Battery Module Multi-Voltage Design for xEV Conversion

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Solution Overview

Problem

There is a need for improved battery systems for xEVs that enhance travel distance without recharging, improve performance, and reduce costs, while also addressing packaging challenges in converting traditional vehicles to hybrid electric vehicles.

Innovation Solution

The development of lithium ion battery modules that provide multiple voltages (e.g., 12V and 48V) within a form factor equivalent to traditional lead acid batteries, incorporating heat transfer devices and phase change materials for thermal management, and featuring a flexible terminal design for efficient energy storage and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If lithium ion battery modules are designed with multiple voltage outputs (12V and 48V) to improve vehicle performance and extend travel distance, then the battery system's versatility and energy efficiency are enhanced, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvemultiple voltage outputsVSAvoidbattery module structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The battery module is designed with multiple voltage outputs (12V and 48V) from a single module, allowing it to serve multiple functions - powering both traditional 12V vehicle systems and high-voltage 48V hybrid systems. This multi-functionality approach enables the same battery module to replace what would traditionally require separate battery systems, reducing overall system complexity despite the increased internal complexity of the module itself.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The battery module is segmented into multiple cells (e.g., six 48V cells and two 12V cells) that can be independently connected through a tab arrangement system. This segmentation allows flexible configuration of voltage outputs by selectively connecting cell groups, enabling the module to provide both 12V and 48V outputs simultaneously or independently based on system requirements.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If the battery module uses a compact form factor equivalent to traditional lead acid batteries to simplify packaging in converted vehicles, then the ease of installation and packaging efficiency improve, but the energy capacity and travel distance are limited

Engineering Contradiction:

Improvebattery module sizeVSAvoidtravel distance

Core Design Contradiction:

Volume of moving objectVSDuration of action of moving object

Solution Approach 1:

The battery module employs a nested cell arrangement where multiple battery cells are positioned in a compact, space-efficient configuration within the module housing. Cells are arranged in nested or closely packed patterns that maximize energy density within the constrained volume, allowing sufficient energy capacity for extended travel while maintaining a form factor compatible with traditional battery packaging spaces.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Loss of energy

If traditional vehicles are converted to hybrid electric vehicles using battery systems, then fuel efficiency and emission reduction are improved, but the manufacturing cost and conversion complexity increase

Engineering Contradiction:

Improvefuel efficiencyVSAvoidconversion cost

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The battery module merges multiple functions into a single integrated unit - it combines 12V and 48V battery capabilities, thermal management features, and structural mounting elements into one consolidated module. This merging reduces the number of separate components needed for vehicle conversion, simplifying the manufacturing process and reducing overall conversion costs while maintaining the energy efficiency benefits of hybrid electric propulsion.

Inventive Principle:

Principle #5Merging (Combining)

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 solution enables extended travel distances, improved performance, and reduced costs by providing multiple voltage levels within a standard battery form factor, simplifying the conversion of traditional vehicles to xEVs and enhancing thermal management for efficient energy storage and distribution.

Implementation Method 1

incorporating heat transfer devices and phase change materials for thermal management

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

incorporating heat transfer devices and phase change materials for thermal management

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS9553343B2Printed circuit board interconnect for cells in a battery system

Publication Date: 2017.01.24 CPS TECHNOLOGY HOLDINGS LLC

AI summary

A system includes a cell interconnect board including a printed circuit board (PCB) disposed proximate a power assembly having a plurality of pouch battery cells, including at least a first battery cell and a second battery cell in a stacked orientation relative to each other. The cell interconnect board includes an interconnect spanning a slot in the cell interconnect board and configured to receive a first tab electrode extending from the first battery cell and a second tab electrode extending from the second battery cell, such that the first and second tab electrodes are in contact with each other. The system also includes a sensor configured to measure a parameter associated with the power assembly.