Modular Li-Ion Battery Modules With Shared Footprint and Cell Configurations
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Solution Overview
Problem
Traditional battery modules are designed individually for specific applications, making it difficult to construct modules with different voltages and capacities using shared components and approaches, limiting flexibility and efficiency in battery systems for electric vehicles and other applications.
Innovation Solution
Development of a lithium-ion battery module portfolio with modular designs that use standardized components and architectures, allowing for the creation of battery modules with different voltages and capacities by varying the number of prismatic electrochemical cells and their connections, while maintaining compatibility through interchangeable components and common manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional battery modules are designed individually for specific applications, then each module can be optimized for its specific voltage and capacity requirements, but it becomes difficult to construct modules with different electrical characteristics using shared components and approaches
Solution Approach 1:
The battery module is segmented into standardized sub-components (cell groups, modules, packs) that can be independently designed and manufactured. Each segment has standardized electrical characteristics and physical dimensions, allowing them to be combined in different configurations to create battery systems with various voltages and capacities without redesigning the entire system.
Solution Approach 2:
The patent creates universal standardized components that can serve multiple functions across different battery applications. The same standardized cell group design can be used to build battery modules with different electrical characteristics by varying the number and arrangement of cell groups, eliminating the need for application-specific designs.
2Productivity
If battery modules are designed with standardized components and architectures, then manufacturing efficiency and compatibility increase, but flexibility in creating modules with different electrical characteristics may be limited
Solution Approach 1:
The standardized architecture incorporates dynamic configurability where the electrical characteristics of the battery module are determined by the dynamic arrangement and quantity of standardized cell groups. This allows the same manufacturing process to produce modules with different voltages and capacities by simply changing the configuration parameters rather than the fundamental design.
Solution Approach 2:
The patent enables parameter changes in electrical characteristics (voltage, capacity) by changing the number and arrangement of standardized cell groups while maintaining the same basic architectural framework. This allows flexible customization of electrical parameters without sacrificing manufacturing efficiency or requiring complete redesign.
3Reliability
If individualized battery module designs are used, then specific application requirements are met, but manufacturing costs increase due to lack of component sharing
Solution Approach 1:
The standardized components are designed to be universal and interchangeable across different battery module applications. The same cell group design, housing, and electrical connections can be used in multiple applications, reducing per-unit manufacturing costs through economies of scale while still meeting specific application requirements through configurable arrangements.
Solution Approach 2:
The patent achieves cost reduction by maintaining standardized component designs that can be manufactured in large volumes, while allowing parameter changes (voltage, capacity) through simple configuration variations. This volume production of standardized parts significantly reduces manufacturing costs compared to individualized designs, while application-specific performance is achieved through parameter adjustment rather than design customization.
Data Source
AI summary
Present embodiments include a series of lithium battery modules having a plurality of electrochemical cells having different electrical characteristics such as voltages and/or capacities. The battery modules are each constructed using components, architectures, production methods, among other things, in common with each other. The lithium ion battery modules may include a first battery module type having a first capacity and a first voltage, a second battery module type having a second capacity and a second voltage, and, in some embodiments, additional battery module types (e.g., a third battery module type having a third capacity and a third voltage) having different voltages and/or capacities. The lithium ion battery modules may all have the same footprint.