Horizontal Composite Electricity Supply Element Group for EV Safety
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Solution Overview
Problem
Electric vehicles face safety concerns due to high voltage drops and potential explosions when punctured by metal objects, especially with vertically stacked battery elements connected in series, which limits the capacity and voltage of the battery module.
Innovation Solution
A horizontal composite electricity supply element group is designed with series and/or parallel connections between independent electricity supply elements, sandwiched between insulation layers and connected via patterned conductive layers, preventing electrochemical reactions and allowing for higher voltage and capacity without electrolyte limitations, while reducing the risk of puncture damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple battery elements are vertically stacked and connected in series to increase voltage and capacity, then the energy density and mileage are improved, but the safety risk increases due to potential puncture damage causing high voltage drops and explosions
Solution Approach 1:
The patent transitions from vertical stacking to horizontal arrangement of battery elements. This dimensional change allows the battery pack to achieve high voltage and capacity through horizontal series/parallel connections rather than vertical stacking, thereby reducing the risk of puncture damage while maintaining energy density
Solution Approach 2:
The battery pack is divided into multiple independent battery element groups arranged horizontally. Each group can be independently sealed and protected, allowing for modular safety management. This segmentation enables the system to maintain high capacity while reducing the vulnerability of any single vertical stack to puncture damage
2Device complexity
If internal series connection is adopted within a single housing to increase voltage, then the structural complexity is reduced, but the electrolyte decomposition risk increases when voltage exceeds the sustainable range
Solution Approach 1:
The patent divides the battery system into multiple independent battery element groups, each with its own housing and electrolyte system. This segmentation allows each group to operate within safe voltage ranges while the overall system achieves higher voltage through series connection of multiple groups, preventing electrolyte decomposition
Solution Approach 2:
The patent introduces insulation layers as intermediary elements between adjacent battery element groups. These insulation layers prevent direct electrical contact and potential short circuits while allowing the groups to be connected in series, thus enabling higher voltage operation without compromising electrolyte stability
3Reliability
If a common electricity collecting layer is shared by adjacent battery modules to solve electrolyte decomposition, then the electrolyte stability is improved, but the design flexibility is reduced due to limited connection configurations
Solution Approach 1:
The patent assigns separate electricity collecting layers to each battery element group rather than using a common layer. This segmentation enables independent connection configurations for each group, allowing flexible series and parallel arrangements to achieve desired voltage and capacity while maintaining electrolyte stability through proper isolation
4Quantity of substance
If massive battery elements are vertically stacked to achieve high capacity, then the specific capacity is improved, but the vulnerability to puncture damage increases
Solution Approach 1:
The patent arranges battery elements horizontally rather than vertically stacking them. This dimensional change maintains high specific capacity through increased number of elements while reducing puncture vulnerability, as horizontal arrangement distributes elements across a larger area and reduces the concentration of risk in any single vertical location
Data Source
AI summary
A horizontal composite electricity supply element group comprises a first insulation layer, a second insulation layer, a first patterned conductive layer, a second patterned conductive layer, and a plurality of electricity supply element groups. The first patterned conductive layer is disposed on the first insulation layer. The second patterned conductive layer is disposed on the second insulation layer. The plurality of electricity supply element groups are disposed between the first insulation layer and the second insulation layer, and connected in series and/or in parallel via the first patterned conductive layer and the second patterned conductive layer. The electricity supply element group is formed by several serially connected independent electricity supply elements whose electrolyte systems do not circulate with one another. Thereby, the high voltage produced by connection will not influence any single electricity supply element nor decompose their respective electrolyte systems.