Modular Battery Pack Layout for Compact High-Voltage Thermal Management
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Solution Overview
Problem
Heavy-duty electric vehicles face challenges in efficiently packaging and safely integrating high-voltage battery systems due to size, weight, and regulatory constraints, requiring compact and safe battery pack assemblies that can manage high voltage and thermal management effectively.
Innovation Solution
A battery pack assembly design featuring a modular structure with vertically and horizontally oriented internal dividing panels, a junction box system, and a laminated busbar assembly, along with a thermal system for coolant distribution, to manage high voltage and thermal energy efficiently, while allowing for flexible module orientation and easy integration with the vehicle frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery modules are arranged in a compact stacked configuration, then space utilization is improved, but thermal management complexity increases
Solution Approach 1:
The battery pack is divided into multiple modules (first through eighth battery modules) that are stacked vertically and arranged in columns. This segmentation allows for modular thermal management where each module can be independently cooled, reducing the overall complexity compared to managing a single large battery mass.
Solution Approach 2:
The battery modules are nested in a compact stacked configuration within the battery enclosure, with multiple modules positioned one above another and arranged in columns. This nesting approach maximizes space utilization while maintaining a manageable thermal structure through the modular arrangement.
2Ease of operation
If high voltage connectors are integrated into the junction box, then electrical connectivity is improved, but safety risks increase
Solution Approach 1:
The junction box serves as an intermediary component that houses and protects the high voltage connectors (first through fourth high voltage connectors). This intermediary structure provides a safe, enclosed environment for electrical connections, isolating the high voltage components from direct exposure and reducing safety risks while maintaining connectivity.
Solution Approach 2:
The junction box performs multiple functions: it provides electrical connectivity through the high voltage connectors, offers structural support within the battery pack, and serves as a protective enclosure for the electrical components. This multi-functionality integrates connectivity and safety in a single component.
3Volume of moving object
If battery modules are positioned in vertical columns, then space efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The battery system is segmented into standardized modules that can be manufactured independently and then assembled into vertical columns. This segmentation allows for simplified manufacturing of individual modules while achieving space-efficient vertical stacking during assembly.
Solution Approach 2:
The battery modules are arranged in a vertical dimension, stacking multiple modules one above another to form columns. This vertical arrangement maximizes space efficiency by utilizing the height of the battery enclosure, while the modular design maintains manufacturing simplicity through standardized module construction.
4Reliability
If internal dividing panels are added to separate battery modules, then safety is improved, but device complexity increases
Solution Approach 1:
Vertically oriented internal dividing panels are positioned between adjacent battery modules within the columns. These panels segment the battery pack into distinct sections, providing safety isolation between modules while maintaining a relatively simple overall structure through the use of straightforward partitioning elements.
Data Source
AI summary
A battery pack assembly comprises a battery enclosure having a first side panel, a second side panel, a third side panel, a fourth side panel, a top panel, and a bottom panel defining a module containing volume. The battery pack assembly may contain a plurality of battery modules in the module containing volume, the plurality of battery modules having a first battery module, a second battery module, and a third battery module. The first battery module and the second battery module are positioned in a first orientation and stacked to form a column of battery modules and the third battery module is positioned in a second orientation and positioned adjacent to the column of battery modules.