Modular Design for Efficient EV Battery Systems

A modular battery system for electric vehicles that provides efficient cooling and assembly of cylindrical battery cells. The system uses pairs of receptacles to hold cylindrical battery cells, with the cells connected in series. The system has adhesive blobs or protrusions to fix the cell orientation and allow heat dissipation from one end. Multiple of these battery units can be combined into modules, with cooling plates and a battery management system. These modules can then be combined into a full battery system.

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Modular EV battery system that allows easy repair and replacement of individual battery modules to reduce costs and enable efficient storage and serviceability. The battery system consists of removable carriers that each house battery cells and can be detached individually from a frame. The carriers interconnect electrically and mechanically, and also form a cooling channel when connected, thus creating a modular battery system that can be disassembled and reassembled at the carrier level.

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Battery submodule carrier for lithium-ion battery packs that provides mechanical stability, cooling, and modularity to simplify battery assembly and cell replacement. The carrier includes trays with cell retainers to hold aligned battery cells. The trays stack vertically within a larger carrier frame. The frame has cooling channels to cool the cells. Tray fasteners attach the trays to the frame. This modular design allows easy replacement of individual cells and provides structural integrity and cooling to the battery pack.

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Battery module for electric vehicles that allows rapid battery cell replacement. The module has multiple battery cells each with an electronic monitoring module. The monitoring modules connect via a balancing bus to balance cells. The cells plug into a carrier with contacts. The carrier also has an energy storage module. This allows swapping cells without tools, prevents fixed connections, and enables fast cell balancing.

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Modular vehicle powertrain with electrically isolated parallel systems that can be apportioned optimally by a control system to maximize efficiency, durability, drivability, and performance. The modular powertrain has multiple parallel systems with motors and power sources that can be individually controlled to distribute power based on system states to meet torque demands. The control system can request different torque amounts, percentages of total power, or equalize power draw between modules. The apportioning allows driving optimization and battery management across modules.

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Battery module design that enables scalable battery packs for electric vehicles. The battery module consists of removable cassettes containing battery cells that can be connected to each other in parallel to form bricks. The bricks are then connected in series using collection plates to form the battery module. By adding or removing cassettes, the module voltage and capacity can be scaled independently, allowing flexible customization of battery packs.

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Scalable and reconfigurable battery system for heavy duty electric vehicles used in mining. The modular battery system allows easy replacement of individual battery modules without disassembling the entire battery pack. The modules are coupled together end-to-end using conical positive and negative terminals, which can be quickly uncoupled to remove or add modules. The battery system also uses a track system to slide modules in and out for replacement. This allows fast and efficient swapping of modules to maintain peak performance and extend overall battery life.

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Scalable and versatile battery module design for electric vehicles that allows easy customization and adaptation to different vehicle types. The battery module contains a casing with connectors and removable sub-modules each containing multiple battery cells. The modules can be connected together to form a scalable battery system.

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Modular battery system for electric vehicles that allows customizable battery capacity and standardized battery pack interchangeability. The modular battery packs can be quickly attached/detached to/from the vehicle chassis and to adjacent packs. The packs contain electrical storage devices interconnected in parallel. The ability to add/remove packs allows customization of vehicle range. The standardized pack connectors enable battery swapping infrastructure compatibility.

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Battery pack case for electric vehicles that allows easier and cheaper replacement of worn or damaged parts. The case uses a bolt and nut coupling instead of welding. The bolt attaches to the vehicle frame, with a first nut tightening onto it and a second nut tightening onto the first nut. This provides a secure connection without welding. When the battery pack is repeatedly attached and detached, only the nuts may wear out or get damaged. By avoiding welding, these nuts can be easily replaced instead of the entire frame, reducing maintenance cost.

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A battery module design and system to track, control, and recover removable vehicle battery modules. The design has an authentication controller that checks if module use is authorized. It also has unique IDs to track modules and deter theft. The modules can transition between programmed states based on secure communication with the controller. Stolen modules can be reported as such to mark them as unauthorized. The module design facilitates tracking module use and assists in locating and recovering stolen ones.

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Recyclable battery pack assembly for electric vehicles that enables easy disassembly and reuse of battery cells. The battery pack consists of two holding frames that clamp the cells together using fasteners. The cell terminals are pressed against conductive plates. Removing the fasteners allows the cells to be freed from the assembly.

