Modular EV Battery Pack with Liquid Cooling and Independent Strings
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Solution Overview
Problem
Existing energy-storage systems for electric vehicles face challenges in size efficiency, thermal management, and balancing battery cells, which affect their performance and longevity.
Innovation Solution
The implementation of modular energy-storage systems with independently removable battery strings, each comprising multiple modules of electrochemical cells organized in rows and columns, connected in parallel and series, and cooled using liquid cooling, along with a battery management system that monitors and controls voltage, current, and temperature across multiple strings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in a dense configuration to increase energy storage density, then the energy storage capacity increases, but thermal management becomes more difficult
Solution Approach 1:
The battery pack is divided into multiple modules, each containing a specific number of cells arranged in a grid pattern. This segmentation allows for better thermal management by creating discrete thermal zones while maintaining high overall energy density. Each module can be independently cooled, preventing thermal runaway propagation.
Solution Approach 2:
A liquid cooling system with cooling plates positioned between cell layers serves as an intermediary thermal management mechanism. The cooling plates conduct heat away from the cells through direct contact, enabling efficient heat dissipation in the high-density configuration without compromising cell performance.
2Reliability
If multiple battery strings are used to provide continuous power delivery, then system reliability increases, but device complexity increases
Solution Approach 1:
The battery system is divided into multiple independent strings, each capable of providing full power output. This segmentation enables continuous power delivery through string switching while maintaining relatively simple control logic. Each string is a complete, functional unit that can operate independently.
Solution Approach 2:
The system uses voltage and current parameter monitoring to detect string health status and automatically switches between strings based on predefined thresholds. This parameter-based control approach maintains reliability without requiring complex decision-making algorithms, keeping the control system simple.
3Ease of manufacture
If battery cells are organized in modular strings with standardized configurations, then manufacturing efficiency increases, but flexibility in system design decreases
Solution Approach 1:
The battery system uses standardized modules as building blocks, each containing a fixed number of cells in a specific configuration. This standardization dramatically simplifies manufacturing and assembly while the modular nature allows flexible combination of multiple modules to achieve different total capacities and voltage ratings.
Solution Approach 2:
The standardized module design serves multiple functions: it is a manufacturing unit, an assembly unit, a thermal management zone, and an electrical configuration building block. This multi-functionality maintains design flexibility despite standardization, as the same module type can be combined in various quantities to meet different system requirements.
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 configuration reduces battery cell cycling, increases energy storage density, and allows for continuous power delivery even if one string fails, enhancing safety and reliability while reducing costs through lower current handling components and avoiding redundant sensors.
Implementation Method 1
The cells may be disposed within various cell holder structures, and may be electrically connected by flexible circuitry. In some embodiments, battery packs, strings, and/or modules may be liquid cooled.
Implementation Method 2
battery packs, strings, and/or modules may be liquid cooled
Data Source
AI summary
The present disclosure is directed to energy storage systems for vehicles. In some aspects, the energy storage system may be used to power an electric automobile. The energy storage system may include a plurality of individual battery cells. The cells may be cylindrical and have a positive and negative terminal on the same side. The cells may be physically and/or electrically organized into bricks. The bricks may be physically and/or electrically organized into modules. The modules may be physically and/or electrically organized into strings. The strings may be physically and/or electrically organized into a pack. In some embodiments, packs, strings, modules and/or bricks may include flexible circuitry and/or may be liquid cooled.