Removable Battery Disconnect Unit for EV Pack Service Access
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Solution Overview
Problem
Existing battery disconnect units in electric vehicles are difficult and costly to service, often requiring the removal of substantial portions of the battery assembly for maintenance.
Innovation Solution
A battery disconnect unit design that allows for removably connecting to the battery pack enclosure using external brackets and a bottom support substrate, enabling service without disassembling the battery assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery disconnect unit is integrated into the battery assembly, then the connection is stable and reliable, but the serviceability deteriorates requiring removal of substantial battery components
Solution Approach 1:
The battery disconnect unit is segmented from the battery assembly into separate removable components. The disconnect unit includes a housing with contactors that can be independently removed from the battery pack, allowing service without dismantling the entire battery assembly while maintaining stable electrical connections during operation.
Solution Approach 2:
External brackets serve as intermediary components that facilitate the removable connection between the battery disconnect unit and the battery pack enclosure. These brackets enable easy installation and removal while providing stable mounting during operation, resolving the contradiction between secure connection and serviceability.
2Device complexity
If the battery disconnect unit uses a fixed integrated design, then the structural complexity is reduced, but the service cost increases due to required component removal
Solution Approach 1:
The battery disconnect unit employs a dynamic removable design rather than a fixed integrated structure. The unit can be easily installed and removed from the battery pack using external brackets, reducing service costs while maintaining operational reliability. This dynamic approach allows the disconnect unit to be serviced independently without requiring removal of battery components.
3Ease of operation
If the battery disconnect unit is permanently mounted to the battery pack, then the installation is simple, but the maintenance complexity increases requiring battery assembly disassembly
Solution Approach 1:
The disconnect unit is segmented into a separate removable module that can be independently installed and maintained. The housing with contactors is designed as a discrete unit that interfaces with the battery pack through external brackets, enabling simple initial installation while allowing easy maintenance without battery assembly disassembly.
Solution Approach 2:
External brackets act as intermediary components that simplify both installation and maintenance. During installation, the brackets provide easy mounting points for the disconnect unit. During maintenance, the same brackets enable quick removal and replacement of the disconnect unit without requiring disassembly of the battery pack enclosure or internal components.
Data Source
AI summary
Disclosed is a battery disconnect unit including a bottom support substrate having at least one fastening feature for removably connecting the battery disconnect unit to a battery pack enclosure. The battery disconnect unit may include at least one of a contactor, a fuse, or a pre-charge circuit carried on top of the bottom support substrate. Disclosed also are methods of assembling the battery disconnect unit to a battery pack enclosure and a method of removing the battery pack disconnect unit from the battery pack enclosure without removing a battery pack and associated components from the battery pack enclosure.