce the number of connectors and cables needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If common components are designed with many connectors to support maximum battery packs, then system scalability is improved, but packaging volume, weight, and production costs increase

Engineering Contradiction:

Improvesystem scalabilityVSAvoidpackaging volume

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The electrical connection system is segmented into modular units where each battery pack has its own junction box with a limited number of connectors. This allows the system to scale by adding more identical modular units rather than requiring a single large junction box with many connectors, thereby reducing the packaging volume of individual components while maintaining system scalability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from a centralized junction box architecture to a distributed architecture where connection points are distributed across multiple battery packs. This dimensional change in system architecture allows scalability without proportionally increasing the volume of any single component, as the connection capacity scales across multiple units rather than within a single unit.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If flexible cables are used for high voltage wiring, then ease of installation is improved, but assembly time increases and installation errors increase

Engineering Contradiction:

Improveease of installationVSAvoidassembly time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The electrical connection system is segmented into modular units where each battery pack has its own junction box with a limited number of connectors. This allows the system to scale by adding more identical modular units rather than requiring a single large junction box with many connectors, thereby reducing the packaging volume of individual components while maintaining system scalability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from a centralized junction box architecture to a distributed architecture where connection points are distributed across multiple battery packs. This dimensional change in system architecture allows scalability without proportionally increasing the volume of any single component, as the connection capacity scales across multiple units rather than within a single unit.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Quantity of substance

If battery packs are arranged to optimize energy density, then range is improved, but packaging space utilization becomes constrained

Engineering Contradiction:

Improveenergy densityVSAvoidpackaging space

Core Design Contradiction:

Quantity of substanceVSVolume of moving object

Solution Approach 1:

The battery system is divided into multiple independent battery packs that can be individually sized and configured. This segmentation allows the vehicle manufacturer to select and arrange a specific number of packs to optimize both energy density and packaging space utilization according to different vehicle platform requirements, rather than being constrained by a single large battery assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent enables dynamic configuration of the battery system by allowing selection of different numbers and arrangements of battery packs based on specific application requirements. This dynamic adaptability allows optimization of energy density for range-oriented applications while also enabling compact arrangements for vehicles with limited packaging space.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20250202021A1Systems and methods for connection of modular and scalable battery packs

Publication Date: 2025.06.19 PACCAR INC

AI summary

A battery system for a vehicle includes a number of battery packs that are arrangeable in the vehicle in a number of different configurations to optimize vehicle power and range. The system includes a junction box and cables that electrically couple the battery packs to the junction box. The cables extend between successive ones of the battery packs in a daisy chain arrangement. Thus, a common junction box with a maximum number of electrical connections can be utilized in the system with a selected number of batteries to provide a scalable and modular battery system.