Modular EV Battery Pack Architecture Without a Low-Voltage Battery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric vehicles rely on separate low-voltage batteries, which increase complexity, reduce efficiency, and limit the vehicle's range and serviceability.
Innovation Solution
A power supply architecture that provides both high and low voltage power from a common high voltage energy volume without a separate low-voltage battery, using direct-current-to-direct-current converters and modular enclosures to house power electronics, allowing for redundant low-voltage power sources and load balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate low-voltage battery is used in addition to the high-voltage battery, then the vehicle can provide both high-voltage and low-voltage power, but the device complexity increases and the vehicle range decreases
Solution Approach 1:
The patent merges the high-voltage and low-voltage power supply systems into a single integrated battery pack. The battery pack includes both high-voltage battery modules and low-voltage battery modules, along with a power conversion device that can convert between high-voltage and low-voltage. This eliminates the need for separate high-voltage and low-voltage battery packs, reducing overall system complexity while maintaining the ability to provide both voltage levels.
Solution Approach 2:
The single battery pack is designed to serve multiple functions: it can provide high-voltage power directly to high-voltage loads, convert to low-voltage and supply low-voltage loads, and dynamically allocate power between different voltage levels based on vehicle needs. The power conversion device enables this multi-functionality by bidirectionally converting between high-voltage and low-voltage as required.
2Reliability
If a separate low-voltage battery is used, then the vehicle has dedicated low-voltage power source, but the vehicle weight increases and efficiency decreases
Solution Approach 1:
The patent combines high-voltage and low-voltage battery modules into a single integrated battery pack structure. This consolidation eliminates the need for separate battery packs and their associated mounting structures, wiring harnesses, and control systems, thereby reducing total weight while maintaining reliable low-voltage power supply through the integrated low-voltage modules and power conversion capability.
3Reliability
If a separate low-voltage battery is used, then the vehicle can operate essential components during high-voltage disconnection, but the serviceability and maintenance complexity increase
Solution Approach 1:
The integrated battery pack design consolidates high-voltage and low-voltage components into a single serviceable unit. The power conversion device is integrated within the same enclosure, allowing technicians to service the entire power supply system through one access point rather than dealing with separate battery packs. This improves serviceability while maintaining the ability to operate essential low-voltage components during high-voltage disconnection events.
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
Improves the efficiency, reliability, and range of electric vehicles by eliminating the need for a separate low-voltage battery, ensuring continuous power supply to essential components even in failure scenarios.
Implementation Method 1
using direct-current-to-direct-current converters
Data Source
AI summary
Aspects of the subject disclosure relate to a modular electronic component assembly for a battery pack. The battery pack may be implemented in a vehicle. The modular electronic component assembly may include an electrical architecture housed within a modular enclosure that is configured to be attached to a frame or housing of an energy volume of the battery pack. The electrical architecture may include components and/or circuitry configured to provide a high voltage from the energy volume to one or more high voltage connectors on the modular enclosure, and components and/or circuitry configured to provide a low voltage (lower than the high voltage) to one or more low-voltage connectors on the modular enclosure, without the use or presence of a separate low-voltage battery.