Modular EV Battery Pack Layout for Thin High-Density Packaging
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Solution Overview
Problem
Existing battery packs are bulky and inflexible, making them challenging to incorporate as a power source in applications where space is limited, such as in electric vehicles.
Innovation Solution
The battery system comprises modular battery packs with a cooling plate and battery blocks, allowing for a thin and energy-dense configuration. Each battery pack includes a circuit board for connecting battery modules in series and parallel, and a battery management device for controlling the electrical output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed-size battery modules are used as building blocks, then the battery pack structure is simple and easy to manufacture, but the battery pack occupies large volume and has inflexible dimensions
Solution Approach 1:
The battery pack is segmented into multiple battery modules, each module containing a specific number of battery cells arranged in series. This segmentation allows the overall battery pack volume to be reduced while maintaining the required voltage and power output through modular assembly of smaller units.
Solution Approach 2:
The patent transitions from traditional horizontal/vertical stacking of battery modules to a three-dimensional configuration where modules are arranged in multiple layers and orientations. This dimensional change optimizes space utilization and reduces the overall footprint of the battery pack while maintaining structural integrity.
2Power
If multiple battery packs are combined to meet voltage and power requirements, then the power output is sufficient, but the battery system becomes bulky and occupies substantial physical space
Solution Approach 1:
Multiple battery modules are merged into a single integrated battery pack structure with shared housing, cooling systems, and control electronics. This consolidation achieves the required voltage and power output through internal series/parallel connections while eliminating the need for separate packs, thereby reducing overall system volume.
Solution Approach 2:
The battery pack design incorporates multi-functional components that serve multiple purposes: the housing provides both structural support and thermal insulation, the cooling plates serve both thermal management and structural reinforcement functions, and the module design allows flexible configuration for different voltage requirements without changing the basic pack architecture.
3Strength
If traditional battery pack configurations are used, then the structural integrity is maintained, but the design flexibility is limited for applications where volume is at a premium
Solution Approach 1:
The battery module design incorporates flexible mounting interfaces and adjustable positioning mechanisms that allow the modules to be configured in different orientations and arrangements within the pack housing. This dynamic adaptability enables the same structural components to accommodate various design requirements while maintaining structural integrity through standardized connection points.
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 configuration results in a significantly thinner battery pack that occupies less volume, increasing design flexibility and allowing for easier integration into vehicles and other applications. The modular design also simplifies the addition or removal of battery packs and allows for efficient power management.
Implementation Method 1
a cooling plate defining a central plane of the battery module, the cooling plate having a first length
Data Source
AI summary
A battery system of an electric vehicle includes a plurality of battery packs. Each battery pack includes a plurality of battery cells enclosed within a housing. A battery management device is electrically connected to each of the battery packs and configured to control an electrical output of the plurality of battery packs.