Modular Battery Pack Architecture for Multi-Format Li-Ion Cells
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Solution Overview
Problem
Existing lithium-ion battery packs are designed for specific cell technologies and form factors, making it difficult to switch between different cell suppliers or technologies without redesigning the battery pack and undergoing recertification, which is time-consuming and costly.
Innovation Solution
A cell agnostic battery module architecture that comprises sub-modules with lithium-ion cells of various technologies and form factors, which can be interconnected in series, parallel, or both to create a power bus, and are individually certified, reducing the burden on battery pack manufacturers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery packs are designed for specific cell technologies and form factors, then manufacturing precision and reliability are improved, but adaptability deteriorates
Solution Approach 1:
The battery pack is divided into multiple interchangeable modules, each module containing cells of the same form factor. These modules can be independently certified and then mixed and matched to create different battery pack configurations, enabling adaptability while maintaining reliability through standardized module design and certification.
Solution Approach 2:
The battery pack system is designed with universal interfaces and standardized module dimensions that can accommodate different cell technologies and suppliers. The modular architecture allows the same pack design to support multiple cell types (cylindrical, pouch, prismatic) from different manufacturers, achieving multi-functionality without sacrificing reliability.
2Adaptability or versatility
If battery packs are redesigned to accommodate different cell technologies, then adaptability is improved, but loss of time and productivity deteriorate
Solution Approach 1:
By segmenting the battery pack into independently certifiable modules, the recertification process is dramatically reduced. When switching cell suppliers or technologies, only the affected modules need to be recertified rather than the entire battery pack, saving significant time and resources.
Solution Approach 2:
Modules are pre-certified for specific cell technologies and form factors before integration into battery packs. This preliminary certification of individual modules creates a library of pre-approved components that can be quickly combined and deployed, eliminating the need for complete battery pack recertification when switching suppliers.
3Adaptability or versatility
If battery packs are redesigned for different cell technologies, then adaptability is improved, but manufacturing cost deteriorates
Solution Approach 1:
The modular segmentation allows for economies of scale in module production. Standardized modules can be manufactured in volume for different cell types and then assembled into various battery pack configurations, reducing per-unit manufacturing costs compared to custom-designed packs for each application.
Solution Approach 2:
The universal module design with standardized interfaces and mounting configurations reduces manufacturing complexity. The same module design can serve multiple applications and cell types, amortizing tooling and tooling setup costs across larger production volumes, thereby reducing overall manufacturing cost.
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
Enables flexibility in using lithium-ion cells from different suppliers and technologies, reduces the need for extensive redesign and recertification, and lowers production costs by allowing for the use of certified sub-modules.
Implementation Method 1
In a discharge process of a typical lithium-ion battery, lithium ions move from a negative electrode to a positive electrode, through an electrolyte, generating a voltage
Implementation Method 2
The chassis further comprises one or more fans to provide airflow through an interior of the chassis
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A cell agnostic battery pack that is capable of receiving sub-modules including lithium-ion cells regardless of form factor type, technology or supplier is described. The battery pack includes a chassis comprising compartments for receiving lithium-ion cells in the form of sub-modules that are connectable in series, parallel or series and parallel, and a battery pack controller. The battery pack further comprises internal interconnects adapted for coupling the sub-modules received in the compartments to the battery pack controller to create a target pack voltage and energy density.