Asymmetric LFP Battery Pack Layout for Space and Thermal Balance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs for electric vehicles face challenges in optimizing energy density, capacity, and mass distribution due to limited space, and require improved thermal management and integration efficiency.
Innovation Solution
A battery pack configuration with two sets of battery modules, where one set includes more lithium iron phosphate (LFP) cells than the other, along with a battery voltage temperature monitor, high/low voltage interfaces, thermal components, and a voltage distribution box, to enhance energy density, capacity, and mass distribution while ensuring efficient thermal control and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are arranged in a conventional uniform configuration, then the battery pack structure is simple, but the energy density and mass distribution are suboptimal due to limited vehicle space
Solution Approach 1:
The battery pack is divided into multiple battery modules with different numbers of cells (e.g., first battery module with 96 cells, second battery module with 144 cells). This segmentation allows each module to be optimized for specific spatial and thermal requirements, improving overall energy density while maintaining manageable complexity through modular design
Solution Approach 2:
Different battery modules are assigned different cell quantities based on local requirements within the battery pack. The first battery module has fewer cells (96) while the second has more cells (144), allowing each region to be optimized for its specific thermal management needs and spatial constraints, thereby improving overall energy density
2Quantity of substance
If more battery cells are added to increase capacity, then the energy capacity increases, but the thermal management becomes more challenging
Solution Approach 1:
The battery pack with 240 total cells is segmented into multiple modules (e.g., 96-cell module and 144-cell module) rather than being a single large module. This segmentation enables distributed thermal management where each module can be cooled independently, making thermal control more effective despite the high total capacity
Solution Approach 2:
Each battery module is equipped with its own thermal management resources (coolant flow paths, temperature sensors). The first battery module and second battery module have differentiated thermal management configurations matching their respective cell counts and heat generation profiles, enabling precise local temperature control
3Productivity
If the battery pack uses uniform battery modules, then the manufacturing is simpler, but the integration efficiency and space utilization are reduced
Solution Approach 1:
The battery pack is constructed from standardized battery module units that can be manufactured uniformly, but these modules are then segmented into different configurations (96-cell, 144-cell) within the pack. This maintains manufacturing simplicity while achieving integration efficiency through optimized spatial arrangement
Solution Approach 2:
The battery modules use universal connection interfaces and standardized mounting structures that allow them to be assembled in different configurations. The same basic module design serves multiple functions by being arranged in different quantities and patterns to achieve optimal space utilization and integration efficiency
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
The configuration improves energy density, capacity, and mass distribution within the limited space of electric vehicles, providing efficient thermal management and integration, thus enhancing the performance and reliability of the battery pack.
Implementation Method 1
The battery pack can include a battery voltage temperature monitor (BVT) that measures voltage and temperature sensor readings for one or more of the battery modules
Implementation Method 2
Thermal components can laterally span underneath the battery modules and the thermal insulation
Implementation Method 3
The pack cover (e.g., an aluminum pack cover) can overlay the battery modules with thermal insulation between the pack cover and the battery modules
Data Source
AI summary
A system can include a first battery module. The system can include a second battery module. The second battery module can have more lithium iron phosphate (LFP) battery cells than the first battery module.