Modular High-Voltage Battery Packs for Emergency Isolation
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Solution Overview
Problem
Conventional battery electric vehicles lack customization options for battery packs, leading to inefficiencies in power and range, and pose safety risks due to unintended electrical discharges and battery fires during collisions.
Innovation Solution
A modular battery pack system with multiple series-connected modules, a circuit breaking system, and a battery management system that allows for emergency disconnection of affected battery packs, reducing cable length and weight, and maintaining voltage balance across packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single battery pack is used for all electric vehicles, then manufacturing simplicity is maintained, but customization capability for different operational needs is lost
Solution Approach 1:
The battery system is divided into multiple independent battery packs, each containing modular battery modules that can be individually configured. This segmentation enables customization of battery capacity and voltage by selecting different numbers and arrangements of battery packs, while each pack maintains a standardized internal structure for manufacturing efficiency.
2Weight of moving object
If battery packs are connected with long cables, then electrical connectivity is ensured, but cable length and weight increase
Solution Approach 1:
The battery system is divided into multiple independent battery packs with integrated connection points, allowing cables to be routed directly between adjacent packs rather than from a central location. This reduces cable length and weight while maintaining reliable electrical connectivity through distributed connection architecture.
3Reliability
If battery packs remain connected during emergencies, then system operation is maintained, but safety risks from electrical discharges and fires increase
Solution Approach 1:
Each battery pack is pre-equipped with a circuit breaking system including disconnect switches and fusion elements positioned at strategic connection points. Upon detecting an emergency condition, these pre-positioned safety devices rapidly open circuits to isolate affected packs, preventing electrical discharges and fire propagation before they can spread to other packs.
Solution Approach 2:
Circuit breaking systems act as intermediary safety devices between battery packs, providing controlled isolation points that can rapidly disconnect electrical connections during emergencies. These intermediaries prevent direct electrical contact between faulty and healthy packs, eliminating the harmful effect of fire and electrical discharge propagation.
4Adaptability or versatility
If modular battery pack system is implemented, then customization and safety are improved, but device complexity increases
Solution Approach 1:
The battery system is divided into multiple independent battery packs with standardized internal structures, enabling customization through modular assembly while maintaining manufacturing efficiency. Each pack contains battery modules arranged in series configurations that can be selectively combined to achieve different voltage and capacity requirements.
Solution Approach 2:
The battery packs are designed with universal connection interfaces and standardized circuit breaking systems that can be used across different vehicle configurations. This multi-functionality allows the same basic pack design to serve various customization needs, reducing overall system complexity despite the modular architecture.
Data Source
AI summary
Connection and control concepts for battery packs in a high voltage battery assembly are provided. Parallel, modular configurations permit improved safety, voltage balancing, and redundancy, improving operation and reliability of an associated high voltage electrical vehicle such as a heavy-duty truck.