Cassette Battery Pack Layout for Compact EV Thermal Management
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Solution Overview
Problem
Battery packs built around fixed-size modules occupy large volumes and have inflexible dimensions, posing design constraints in applications where space is limited, such as vehicular applications.
Innovation Solution
A battery system design featuring a cooling plate with battery blocks on either side, oriented transversely, and a cassette structure with aligned terminals, allowing for compact and flexible battery packs with adjustable dimensions and efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery packs are built around fixed-size battery modules, then structural stability and ease of manufacture are improved, but volume and dimensional flexibility deteriorate
Solution Approach 1:
The battery system is divided into modular battery packs that can be independently configured. Each battery pack contains battery cells arranged in series strings, allowing the system to be segmented into reusable modules that can be combined in different configurations to meet various voltage and capacity requirements without being constrained by fixed module sizes.
Solution Approach 2:
The patent transitions from two-dimensional fixed module arrangements to three-dimensional flexible packaging. Battery cells are arranged in series strings that can be folded or bent to fit complex spatial configurations, enabling the battery system to adapt to varying volume constraints by utilizing the third dimension for optimal space utilization.
2Power
If multiple battery packs are combined to meet voltage and power requirements, then power capability is improved, but volume and design flexibility deteriorate
Solution Approach 1:
The battery system employs universal battery pack modules that can serve multiple functions and be configured for different power requirements. The same modular units can be arranged in series to increase voltage or in parallel to increase current capacity, providing multi-functionality and design flexibility without requiring separate specialized packs for different power levels.
Solution Approach 2:
The system allows dynamic reconfiguration of battery modules through electrical switches or connectors that enable changing the series-parallel arrangement of battery cells. This dynamic adaptability permits the same physical battery pack to deliver different voltage and power outputs based on real-time requirements, enhancing both power capability and design flexibility.
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 design results in a thinner, energy-dense battery pack that can be easily integrated into various applications, minimizing failure propagation and reducing manufacturing complexity while maintaining efficient thermal management.
Implementation Method 1
a cooling plate defining a central plane of the battery module, the cooling plate having a first length
Data Source
AI summary
A battery system of an electric vehicle includes a plurality of battery packs. Each battery pack includes a plurality of battery cells enclosed within a housing. A battery management device is electrically connected to each of the battery packs and configured to control an electrical output of the plurality of battery packs.