Stacked Battery Power Supply Direct Connector Assembly
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Solution Overview
Problem
Existing power supply devices for electric and hybrid vehicles face challenges in routing thick cables for high-voltage battery stacks, which complicates the connection process and reduces productivity due to the need for both stacking cases and cable connections.
Innovation Solution
A stacked type power supply device design where two battery stacks are accommodated in separate cases with exposed connectors that can be easily aligned and connected without dedicated cables, allowing for direct electrical connection by stacking the cases, thereby simplifying the assembly and reducing the need for complex cable management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick cables are used for connecting high-voltage battery stacks, then electrical connection reliability is improved, but device complexity and routing difficulty increase
Solution Approach 1:
The patent merges the electrical connection function directly into the mechanical stacking interface. The connectors are integrated into the case structures, allowing electrical connection to occur automatically when cases are stacked, eliminating the need for separate cable routing operations.
Solution Approach 2:
The patent extracts the cable function entirely from the system by replacing it with direct connector-to-connector contact. The thick cables that previously served as intermediaries for electrical connection are removed, simplifying the overall device structure while maintaining reliable electrical connection.
2Reliability
If dedicated cables are used for battery stack connection, then electrical connection stability is improved, but productivity deteriorates due to additional connection steps
Solution Approach 1:
The patent combines the mechanical stacking operation with the electrical connection operation into a single action. By integrating connectors into the case structures and aligning them through stacking, the system achieves both mechanical assembly and electrical connection simultaneously, doubling productivity.
Solution Approach 2:
The patent segments the battery pack system into modular cases with integrated connectors. This segmentation allows each case to be independently assembled and then quickly connected to other cases through simple stacking, eliminating the need for separate cable connection steps for each battery stack interface.
3Reliability
If thick cables are routed within narrow spaces, then electrical connection is achieved, but ease of operation deteriorates due to routing difficulty
Solution Approach 1:
The patent removes the cable routing operation entirely from the assembly process by extracting the cable function and replacing it with direct connector contact. This eliminates the need to route thick cables through narrow spaces, making the operation trivial.
Solution Approach 2:
The patent changes the dimension of connection from lateral cable routing to vertical stacking alignment. By positioning connectors to engage in the vertical stacking direction, the system utilizes the vertical dimension for connection, avoiding the need to route cables laterally through constrained spaces.
Data Source
AI summary
A stacked type power supply device includes a first battery stack and a second battery stack in which a plurality of battery cells are stacked on each other, a first case and a second case in which the first battery stack and the second battery stack is accommodated respectively, a first connector electrically connected to the first battery stack and disposed to be exposed at a first opening provided in the first case, and a second connector electrically connected to the second battery stack and disposed to be exposed at a second opening provided in the second case. The first case and the second case are stacked on each other in a vertical direction, the first connector and the second connector are fitted to each other through the first and second openings, and the first battery stack and the second battery stack are electrically connected to each other.