Modular LFP Battery Pack Layout for Space and Thermal Balance
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Solution Overview
Problem
Existing battery packs for electric vehicles face challenges in optimizing energy density, capacity, and mass distribution due to limited space, and require improved thermal management and integration efficiency.
Innovation Solution
A battery pack configuration with two sets of battery modules, where one set includes more lithium iron phosphate (LFP) cells than the other, along with a battery voltage temperature monitor, high/low voltage interfaces, thermal components, and a voltage distribution box, to enhance energy density, capacity, and mass distribution while ensuring efficient thermal control and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are made larger to increase capacity, then energy density and capacity improve, but available space and mass distribution become constrained
Solution Approach 1:
The battery pack is divided into multiple battery modules (first plurality, second plurality, third plurality of cells) that can be independently configured and arranged. This segmentation allows optimal utilization of available space while achieving target capacity through modular assembly.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement of battery modules within the pack, optimizing mass distribution and energy density by arranging modules across multiple dimensions rather than simply increasing single-module size.
2Quantity of substance
If more battery cells are added to increase capacity, then energy density improves, but thermal management complexity increases
Solution Approach 1:
The battery pack is divided into multiple modules (first, second, third pluralities of cells) that can be independently thermally managed. This segmentation allows distributed thermal control, reducing the complexity of managing heat across the entire high-capacity battery system.
Solution Approach 2:
Different thermal management approaches can be applied to different battery modules based on their specific thermal characteristics and operating conditions, allowing optimized thermal control for each module rather than a uniform approach.
3Quantity of substance
If battery modules are made bigger to improve energy density, then capacity increases, but integration efficiency and manufacturing complexity worsen
Solution Approach 1:
The battery system is modularized into standardized battery modules that can be independently manufactured and then integrated into the final pack. This modular approach improves manufacturing efficiency by allowing parallel production of modules and simplifies integration through standardized interfaces.
Solution Approach 2:
The patent employs a hierarchical structure where battery cells are grouped into modules, and modules are arranged into the final battery pack. This nested modular structure enables efficient manufacturing at multiple levels and simplifies assembly and maintenance.
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
The configuration improves energy density, capacity, and mass distribution within the limited space of electric vehicles, enhances thermal management, and integrates components efficiently, providing improved performance and reliability for electric vehicle battery packs.
Implementation Method 1
Thermal components can laterally span underneath the battery modules and the thermal insulation
Implementation Method 2
The pack cover (e.g., an aluminum pack cover) can overlay the battery modules with thermal insulation between the pack cover and the battery modules
Data Source
AI summary
A system can include a first battery module. The system can include a second battery module. The second battery module can have more lithium iron phosphate (LFP) battery cells than the first battery module.