Remote Battery Pack Service Unit for Higher Power Density
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Solution Overview
Problem
Existing battery pack arrangements face challenges in reducing the size and increasing the power per occupied space, with a need for improved space utilization and design flexibility.
Innovation Solution
The battery pack arrangement separates the battery pack service unit from the battery pack housing, incorporating a contactor to disconnect the battery pack from a load or power source, and utilizes a communication link and power cable or rail for seamless data and power transmission, allowing for more efficient space utilization and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery pack service unit is integrated into the battery pack housing, then the structure is compact and simpler, but the battery pack size increases and maintenance accessibility deteriorates
Solution Approach 1:
The battery pack arrangement is divided into two separate functional units: the battery pack housing containing battery cells and the service unit housing containing the service unit. This segmentation allows the battery pack to be optimized for size while the service unit can be accessed independently for maintenance, resolving the contradiction between compactness and maintainability.
Solution Approach 2:
A communication link and power cable or power rail are introduced as intermediary elements to connect the battery pack and service unit. These intermediaries enable data transmission and power delivery while allowing the two units to be physically separated, thus reducing battery pack size without compromising service functionality.
2Ease of operation
If the battery pack service unit is arranged remotely from the battery pack housing, then maintenance accessibility improves and design flexibility increases, but the structure becomes more complex
Solution Approach 1:
By segmenting the system into separate battery pack and service unit housings, the patent enables independent access to the service unit for maintenance while keeping the battery pack compact. This segmentation naturally improves maintenance accessibility without requiring complex internal rearrangements.
Solution Approach 2:
The service unit is designed as a separate modular unit that can be universally applied to different battery pack configurations. This multi-functional design allows the same service unit to work with various battery pack types, reducing overall system complexity despite the remote arrangement.
3Power
If more battery cells are included in the battery pack to increase power density, then the power per occupied space increases, but the battery pack size increases
Solution Approach 1:
The service unit functions are extracted from the battery pack housing and placed in a separate service unit housing. This extraction creates space within the battery pack housing that can be utilized to accommodate additional battery cells, thereby increasing power density without proportionally increasing the overall system volume.
Solution Approach 2:
The patent reorganizes the spatial arrangement by separating the service unit from the battery pack in a different spatial dimension. This dimensional reorganization allows the battery cells to be arranged more efficiently within the battery pack housing, maximizing power density within the available volume.
4Volume of moving object
If the battery pack service unit is separated from the battery pack housing, then space utilization improves, but the connection requirements (power cable and communication link) increase system complexity
Solution Approach 1:
The power cable and communication link are combined into an integrated connection system that simultaneously handles both power transmission and data communication between the battery pack and service unit. This merging reduces the number of separate connections required and simplifies the overall connection architecture despite the physical separation of units.
Solution Approach 2:
The connection system is designed with multi-functional capability, where the same physical interface and cable assembly handle both electrical power transmission and digital communication protocols. This universal connection approach reduces complexity compared to having separate dedicated connections for each function.
Data Source
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AI summary
A battery pack arrangement (30) comprising: a battery pack (31) comprising a plurality of battery cells (33) arranged in a battery pack housing (35); a battery pack service unit (40) for managing the battery pack (31), the battery pack service unit (40) being arranged in a service unit housing (42) arranged remotely of the battery pack housing (35); a communication link (50) arranged between the battery pack housing (35) and the service unit housing (42) for enabling the battery pack service unit (40) to communicate with the battery pack (31); and a power cable or power rail (60) arranged between the battery pack housing (35) and the service unit housing (42) for enabling transmission of a high voltage current between the battery pack (31) and the service unit (40). The battery pack service unit (40) comprises at least a first contactor (44) configured to disconnect the battery pack (31) from a load and/or a power source (10).