EV Battery Parallel Cell Strands for High-Current Disconnection
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Solution Overview
Problem
Existing battery configurations for electric vehicles face challenges with high short-circuit currents, exceeding the limits of commercially available contactors and fuses, leading to stress and the need for larger wiring and connectors, while current disconnection methods like pyrotechnic switches are one-time use and require safety factors for asymmetric current distribution, limiting battery capacity utilization.
Innovation Solution
A vehicle energy storage device with parallel strands containing semiconductor switching elements, such as field-effect transistors, to manage and quickly interrupt high currents, eliminating the need for fuses and contactors, and allowing symmetric current distribution for efficient utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fuel tank is integrated into the vehicle body structure, then structural strength and rigidity are improved, but corrosion risk and maintenance difficulty increase
Solution Approach 1:
The fuel tank is divided into a modular assembly comprising a separate tank body, mounting brackets, and sealing elements. This segmentation allows the fuel tank to be replaced as a complete unit without affecting the vehicle body structure, thereby maintaining structural strength while enabling easy replacement of corroded components.
Solution Approach 2:
Mounting brackets and sealing elements act as intermediary components between the fuel tank and vehicle body. These intermediaries isolate the fuel tank from direct contact with the vehicle body structure, preventing corrosion transfer while maintaining the integrated structural benefits.
2Duration of action of moving object
If fuel tank capacity is increased to extend range, then operating duration is improved, but vehicle weight and volume increase
Solution Approach 1:
The fuel tank utilizes high-density fuel formulations and optimized tank geometry to increase capacity without proportional increases in weight. The tank design incorporates variable cross-sections and strategic reinforcement zones that maximize volume efficiency while minimizing material usage.
3Duration of action of moving object
If fuel tank capacity is increased to extend range, then operating duration is improved, but vehicle volume occupied increases
Solution Approach 1:
The fuel tank is designed with nested structural elements where mounting brackets, sealing channels, and reinforcement ribs are integrated within the tank wall thickness. This nesting approach maximizes internal capacity while minimizing external volume occupation.
Solution Approach 2:
The fuel tank utilizes three-dimensional space optimization with irregular geometries that conform to available vehicle space. The tank extends into vertical and lateral dimensions rather than occupying uniform horizontal space, efficiently utilizing otherwise wasted vehicle volume.
4Device complexity
If integrated fuel tank design is used to reduce component count, then device complexity is reduced, but repairability and replacement difficulty increase
Solution Approach 1:
The fuel tank system is segmented into a modular assembly with standardized mounting interfaces. This segmentation maintains the benefits of integration by reducing the number of separate components while enabling the entire tank assembly to be replaced as a single serviceable unit, simplifying repair operations.
5Weight of moving object
If lightweight materials are used to reduce weight, then vehicle weight is reduced, but manufacturing precision requirements and cost increase
Solution Approach 1:
The fuel tank employs composite material construction combining lightweight alloys with corrosion-resistant coatings and polymer linings. This composite approach reduces overall weight while the layered structure provides built-in corrosion protection, eliminating the need for high-precision manufacturing of individual corrosion-resistant components.
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
Enables reliable, non-destructive disconnection of high currents, reduces the size and weight of wiring and connectors, and allows for 10% performance increase by eliminating safety factors, thus meeting warranty limits and preventing breakdowns.
Implementation Method 1
mounting brackets for securing the tank to a vehicle body
Implementation Method 2
sealing elements for engaging with vehicle body structures
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
The invention relates to vehicle energy store (2) for supplying electricity to an electric drive assembly (M) of a motor vehicle, which vehicle energy store (2) has: a connection with positive potential (21) and a connection with negative potential (22) which are connected to the drive assembly (M) during normal operation of the vehicle energy store; a first section (23) which connects the connection with the positive potential (21) and the connection with the negative potential (22) to one another and in which at least one electric energy storage cell (EZ) is arranged; and a second section (24 - 26) which, in parallel with the first section (23), connects the connection with the positive potential (21) and the connection with the negative potential (22) to one another, and in which at least one electrical energy storage cell (EZ) is also arranged; wherein at least one semiconductor switch element (27) is respectively arranged in the first section (23) and in the second section (24 - 26), which semiconductor switch element (27) can be actuated to interrupt a current flowing in the respective section.