Modular Architecture in EV Battery Systems

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

Source

Battery pack design for electric vehicles that improves energy density, mechanical rigidity, and space utilization compared to conventional packs. The pack has a unique arrangement of battery modules inside a case. Each module has battery cells arranged in one direction, enclosed in a case with beams between the cells. The modules are fixed to the cover of the pack instead of a separate tray. This eliminates gaps, beams, and covers inside the pack. Cooling is integrated into the module base plate. The pack cover has a water channel to circulate cooling fluid around the modules. This reduces heat transfer path, parts, and space compared to separate heatsinks.

Source

Modular system and method to produce customized housing elements for vehicle battery packs. The system allows creating different battery pack housings for vehicles with varying needs by using specific reinforcing elements. The housing itself is a universal part. For each variant, the housing is reinforced with a variant-specific element. This avoids unnecessary reinforcement in variants that don't need it. The reinforcing elements have unique perforation patterns to tailor the material properties for specific load scenarios. The housing is formed separately and then reinforced for each variant.

Source

Enabling efficient and convenient battery swapping for electric vehicles to enable longer range and faster charging compared to battery charging. The method involves using vehicles themselves to transfer batteries between each other in a peer-to-peer fashion. When a vehicle's battery needs charging, it finds another nearby vehicle with a fully charged battery using onboard sensors and communication. The vehicles then physically connect and swap batteries. This allows a vehicle to quickly obtain a fully charged battery instead of waiting for its own battery to charge. The swapped battery can then be returned to the original vehicle for future use. This peer-to-peer battery swapping leverages the mobility of vehicles themselves to facilitate rapid and convenient battery swapping.

Source

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.

Source

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.

Source

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.

Source

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.

Source

Electric vehicle with detachable battery pack that can be easily removed for charging or used as a portable power source. The vehicle has a detachable power supply device that includes a charger and a battery pack. The charger has a power interface to connect to external power, a charging portion to connect to the battery pack, and an output part to provide power to the vehicle. The battery pack can be inserted into the charger for charging, or removed for use as a portable power source. This allows the user to charge the battery separately from the vehicle, or use the battery as a backup power source for other tools. The detachable battery pack also allows compact vehicle design as the battery doesn't need to be integrated into the vehicle body.

Source

A movable battery system for electric vehicles that enables independent charging, discharging, and thermal management of auxiliary batteries. The system comprises a separate battery pack mounted on the auxiliary vehicle, with its own cooling system and power management components. A thermal management module and power conversion module are integrated into the main vehicle's battery pack, while the auxiliary vehicle's battery has its own cooling system and thermal management components. The system allows the auxiliary vehicle's battery to be charged and discharged independently of the main vehicle's battery, with its own cooling and thermal management systems.

Source

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.

Source

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.

Source

Autonomous transportation system with a battery management system that enables efficient battery replacement. The system features a detachable battery unit with a guided rail that moves between the transportation unit and charging station, allowing for seamless battery transfer. The rail's movement enables both charging and battery replacement in a single operation, with the transportation unit automatically moving between charging and battery storage positions.

Source

Stackable battery modules for electric vehicles that can be joined together without fasteners or tools to form a stack, and that provide cooling without additional seals. The modules have interlocking features on their housings to center and secure the stack. The housing has a tongue and groove connection that engages with a corresponding feature on another module to create a cooling channel between them. The modules are inserted into a housing that seals against coolant loss. This allows coolant to flow through the channels between modules without needing separate seals.

Source

Electric vehicle structure that increases range by maximizing battery capacity while minimizing weight and maintaining crashworthiness. The structure uses integrated battery modules and cross members to pack more batteries without adding much body weight. The design involves side sills, a floor panel, a battery tray, an integrated-battery front cross member, and a dash cross member. The integrated-battery front cross member connects the battery tray and front of the floor panel to form a continuous frame. This allows stacking more batteries in the tray without increasing body weight. The dash cross member connects the floor and front of the integrated-battery member. This provides crash protection while enabling more batteries in the front. The integrated battery frame and cross members distribute forces to the body and side sills, allowing more battery capacity.

Source

Battery module and pack design to improve safety by efficiently dissipating heat and smoke during cell runaway. The module has a compact enclosure with channels and holes to route smoke and heat out. The top cover has holes for smoke venting. The sidewalls have channels to guide smoke to end plates with holes for further venting. This allows smoke to escape quickly from the enclosure when a cell runs away, preventing spread to other cells. The enclosure geometry and venting configuration allows effective smoke and heat dissipation in compact modules with limited lateral and vertical space.

Source

Battery packs for metal-air batteries that enable higher voltage and capacity through dynamic switching between series and parallel configurations. The pack comprises air channels, electrolyte channels, and electronic circuitry to manage the battery cells. The circuitry dynamically switches between series and parallel connections for the individual cells, enabling voltage increases while maintaining capacity. The pack also incorporates air intake and output systems to maintain ambient oxygen levels. This configuration allows for battery packs with multiple voltage levels, enabling applications beyond simple battery packs.

Source

Off-road vehicle with integrated battery pack in the frame to provide a low center of gravity and simplify manufacturing. The vehicle has electric motors on the front and rear wheels, with separate final drive units for each wheel. The battery pack is mounted in the middle frame section to connect the front and rear sections. This provides a structural battery assembly that supports loads from the front, rear, and middle sections. It also allows the driveshaft to pass through the battery pack. The integrated battery reduces weight compared to separate batteries and improves handling by lowering the vehicle's center of gravity.

Source

An energy storage device with modular design and removable components for easy maintenance and space efficiency. The device has two detachable end covers, a box body, battery module, and battery management system. The battery module contains multiple battery groups removable through openings in the end covers. The battery management system is also removable. This allows service access without disassembling the whole device. The modular design enables customization of capacity by adding/removing modules. The device can also be mounted on walls.

Source

A layout for an electrical power supply system in a vehicle that increases battery capacity without taking up more space inside the vehicle. The layout involves having separate battery housings, one on each side of the vehicle, that partially overlap. This allows multiple battery modules in each housing to be arranged in groups. By having separate housings that can be spaced apart, it's possible to fit more battery capacity compared to if all the batteries had to be inside the main vehicle body.

Source