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A vehicle battery pack for electric vehicles with multiple service doors enabling selective access to the battery pack components without removing it from the vehicle. The battery pack has a cover with two or more hinged access doors. Rectangular service lids can be attached to the cover over the access doors. This allows opening specific doors to reach components like battery modules, management systems, etc. by removing only corresponding lids. The overall battery pack remains sealed for protection while enabling targeted servicing through the access doors.

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Secondary battery module with an easily exchangeable battery pack for electric vehicles. The battery module has a case containing multiple battery cells and a label attached to the case. The label serves as a handle for removing and installing the battery module. This allows easy battery swaps without needing a separate handle component.

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Battery pack for energy storage systems that can be easily installed, carried, replaced, and maintained. The battery pack is made up of multiple battery modules that each have at least one battery cell. The modules are covered by an enclosure with a battery management system (BMS) integrated into it. This allows the pack to be easily handled as a single unit during installation and maintenance, rather than having to handle each individual module. It also enables easy module replacement when needed.

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A secondary battery module that can be easily exchanged in a convenient and easy way. The module has a case to hold the battery cells and a label attached to the case that serves as a handle.

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Battery design that improves thermal management, ease of assembly and reduces cost while improving energy density in cylindrical cells. The battery uses a riveted pole that penetrates the cover plate to connect to the cell. The riveted pole allows cell connection without separate terminals, enabling flexible cell polarity arrangement during assembly. It also improves heat dissipation compared to traditional tabs. The riveted pole reduces complexity, parts count and cost while increasing energy density.

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Battery pack design with an internal channel for securing sensing wires between battery cells. The battery pack has a frame with pillars and bent extensions that create spaces for the sensing wires. The wires can be easily inserted and held in place by the frame without needing adhesive. This simplifies wire installation compared to using tape or adhesive to secure them.

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Battery cell with simplified assembly for reducing battery manufacturing complexity. The battery cell has an integral housing with an opening, an electrode assembly with a protruding tab, and a pole. The housing has two opposite side walls enclosing a cavity. The electrode assembly is placed in the cavity with the pole on one side wall connected to the tab. An adapter with separate pieces connects the pole and tab. This allows separately connecting the adapter pieces before placement in the housing.

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Simplified design of a battery cell, adapter component and manufacturing process to simplify battery assembly. The design uses an adapter component that has separate pieces to connect the electrode post and tab, instead of a single integrated adapter. This allows the electrode assembly to be loaded into the housing before connecting the adapter pieces. The housing also has openings on opposite sides so the electrode assembly can be inserted straight through.

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The high voltage battery for electric vehicles simplifies battery assembly and reduces components compared to conventional batteries. This is done by using plates that are folded together to form cell insertion spaces. Bus bars are inserted between the plates to connect the cell taps. Joining bars and a presser hold the plates together. This allows cells of different shapes to be inserted and connected without welding.

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A battery casing design that improves the sealing between case halves to prevent leaks. The design uses a groove in the first case half filled with sealant. When the second case half covers the opening, a protruding joint part inserts into the groove and embeds in the sealant. This securely connects and seals the case halves. Adding a holder inside the first case half reinforces it and prevents battery movement. This improves sealing by avoiding direct contact between the sealant and case body, and provides a stable interface that resists vibration.

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A battery module formed from wound or stacked battery cells that are contained in a common housing. The battery cells have electrodes that are stacked or wound and the cells are arranged in the housing with the cell connectors accessible within the housing. Current-collecting rails extend into the housing to contact the cell connectors. This allows the cells to be connected without separate connecting links or welding. The common housing can have separating walls to isolate the cells if desired.

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Battery module design that allows easy and secure fixation of battery cells within a housing. The module uses spacers between cells with upper flanges that have holding grooves. The top plate has holding members that fit into the groove to prevent cell separation. The housing has bending portions with grooves that mate with protrusions on the end plates to apply constant pressure to cells. This prevents cell movement and distortion even if they swell.

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Battery module formed from a number of wound or stacked battery cells contained in a common housing. The battery module has current-collecting rails that extend through the housing and make contact with the battery cell connectors. This allows the battery cells to be easily connected without additional linking components.

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