Modular EV Battery Strings with Thermal Barriers
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Solution Overview
Problem
Current energy-storage systems for electric vehicles face challenges in spatial efficiency, thermal management, and balance among battery cells, which affect their size, efficiency, and safety.
Innovation Solution
The development of an electric vehicle battery pack with a rack system that allows for independently removable battery strings, each equipped with a housing, electrochemical cells, a circuit for connecting cells, high-voltage connectors, a switch, and a string control unit for managing the battery strings, along with coolant management and thermal barriers for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If battery strings are configured as independently removable modules, then ease of repair and maintenance is improved, but device complexity increases due to multiple connectors and control units
Solution Approach 1:
The battery system is divided into multiple independent battery strings, each functioning as a separate replaceable module. Each string contains its own housing, electrochemical cells, circuit, connectors, and control unit, enabling individual removal and replacement without affecting other strings. This segmentation directly improves ease of repair while the modular design manages complexity through standardization.
Solution Approach 2:
Each battery string is designed as a universal module that can be independently coupled to or disconnected from the vehicle power bus. The standardized connectors and control interfaces allow any string to replace any other, providing multi-functionality and flexibility in system configuration and maintenance operations.
2Reliability
If multiple independent battery strings are used, then reliability is improved through redundancy, but device complexity increases due to multiple control units and connectors
Solution Approach 1:
The power distribution system is segmented into multiple independent battery strings, each with its own control unit and connectors. This segmentation creates redundancy where failure of one string does not affect others, improving reliability while distributing control complexity across independent modules rather than a single centralized system.
Solution Approach 2:
The system incorporates redundant battery strings that can compensate for failures in advance. If one string fails, the remaining strings continue to provide power, cushioning against complete system failure and maintaining operational reliability.
3Volume of moving object
If battery strings are densely packed to improve spatial efficiency, then volume utilization is improved, but thermal management becomes more difficult due to reduced cooling space
Solution Approach 1:
The battery system is segmented into separate modular strings with individual housings, allowing flexible arrangement that optimizes both space utilization and thermal management. Each module can be positioned to maximize density while maintaining adequate spacing for cooling channels and thermal barriers.
Solution Approach 2:
Thermal barriers are selectively placed between adjacent battery strings at critical locations where heat transfer occurs. This local quality approach provides thermal isolation where needed while maintaining overall system compactness and spatial efficiency.
4Reliability
If thermal barriers are added between battery strings, then safety is improved through thermal isolation, but device complexity increases due to additional insulating components
Solution Approach 1:
Thermal barriers are implemented as localized insulating elements positioned between adjacent battery string housings at specific thermal interfaces. This provides targeted thermal isolation and safety where heat transfer is most critical, while avoiding unnecessary complexity in areas where thermal management is already adequate.
Data Source
AI summary
Systems and methods for storing energy for use by an electric vehicle are disclosed. Systems can include an electric vehicle battery pack including a rack configured to couple a plurality of independently removable battery strings to the vehicle, the battery strings configured to be selectively coupled in parallel to a vehicle power bus. The battery strings may include a housing, a plurality of electrochemical cells disposed within the housing, a circuit for electrically connecting the electrochemical cells, a positive high-voltage connector, a negative high-voltage connector, a switch within the housing, and a string control unit configured to control the switch. Each battery string can include a coolant inlet and a coolant outlet configured to couple with and sealingly uncouple from an external coolant supply conduit and an external coolant return conduit, and an auxiliary connector configured to couple with an external communications system and/or an external low-voltage power supply.