Some suppliers of modular batteries About:Energy - www.aboutenergy.io BorgWarner +1 248 754 9200 www.borgwarner.com Hypercraft +1 801 317 8475 www.hypercraftusa.com IONETIC - www.ionetic.uk Kreisel Electric +43 7949 21400 www.kreiselelectric.com MEP Technologies +44 1382 492901 www.meptec.co.uk Ricardo +44 1273 455611 www.ricardo.com Turntide +44 191 497 9007 www.turntide.com Webasto +49 89 8 57 94 0 www.webasto.com along with functional redundancy for safety-critical applications. There is still room for better integration of BMSs into modules to minimise interfaces. Furthermore, a modern BMS should be capable of learning more about the state of the battery and cells in real time, enabling it to make predictions and derive immediate control measures to optimise the battery continuously. Coupled with physics-based models, increasingly sophisticated algorithms enable real-time data processing, predictive analytics and proactive management of battery conditions. These advancements are crucial in enhancing battery longevity, safety and performance. Integration of AI into BMS functions is particularly promising, allowing systems to predict failure modes, optimise charge cycles and adapt dynamically to changing operational demands. The inclusion of AI also supports functional redundancy; a critical safety requirement in automotive and highperformance applications. Because wireless communication simplifies system integration and improves reliability, its wider use within modular batteries and further development of the technology can be expected. Thermal management will remain foundational to modular battery design, with approaches ranging from basic passive to advanced active cooling. Direct immersion cooling is gaining traction for its ability to maintain consistent thermal conditions across cells, resulting in longer lifespans and improved energy density. By partially immersing cells in a thermally conductive fluid, these systems achieve efficient heat dissipation without significantly increasing weight or complexity. This is particularly beneficial in high duty-cycle applications, such as off-highway and industrial vehicles, where sustained thermal stability is paramount. A well-designed immersion cooling system can guarantee that cells operate consistently within their optimal temperature range, resulting in a longer lifespan of up to 60% compared with cooling-plate technologies in equivalent applications and conditions. Modular battery technologies are also leveraging advanced coolingplate designs. Individual plates for each module allow greater flexibility in cell arrangement and enable better customisation for specific vehicle architectures. This modular approach minimises thermal gradients within the pack, improving overall safety and performance. Some designs integrate cooling systems directly into the structural components of the module, combining mechanical stability with thermal management to streamline assembly and reduce material usage. Another advanced approach is the development of modules designed to support multiple cooling systems to allow more flexibility for customers, enabling the replacement or upgrade of subcomponents, such as cooling systems or control units, without requiring wholesale changes to the battery pack, supporting long-term cost-efficiency and sustainability. The inherent scalability of the modular approach facilitates easier adaptation to evolving cell chemistries and emerging technologies. For instance, solid-state batteries, which may require higher compression and more flexible designs, could benefit from the modular framework’s adaptability. Similarly, the trend towards larger-format cells, such as prismatic LFP designs, aligns with modular architectures that accommodate various cell types without significant redesigns. Engineers are exploring thinner and lighter materials for module construction, striving to improve volumetric energy density while maintaining structural integrity. Precision manufacturing techniques enhance production quality, reducing variability and optimising performance across modules. These incremental improvements collectively push the boundaries of what modular battery systems can achieve. Modular battery-pack development is a dynamic interplay of innovation, standardisation and practical engineering challenges. By balancing trade-offs in flexibility, energy density and cost, engineers can create solutions that meet the diverse needs of the EV industry while paving the way for future advancements in energy storage technology. Acknowledgements The author would like to thank the following for their help with this article: Kieran O’Regan, co-founder and chief growth officer at About:Energy; Dr. Martin Busche, vice-president, battery r&d, product strategy and programme management at BorgWarner; James Eaton, CEO and founder of IONETIC; Anna Stadler, manager, battery technology development at Kreisel Electric; Stuart Morrison, CTO and managing director at MEP Technologies; Dr Bahareh Yazdani Damavandi, technical authority head for batteries at Ricardo; Seth Yates, head of product for battery systems at Turntide; and Jörg Hornung, vice-president, business line thermo-management at Webasto. 73 E-Mobility Engineering | January/February 2025
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