High voltage junction box for a battery pack

Patent metadata

Field	Value
Publication number	US-12519151-B2
Application number	US-202519014981-A
Country	US
Kind code	B2
Filing date	Jan 9, 2025
Priority date	Nov 14, 2022
Publication date	Jan 6, 2026
Grant date	Jan 6, 2026

Abstract

A battery pack assembly, comprising: a battery pack, the battery pack comprising: a battery pack enclosure, and one or more battery cells within the battery pack enclosure, and a junction box, the junction box comprising: a junction box enclosure including one base wall, four side walls connected to the base wall, and one open end, and a battery management unit, at least one fuse, and at least one switch, each located within the junction box enclosure and mounted to the base wall. The four side walls of the junction box enclosure are removably secured to the battery pack enclosure at the open end.

First claim

The invention claimed is:

1 . A battery pack assembly, comprising:
a battery pack, the battery pack comprising:
a battery pack enclosure; and
one or more battery cells within the battery pack enclosure; and
a junction box, the junction box comprising:
a junction box enclosure including one base wall, a side wall structure connected to the base wall, and one open end; and
a battery management unit, at least one fuse, and at least one switch, each located within the junction box enclosure and mounted to the base wall;
wherein the side wall structure of the junction box enclosure is configured to be removably secured to the battery pack enclosure at the open end, such that the base wall is not within the battery pack enclosure.

2 . The battery pack assembly of claim 1 , wherein the battery pack enclosure includes a cut-out portion that is covered by the junction box upon securing the junction box enclosure to the battery pack enclosure.

3 . The battery pack assembly of claim 1 , wherein the side wall structure of the junction box enclosure has a flanged end that is configured to be removably secured to the battery pack enclosure.

4 . The battery pack assembly of claim 1 , wherein the at least one switch is a contactor configured to control power from the one or more battery cells.

5 . The battery pack assembly of claim 1 , wherein the battery pack includes at least one cell management unit mounted within the battery pack enclosure to monitor voltage and temperature of the one or more battery cells of the battery pack.

6 . The battery pack assembly of claim 1 , wherein the battery pack includes at least two cell management units and wherein the at least two cell management units are daisy chained together.

7 . The battery pack assembly of claim 6 ,
wherein the battery pack assembly comprises a wired connection between the battery management unit and a cell management unit of the at least two cell management units; and wherein the battery management unit is configured to receive voltage and temperature measurements of the one or more battery cells through the wired connection.

8 . The battery pack assembly of claim 1 , wherein the junction box base wall includes at least one access panel configured to provide access to electrically connect the junction box and the battery pack.

9 . The battery pack assembly of claim 1 ,
wherein the battery pack assembly is configured to be mounted inside an aircraft wing that includes at least one access panel configured to provide access to electrically connect the junction box to the battery pack.

10 . The battery pack assembly of claim 9 , wherein the battery pack is towards the bottom of the aircraft wing and the junction box is towards the top of the aircraft wing relative to the battery pack and wherein the access panel is on the top of the aircraft wing.

11 . The battery pack assembly of claim 9 , wherein the battery pack includes at least one stiffener and a crush core on the side of the battery pack opposite the junction box.

12 . An aircraft wing, comprising:
a battery pack, the battery pack comprising:
a battery pack enclosure; and
one or more battery cells within the battery pack enclosure; and
a junction box, the junction box comprising:
a junction box enclosure including one base wall, a side wall structure connected to the base wall, and one open end; and
a battery management unit, at least one fuse, and at least one switch, each located within the junction box enclosure and mounted to the base wall;
wherein the side wall structure of the junction box enclosure is configured to be removably secured to the battery pack enclosure at the open end, such that the base wall is not within the battery pack enclosure.

13 . The aircraft wing of claim 12 , wherein the battery pack enclosure includes a cut-out portion that is covered by the junction box upon securing the junction box enclosure to the battery pack enclosure.

14 . The aircraft wing of claim 12 , wherein the side wall structure of the junction box enclosure has a flanged end that is configured to be secured to the battery pack enclosure.

15 . The aircraft wing of claim 12 , wherein the at least one switch is a contactor configured to control power from the one or more battery cells.

16 . The aircraft wing of claim 12 , wherein the battery pack includes at least one cell management unit mounted within the battery pack enclosure to monitor voltage and temperature of the one or more battery cells of the battery pack.

17 . The aircraft wing of claim 12 , wherein the battery pack includes at least two cell management units and wherein the at least two cell management units are daisy chained together.

18 . The aircraft wing of claim 17 ,
wherein the aircraft wing comprises a wired connection between the battery management unit and a cell management unit of the at least two cell management units; and wherein the battery management unit is configured to receive voltage and temperature measurements of the one or more battery cells through the wired connection.

19 . The aircraft wing of claim 12 , wherein the junction box base wall includes at least one access panel configured to provide access to electrically connect the junction box and the battery pack.

20 . The aircraft wing of claim 19 , wherein the battery pack is towards the bottom of the aircraft wing and the junction box is towards the top of the aircraft wing relative to the battery pack and wherein the top of the aircraft wing includes at least one access panel configured to provide access to electrically connect the junction box to the battery pack.

21 . The aircraft wing of claim 12 , wherein the battery pack includes at least one stiffener and a crush core on the side of the battery pack opposite the junction box.

22 . The battery pack assembly of claim 1 , wherein the side wall structure includes four side walls.

23 . The battery pack assembly of claim 1 , wherein the junction box comprises a high voltage connector and a low voltage connector.

Assignees

• Archer Aviation Inc

Inventors

• Clarabut Alex
• Schwekutsch Michael
• Frihauf Paul
• Tepe Alan D
• Spiteri Stephen

Classifications

• H02G3/08

  Distribution boxes; Connection or junction boxes · CPC title

• H01M2010/4271

  Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing · CPC title

• H01M10/486

  for measuring temperature · CPC title

• H01M10/482

  for several batteries or cells simultaneously or sequentially · CPC title

• H01M10/425 Primary

  Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00) · CPC title