EV Battery Pack Design for Safety and Performance

Securing electronics modules within a traction battery pack assembly by suspending them from the enclosure cover. The battery pack has an enclosure with a removable cover. An electronics support plate is secured to the cover using brackets and fasteners. The electronics modules are mounted on the support plate. This allows the modules to be easily accessed and serviced by removing the cover, without having to disconnect wiring harnesses and other connections.

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The rapid growth of electric vehicles (EVs) has heightened the demand for battery systems that not only deliver high performance but are also efficient to maintain, scale, and recycle. While much industrys focus been on energy density cost optimization, serviceabilitydefined by ease maintenance, diagnostic accessibility, component-level replacementhas emerged as a critical yet underprioritized factor. Traditional EV packs, often monolithic tightly integrated, pose significant challenges field technicians, including prolonged disassembly times, high-voltage safety risks, limited transparency. These limitations increase downtime, escalate service costs, constrain long-term sustainability platforms. This paper explores transformative role modular pack design in improving serviceability lifecycle efficiency across ecosystems. From broader perspective, it examines how modularity facilitates streamlined maintenance workflows, safer handling procedures, standardized replacement strategies. analysis narrows compare philosophies leading OEMs such Tesla, GM, Rivian, Lucid, evaluating ... Read More

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Battery technology is an emerging research domain within the automotive sector, with a focus on various battery chemistries such as Li-ion, LiFePO4, NMC, and NaCl, well specialized cells like LiSOCl2. These are crucial in advancing electric vehicle (EV) technology. Batteries available different packaging formats, including prismatic, cylindrical, pouch designs, each tailored to diverse operational environments. This study investigates impact of these packages overall performance. Additionally, it assesses influence temperature efficiency, aiming identify optimal range for maximum A significant part focuses development efficient thermal management (BTM) systems, which designed control maintain desired range, thereby enhancing efficiency. The outcomes this provide valuable insights improving reliability efficiency EV batteries. findings ensuring performance safety across field conditions. Automotive manufacturers suppliers can leverage refine their product dependability By through improved effective management, contributes significantly advancement technology, making vehicles more reli... Read More

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Battery box design to enable directional exhaust of gas from a pressure relief valve when installed in an enclosed electrical appariment like an electric vehicle. The battery box has an auxiliary member that encloses an exhaust channel with an external port. The pressure relief valve mounts through the channel exit. This allows gas expelled by the valve to flow through the channel and out the auxiliary member port instead of inside the battery box. This directs the exhaust to the vehicle's existing air outlet, preventing backpressure buildup in the battery compartment.

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Battery pack design with simplified assembly, improved structural strength, higher space utilization, and energy density compared to conventional packs. The pack uses a single large battery assembly inside the pack housing instead of multiple smaller modules. The cells are connected by a reinforcing member. This assembly serves as a crossbeam/longbeam to reinforce the pack structure. The cells are arranged with misaligned sides to prevent deformation. The pack avoids additional internal frames/beams. The large assembly supports the pack and provides strength. This reduces pack weight, simplifies assembly, and allows higher cell density compared to modular packs.

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Power storage module design with improved gas venting to prevent internal pressure buildup and cell damage. The module has a housing with multiple cells and through holes connecting them to the outside. A duct cover seals the cell exhaust openings. The cover has discrete protrusions facing the cell-free areas of the housing. This allows gas to escape through the holes when cells vent, preventing blockage by the duct cover collapsing. The protrusions stop gas flow from other cells. This ensures venting even if the cover is deformed from impact.

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Driving circular economy in electric vehicle batteries MARBEL project has designed, developed and demonstrated new modular, compact, lightweight high-performance battery packs together with flexible robust management systems for vehicles plug-in hybrids, while maintaining safety levels, allowing fast, high quality cost-effective large-scale production following ecodesign principles.

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Battery module housing with directed and controlled venting for lithium-ion battery packs in electric vehicles. The housing has two types of vents: burst vents to rapidly release excess gas buildup during cell operation, and selective permeability vents to slowly allow gas exchange between the cell stack and housing cavity. This enables directed venting of excess gases away from the vehicle cabin while still allowing controlled breathing of the cells. The burst vents open at high pressure thresholds, while the selective permeability vents have membranes that allow gas exchange but not moisture.

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Thermal management system for electric vehicle battery packs that provides efficient cooling and heating without adding significant weight or cost. The system uses a network of flexible tubes connecting intake and exhaust manifolds with channels tuned for even fluid flow distribution. It allows direct contact cooling/heating of individual battery cells by conforming tubes passing between them. The system connects to a pump and heat exchanger for circulating fluid through the pack. The flexible tubes fill and bleed easily for installation. The manifold design prevents fluid bypassing and ensures full inflation.

