Configurable Battery Module AC Output With Safer Serviceable Isolation
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Solution Overview
Problem
Existing vehicle battery module designs are hazardous to handle, prone to fires and explosions, and require specialized training and equipment for service and repair, especially in high-performance vehicles that experience frequent crashes and severe use.
Innovation Solution
A battery module design that includes an enclosure with series-connected cells electrically isolated from the enclosure, a printed circuit board assembly for cell monitoring and conditioning, and an external interface PCBA with relays and a battery management system, allowing for safe handling and service without specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If modules use groups of cells connected in parallel to achieve large current capability, then current capability is improved, but safety deteriorates due to high risk of fire and energy release from short circuits across external terminals
Solution Approach 1:
The patent divides the battery system into multiple modules, each containing a single string of series-connected cells rather than parallel groups. This segmentation isolates the high voltage to manageable levels (below 50V at module level) while maintaining pack-level power through series connection of modules, eliminating the fire risk associated with parallel-connected modules having large current capability.
Solution Approach 2:
The patent transitions from a two-dimensional arrangement (parallel groups within modules) to a three-dimensional hierarchical structure where multiple single-string modules are connected in series at the pack level. This dimensional change allows the system to achieve high power output while keeping individual module voltages safe and manageable.
2Ease of manufacture
If monolithic non-serviceable battery packs are used, then manufacturing complexity is reduced, but ease of repair deteriorates for high-performance vehicles requiring frequent service
Solution Approach 1:
The patent segments the battery pack into multiple interchangeable modules that can be independently serviced or replaced. Each module is a complete functional unit with its own enclosure, cells, and safety features, allowing technicians to work on individual modules without specialized equipment while maintaining the simplicity of modular assembly.
Solution Approach 2:
The patent designs universal modules that can be used in various configurations and applications. Each module is a self-contained unit with standardized interfaces, allowing them to be interchangeably assembled into different pack configurations depending on the vehicle's power requirements, serving both manufacturing simplicity and serviceability needs.
3Ease of operation
If external terminals are always connected to cells in modules with large current capability, then electrical connectivity is improved, but safety deteriorates due to potential for very large energy release from shorts
Solution Approach 1:
The patent segments the electrical connectivity function across multiple levels: individual cell terminals connect to module terminals through current collectors, and module terminals connect to pack terminals through busbars. This segmentation ensures that any short circuit is limited to the low-voltage module level rather than the high-voltage pack level, maintaining connectivity while limiting hazard.
Solution Approach 2:
The patent introduces intermediate connection elements (current collectors and busbars) between the cells and external terminals. These intermediaries provide low-resistance electrical pathways while physically isolating the high-voltage cells from direct external access, ensuring good electrical connectivity while preventing direct short circuits across high-voltage terminals.
Data Source
AI summary
A battery module is disclosed having a string of series-connected battery cells, three terminals, a battery management system (BMS) circuit, and a voltage source converter (VSC) to selectively connect the positive and negative ends of the string of cells to the three terminals. The unique configuration of the battery module allows it to output power in DC, 1-phase AC, and 3-phase AC forms under the control of the BMS circuit. A power system is disclosed utilizing configurable battery modules to provide DC, 1-phase AC, and 3-phase AC power to one or a plurality of system components.