Modular Battery Cassettes for Independent Voltage and Capacity Scaling
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Solution Overview
Problem
Existing battery systems for electric vehicles are limited in scalability, as they require fixed-size battery modules that cannot be easily scaled up or down in voltage and capacity, leading to inflexible energy storage solutions.
Innovation Solution
The development of a modular battery system comprising interchangeable battery cassettes that can be connected in parallel and series to form scalable battery blocks, allowing for independent adjustment of voltage and capacity by varying the number of cassettes and electrical connection elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed-size battery modules are used to build battery packs, then the battery pack structure is simple and easy to manufacture, but the battery pack cannot be easily scaled in voltage and capacity
Solution Approach 1:
The battery module is segmented into multiple battery cassettes that can be independently configured. Each cassette contains a subset of battery cells, and by varying the number and arrangement of cassettes, the overall voltage and capacity can be scaled without changing the fundamental module structure. This segmentation enables flexible configuration while maintaining manufacturing simplicity.
Solution Approach 2:
The battery module design allows dynamic reconfiguration of battery cassettes to achieve different voltage and capacity levels. The cassettes can be arranged in various series-parallel configurations, enabling the same physical components to adapt to different system requirements. This dynamic arrangement resolves the contradiction by providing scalability without requiring multiple fixed-size module designs.
2Adaptability or versatility
If battery modules are made non-sub-dividable to simplify manufacturing, then the manufacturing process is easier, but the ability to scale up or down in size is limited
Solution Approach 1:
The battery module is divided into standardized battery cassettes that serve as modular units. Each cassette is manufactured independently using the same process, maintaining ease of manufacture. The cassettes are then assembled in varying quantities to achieve different pack sizes, enabling scalability without complicating the base manufacturing process.
Solution Approach 2:
The battery cassette is designed as a universal building block that can be used in multiple configurations and applications. The same cassette design serves different voltage and capacity requirements when combined in different numbers, eliminating the need for multiple specialized module designs and maintaining manufacturing simplicity while achieving scalability.
3Quantity of substance
If battery capacity is increased by adding more battery modules in series, then the energy capacity increases, but the system voltage changes in step changes that are incompatible with narrow voltage range requirements
Solution Approach 1:
The battery system is segmented into smaller battery cassettes that can be configured in fine-grained series-parallel arrangements. This segmentation allows incremental changes in capacity by adding or removing individual cassettes, while the parallel connections within each module help maintain voltage stability. The fine-grained control enables capacity adjustment without the large voltage step changes associated with traditional module-level scaling.
Solution Approach 2:
The patent introduces a new dimension of configuration by arranging battery cassettes in both series and parallel within each module. This two-dimensional configuration space (series connections for voltage, parallel connections for current/capacity) allows independent optimization of voltage and capacity, enabling the system to maintain narrow voltage ranges while scaling energy capacity through parallel cassette additions rather than series additions.
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 approach enables flexible scaling of battery packs to meet specific energy and voltage requirements, enhancing the adaptability and efficiency of electric vehicle battery systems.
Implementation Method 1
In an electric vehicle, energy may be stored in a rechargeable battery system that includes multiple battery cells to power the electric motor
Implementation Method 2
a negative terminal of each battery cell of the battery module is in thermal contact with a cold plate
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A modular and scalable battery module wherein the energy capacity and voltage output are configured to be scaled independent of each other. A battery module has battery cassettes (702) removably coupled together to form a battery block (502). A first set of battery cassettes of the is electrically connected together in parallel to form a first parallel-connected brick of battery cells. A second set of battery cassettes of the plurality of battery cassettes is electrically connected together in parallel to form a second parallel-connected brick of battery cells. Electrical collection plates (602) connect the first and second parallel-connected bricks of battery cells in series. Each battery cell in the battery module is arranged such that a positive terminal of the battery cells are oriented in a same direction.