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Electric vehicles (EVs) are pivotal in reducing greenhouse gas emissions and achieving sustainable transportation goals. However, lithium-ion batteries (LIBs), the primary energy source for EVs, face critical thermal management, safety, long-term efficiency challenges. This study proposes an integrated battery management system that combines a waterethylene glycol-based liquid cooling mechanism with high-conductivity copper tubing to enhance LIB performance, longevity, safety. Through COMSOL multiphysics simulations, this examines behavior under varying operational conditions. The results indicate 20% reduction temperature peaks, maintaining optimal range of 15C 35C, thus mitigating risks runaway. Experimental validation using infrared thermography imaging confirms system's efficiency, showing maximum recorded 43.48C load conditions, significantly lower than unmanaged systems. Beyond work integrates advanced strategies, including state-of-charge estimation, predictive fault diagnostics, active optimization, cell balancing. analysis further reveals proposed improves heat diss... Read More

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Abstract Battery casing is a vital part of the electrical vehicles. The material used in it plays an important role deciding safety vehicle. This chapter refers to polymer composites, which gives good replacement for currently materials. explains concept battery pack along with its issues. It also explores various features and characteristics behind vitality composites. usage composites as energy storage this upper hand.

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Battery pack casings with a total energy of 12.432 kWh were designed using two types materials: aluminum alloy and carbon fiber reinforced composite filament based on polyphthalamide or high-performance/high-temperature nylon (PPA-CF). The effectiveness mechanical metamaterials (lattice auxetic structures) in mitigating the levels random vibrations battery was studied numerical method. Both structures demonstrate outstanding capabilities 97% to 99% reduction vibration casing. However, these PPA-CF casing are very limited, that they can only mitigate approximately 63.8% 92.8% longitudinal at top cover center its front back walls, respectively. Compared PPA-CF, shows better mitigation performance without structural modification.

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A plug design for sealing cooling channels in electric vehicle battery box floors. The plug has an inner piece that contacts the coolant and an outer piece that attaches to the frame. The inner piece is less stiff than the outer piece. This allows the inner piece to adapt to the channel shape while the outer piece provides rigidity for insertion and positioning. The two-piece plug configuration allows easy sealing of the cooling channels in the battery box floor.

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Battery module with enhanced thermal management through strategically integrated phase change materials (PCMs) that absorb heat generated in critical battery connections. The module features a bus bar with integrated phase change members that distribute heat from connecting areas between the cell tab and bus bar, while a secondary phase change member is positioned on the top surface of the cell. This dual-phase design enables targeted cooling of high-temperature areas, particularly the connecting region between the cell tab and bus bar, while maintaining overall system thermal balance. The phase change materials are designed to absorb and release heat efficiently, preventing thermal runaway and fire hazards.

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Electric vehicle power supply layout to improve cooling and ripple current absorption. The power supply components like inverters are arranged in an alternating pattern of power cards and link capacitors along a main axis. This interleaving improves cooling by creating channels between the components for airflow. It also reduces ripple currents by absorbing them in the link capacitors and isolating them from the power cards.

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Off-road vehicle with integrated battery packs in the frame for improved weight distribution and torque transfer. The vehicle has multiple electric motors, one per wheel, and a structural battery assembly integrated into the middle frame section. This provides a centralized, protected battery location while connecting the front and rear sections. It allows the battery to support loads from all sections. The frame also has vertical members with integrated batteries at the front and rear. The integrated batteries simplify assembly by eliminating separate battery boxes.

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Detecting and adjusting film coating on battery cells to improve production quality and avoid issues like film damage during hot melt treatment. The method involves capturing images of the cell and end cover with film, measuring the gap between the film edge and cover edge, and checking if it meets a standard. If not, the film position is adjusted. This ensures proper film-cover separation for hot melt treatment.

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Battery pack design for electric vehicles that maximizes the number of cells while maintaining structural rigidity. The pack uses an integrated cross member system between adjacent battery modules instead of separate housings. The first cross member spans between modules in the width direction. The second cross member connects to the first one's upper end and spans between modules in the length direction. This prevents disconnection and improves rigidity compared to separate housings.

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Sealing method and apparatus for pouch-type secondary batteries to prevent electrolyte leakage from unsealed regions. The method involves moving the battery on a conveyor belt while heating and pressing the sealing portion between two elastic bands. This ensures complete sealing of the electrode lead/pouch junction without gaps. The heating and pressing steps are performed in sequence as the battery passes through the bands.

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Battery module design to optimize bus bar arrangement and increase spatial efficiency within the module case. The battery cells are laminated and accommodated in a posture with electrode leads protruding from opposite sides. The cells have a symmetrical structure where the lead positions don't change inverted views. This allows adjacent cells to be interleaved without complicating bus bar routing or increasing size. The close lead arrangement lets connecting the leads in series at one end of the stack.

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