Modular EV Battery Pack Architecture Without a Separate Low-Voltage Battery

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Solution Overview

Problem

Existing electric vehicles rely on separate low-voltage batteries, which increase complexity, reduce efficiency, and contribute to greenhouse gas emissions.

Innovation Solution

A power supply architecture that provides both high and low voltage power from a common high voltage energy volume without a separate low-voltage battery, using DCDC converters and modular enclosures for electromagnetic interference mitigation, with redundant low-voltage power sources and accessible connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate low-voltage battery is used in addition to the high-voltage battery, then reliable low-voltage power supply is ensured, but device complexity increases and greenhouse gas emissions increase

Engineering Contradiction:

Improvelow-voltage power supply reliabilityVSAvoidpower supply system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the low-voltage and high-voltage battery systems into a single integrated battery pack. The low-voltage battery and high-voltage battery are merged into one modular unit, eliminating the need for separate battery compartments and reducing overall system complexity while maintaining reliable low-voltage power supply through the integrated architecture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated battery pack serves multiple functions: it provides both low-voltage power for auxiliary systems and high-voltage power for propulsion, while also housing the DCDC converter for voltage conversion. This multi-functional design eliminates the need for separate dedicated low-voltage battery systems and reduces the total number of components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate low-voltage battery is used, then continuous low-voltage power is ensured, but manufacturing complexity and service difficulty increase

Engineering Contradiction:

Improvecontinuous low-voltage power supplyVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By merging the low-voltage battery, high-voltage battery, and DCDC converter into a single integrated battery pack, the patent simplifies the manufacturing process. Instead of assembling and coordinating multiple separate battery systems, manufacturers can produce one unified module, reducing assembly steps and improving manufacturing efficiency while ensuring continuous power supply through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If electromagnetic shielding is added to the enclosure, then electromagnetic interference is mitigated, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveelectromagnetic interferenceVSAvoidenclosure manufacturing difficulty

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent employs composite material construction for the battery pack enclosure, combining insulating materials with integrated conductive shielding layers. This approach provides effective electromagnetic interference mitigation while maintaining manufacturing feasibility, as the shielding is incorporated as part of the enclosure structure rather than as a separate complex assembly step.

Inventive Principle:

Principle #40Composite materials

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

Enhances efficiency, serviceability, and reduces greenhouse gas emissions by eliminating separate low-voltage batteries while ensuring continuous low-voltage power supply.

Implementation Method 1

An enclosure for the power supply architecture may be formed from insulating materials and may include one or more conductive layers for electromagnetic interference (EMI) mitigation and/or electromagnetic compatibility (EMC)

Methodology Applied

Scientific EffectElectromagnetic interference mitigation: Absorption (EM radiation)

Implementation Method 2

second circuitry configured to receive the first voltage from the one or more batteries and to provide access to a second voltage, lower than the first voltage, by one or more electrical components of the vehicle

Methodology Applied

Scientific EffectElectrical energy conversion: Electromagnetic Induction

Data Source

PatentUS20250296474A1Low voltage battery-less architecture for electric vehicles

Publication Date: 2025.09.25 RIVIAN HOLDINGS LLC

AI summary

Aspects of the subject disclosure relate to a modular electronic component assembly for a battery pack. The battery pack may be implemented in a vehicle. The modular electronic component assembly may include an electrical architecture housed within a modular enclosure that is configured to be attached to a frame or housing of an energy volume of the battery pack. The electrical architecture may include components and/or circuitry configured to provide a high voltage from the energy volume to one or more high voltage connectors on the modular enclosure, and components and/or circuitry configured to provide a low voltage (lower than the high voltage) to one or more low-voltage connectors on the modular enclosure, without the use or presence of a separate low-voltage battery.