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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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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Secondary battery with integrated safety vent mechanism that enables repeated use of the battery's venting system. The battery features a case with an open side and a cap plate with a vent hole. A safety vent is positioned on the cap plate, comprising multiple layers that can be magnetically controlled to seal or open the vent. This design allows the battery to be charged and discharged multiple times while maintaining its venting capabilities. The safety vent's magnetic biasing system enables precise control over venting behavior, ensuring safe operation even after multiple charge cycles.

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An assembled battery design that prevents state-of-charge (SOC) variations during charging by optimizing electrode positioning. The battery comprises stacked cells connected in series, where the negative-electrode composite layer is positioned above the positive-electrode active material layer. By maintaining the negative-electrode layer above the positive-electrode layer, the battery achieves improved state-of-charge uniformity during charging by minimizing electrode contact resistance. This design addresses the conventional issue of SOC variations in series-connected batteries by ensuring the negative-electrode layer remains above the positive-electrode layer during charging.

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Roll forming a battery pack frame using high-strength steel strips that are roll formed into cavities on the sides and a bottom plate. The cavities are connected to form the longitudinal beams and transverse beams of the frame. This integrated roll formed frame eliminates the need for multiple welded parts and improves dimensional accuracy compared to traditional frame fabrication methods.

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Layout of a battery system in an electric vehicle to increase storage capacity without sacrificing space inside the main cabin. The vehicle has two battery housings, one on each side of the vehicle, that overlap and are offset in the front-rear direction. This allows more batteries to be housed outside the cabin compared to just having a single battery pack under the seat. It also provides some visual benefits by improving forward visibility for the driver due to the front-rear offset and angled upper housing.

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A busbar assembly for connecting cells in battery modules that improves stability, reduces breakage, and allows flexible cell arrangement. The busbar has multiple interconnected sheets with curved positive connections that match cell electrode post shapes. The negative connections are wider to bear pressure and prevent breakage. The sheets connect series cells in one direction and parallel cells in another. This allows flexible cell arrangements like herringbone stacks. The curved positive connections improve stability, wider negatives prevent breakage, and the sheet interconnections allow flexible cell arrangements.

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Energy storage cell design to prevent thermal runaway propagation between cells in high-density batteries like lithium-ion. The cell has an electrode/separator assembly inside a housing with a covering made of porous material between the assembly and housing. The porous covering allows heat transfer between the hotter assembly and cooler housing walls. It prevents insulating layers from trapping heat and stops excessive temperatures in one cell from spreading to others.

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An anti-deflection spring structure for battery compartments that prevents tilting and deflection during compression. The spring has a support ring, a bent connecting segment, and a supporting spring. The bent segment connects to the supporting spring at one end and bends towards the support ring at the other end. This configuration aligns the ends of the support ring on a common plane, preventing tilting.

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A busbar design for battery modules that improves fuse reliability and reduces deformation during operation. The busbar integrates battery cells and has a voltage sense harness (VSH) component electrically connected to it. The busbar connection bars have insulation covering both sides. The VSH component has a first circuit board with insulation covering both sides. Fuses are added to connect the VSH lines to the busbar bars. The fuses are located outside the insulation layers and have welding pads at matching windows. This prevents fuse deformation during operation since they are not inside the battery cell stack.

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Battery pack design with improved cooling to prevent overheating and degradation of the battery cells. The pack has a heat pipe adjacent to each cell that absorbs and conducts the cell's heat. A cooling device circulates a fluid through the heat pipe to extract the heat. The heat pipe has a chamber with wick structure and pillars. The chamber is partitioned into multiple sections with different numbers of pillars adjacent to the cell versus the other sections. This allows preferential flow of fluid through the section closest to the hot cell, enhancing heat transfer.

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