Split Battery Module Layout With Side Power Electronics Housing
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Solution Overview
Problem
Existing battery systems for electric and semi-electric vehicles require complex installation processes and often necessitate a battery box to house both battery cells and power electronics, which can complicate the design and increase the risk of moisture or dirt ingress.
Innovation Solution
A battery system comprising two spaced battery module assemblies with a conduction housing and a terminal box that eliminates the need for a battery box, featuring a power electronics housing positioned on the side of one module assembly to enable a flat vehicle design, with sealed modules and busbar conductors for high mechanical stability and low electrical resistance, and a terminal box with a fuse for safety and easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a battery box is used to house both battery cells and power electronics, then all components are accommodated in one structure, but the installation process becomes complex and the risk of moisture or dirt ingress increases
Solution Approach 1:
The patent divides the battery system into separate modules: battery module assemblies and power electronics housing are positioned independently rather than enclosed in a single battery box. This segmentation simplifies installation and reduces moisture ingress risk by eliminating internal seams.
Solution Approach 2:
The power electronics are extracted from the traditional battery box enclosure and positioned separately in a power electronics housing. This extraction eliminates the complex sealing requirements of a unified battery box while maintaining component integration through the conduction housing structure.
2Shape
If power electronics are housed inside the battery box with battery cells, then all components are protected in one enclosure, but the design becomes complex and vehicle floor height increases
Solution Approach 1:
The power electronics housing is positioned in a different spatial dimension relative to the battery modules - specifically on the side of the second battery module assembly rather than underneath. This dimensional arrangement enables a flat vehicle floor design while maintaining component protection.
Solution Approach 2:
The conduction housing serves multiple functions: it provides structural support, enables electrical connections between modules, and positions the power electronics housing. This multi-functionality eliminates the need for a separate battery box while maintaining component protection.
3Ease of operation
If terminals are only provided in the front region of the vehicle, then connection paths are simple, but consumers in rear regions have long connection paths
Solution Approach 1:
The patent provides terminals at different locations based on local requirements: a first terminal in the front region for front consumers and a second terminal on the power electronics housing for rear consumers. This local differentiation optimizes connection paths for consumers in different vehicle regions.
4Ease of manufacture
If the terminal box is integrated with the battery modules, then assembly is simplified, but access for maintenance becomes difficult
Solution Approach 1:
The terminal box is segmented from the battery modules and positioned in the conduction housing above the modules. This segmentation allows the terminal box to be assembled with the battery modules in advance while maintaining independent accessibility for maintenance operations.
Data Source
AI summary
A battery system (20) has first and second battery module assemblies (31, 32), a conduction housing (40), a terminal box (50), and a power electronics housing (60). The first and second battery module assemblies (31, 32) are spaced from one another so that two footwells (35, 36) are formed between the first battery module assembly (31) and the second battery module assembly (32). A first section (42) of the conduction housing (40) extends between the footwells (35, 36). A power electronics (61) is provided in the power electronics housing (60). The terminal box (50) comprises at least a first terminal (51) for a first consumer (91). First conductors (41) are provided in the conduction housing (40) and electrically interconnect the first battery module assembly (31), the second battery module assembly (32), at least a first terminal (51), and the power electronics (61).