Integrated Wireless-Charging Battery Pack for Simpler EV Assembly
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Solution Overview
Problem
The production process of electric vehicles using wireless charging is complex due to the need for independent design and assembly of electronic components, leading to inefficiencies and increased production time.
Innovation Solution
Integration of the charging reception coil and battery core module into a single unit within the vehicle-mounted power battery, simplifying the structure and reducing assembly complexity by sharing a housing, which also includes a rectifier, heat sink, and controller, enabling simultaneous installation and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wireless charging components are independently designed and assembled, then each electronic component can be optimized for its specific function, but the production process becomes complex and assembly time increases
Solution Approach 1:
The patent integrates the charging reception coil, battery core module, rectifier, heat sink, and controller into a single unified power battery assembly. This merging eliminates the need for independent assembly of multiple electronic components, directly reducing production complexity and assembly time while maintaining functional optimization through integrated design.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection, thermal management (through integrated heat sink), electrical connection (through integrated controller and rectifier), and electromagnetic reception (through integrated charging coil). This multi-functionality reduces the number of separate components needed, improving production efficiency.
2Adaptability or versatility
If multiple electronic components are assembled separately on the vehicle body, then each component can be independently designed, but the assembly complexity in production line increases
Solution Approach 1:
By combining multiple electronic components into a single integrated power battery assembly, the patent reduces assembly complexity from multiple separate installations to a single unit installation, while maintaining design flexibility through modular integration.
3Manufacturing precision
If charging reception coil and battery core module are separate components, then each can be independently optimized, but production process time increases
Solution Approach 1:
The integration of charging reception coil and battery core module into a single assembly allows both components to be optimized together in design while being manufactured and installed as one unit, eliminating sequential production steps and reducing total production process time.
4Ease of operation
If charging reception coil is exposed, then it can be directly accessed for charging, but it becomes vulnerable to water and air damage
Solution Approach 1:
The charging reception coil is nested within the protected environment of the housing, which provides shielding from water and air. The housing acts as a protective container that maintains charging accessibility through controlled openings while preserving component reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This integration simplifies the production process, reduces assembly complexity, and extends the lifespan of the battery by preventing lithium plating in low-temperature environments, while also reducing costs and enhancing electromagnetic compatibility and reliability.
Implementation Method 1
The charging reception coil is accommodated in the recess, and is configured to receive energy from a power supply apparatus and output the energy
Implementation Method 2
The battery core module is accommodated in the accommodation cavity and electrically connected to the charging reception coil, and is configured to receive and store the energy output by the charging reception coil
Implementation Method 3
heat generated by the charging reception coil may fulfil a function of accelerating heating of the battery core module
Data Source
Figure 1~3
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AI summary
A vehicle-mounted power battery (20) is provided, including a housing (1), a charging reception coil (2), and a battery core module (3). The housing (1) includes a groove (101) disposed on an outer surface of the housing (1) and an accommodation cavity (102) disposed in the housing (1). The charging reception coil (2) is accommodated in the groove (101), and is configured to receive energy from a power supply apparatus (10) and output the energy. The battery core module (3) is accommodated in the accommodation cavity (102) and electrically connected to the charging reception coil (2), and is configured to receive and store the energy output by the charging reception coil (2). The vehicle-mounted power battery (20) has a simple structure, and it is less difficult to assemble a production line. This helps improve production efficiency. In addition, a chargeable/dischargeable energy storage system (100) and an electric vehicle (300) include the vehicle-mounted power battery (20).