Modular Architecture in EV Battery Systems

Modular battery system for electric vehicles with customizable voltage and capacity to match requirements of various vehicle types like construction machines. The system uses a scalable modular design with identical base modules connected in different configurations. Each module contains multiple cells with a nominal voltage and capacity. The configurations have varying numbers of modules connected in parallel strings. A balancing control unit per string ensures cell balance within each string. Additional balancing between strings ensures overall pack balance. This allows creating customized packs with desired voltage and capacity by selecting the appropriate module and string configurations.

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Multilevel battery arrangement for electric vehicles that improves thermal management and allows higher charging rates compared to traditional battery packs. The arrangement involves placing a base battery module in the vehicle's existing battery tray and adding additional modules at separate locations. This breaks the close packing constraint of traditional battery packs. The modules share a common cooling system with a phase change material (PCM) in thermal contact with the cells. This allows faster heat dissipation during charging compared to air or fluid cooling. A cold plate at the base module removes heat while the PCM is below its phase change temperature. This stabilizes cell temperatures during charging.

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Liquid-cooled battery module that allows independent output of the battery packs inside. The module has a liquid-cooled plate on the bottom, front and rear output components, and an outer box shell with reinforcements. This enables each battery pack to be connected externally through the front output, while the rear output connects internally to the packs. The module can be series connected using a row of optimizers or a series connection, allowing independent control and charging of each pack.

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A vehicle battery system with parallel connected high-voltage modules to enable fast charging and discharging without overheating. The system uses multiple parallel-connected battery modules, each with a rated voltage over 200V, to distribute the load and current. The modules have independent balancing, charging, and thermal management. This avoids the need for a central control BMS and large currents through it. The modules balance voltages, actively balance cells, and manage temperatures separately.

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Battery design for electric vehicles that allows efficient temperature control without wasting battery charge. The battery has two storage modules, one primary and one secondary. In normal operation, the primary module is charged by the vehicle's onboard electrical system. When parked, the secondary module can charge the primary module to provide a full charge for driving. This allows using the secondary module as a portable charger without decoupling. The secondary module has its own temperature control branch to maintain temperature when decoupled. This prevents wasting battery charge on temperature control when parked. The primary module can be smaller since the secondary provides backup charging. The compact size reduces weight and volume compared to separate modules.

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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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Power battery system for electric vehicles that integrates the battery management and power distribution components to reduce weight and cost compared to traditional dispersed layouts. The battery system has an energy management unit with a power supply, control, and power distribution device. The power battery unit contains the energy storage device, thermal management, and sampling device. The power distribution device connects between the battery and vehicle bus, controlled by the management unit. This integrates high-voltage components into the battery pack, reduces harnesses, and simplifies maintenance compared to dispersed layouts.

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Large battery systems with multiple battery packs for powering devices like electric vehicles and energy storage systems. The system allows balancing and managing the packs to prevent issues like inrush currents when connecting packs with different states of charge. The balancing involves dynamically selecting packs to charge or discharge based on their SOC. This prevents large SOC differences between packs that can damage cells. The packs communicate and a master pack coordinates balancing. If a pack fails, it can be isolated without shutting down the whole system. This enables safe and efficient operation of large battery pack systems with multiple packs.

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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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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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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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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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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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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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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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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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Battery system for electric vehicles that improves life and capacity by using a combination of battery modules with and without internal power electronics. The system has a mix of high-energy and high-power cells. The high-energy modules are directly connected in series, while the high-power modules have internal DCDC converters to balance voltage. This allows optimizing module design for energy vs power. A smart battery management system coordinates cell balancing and converter switching for optimal performance. The converters can also bypass to isolate modules.

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Battery design with integrated cooling and modular reconfigurability to improve thermal management and allow reconfiguration of battery packs. The battery module contains battery cells, an electronics unit with power electronics, and a ribbed cooler with coolant channels. The cells are sandwiched between cooling fins to distribute heat. The electronics are positioned near one side of the base plate with fins between. Multiple modules can be interconnected for packs. The modular reconfigurability allows scaling, replacing failed modules, and customizing pack sizes. The integrated cooling with multiple paths reduces hotspots and overloading.

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