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High-Performance 48V Battery Module Design

[Category : - ELECTRICITY & LIGHTING]
[Viewed 79 times]

The invention relates to a new type of battery module structure design, which uses multi-layer silicon capacitors containing integrated micro-battery materials to enhance the stability and energy density of the battery system. The battery module is composed of multiple layers of 21700 cells. Each layer is equipped with silicon capacitors and integrated micro-batteries, and redundant silicon capacitors are added to it. When the performance of some cells declines, it can automatically intervene to maintain stable overall performance. In addition, the battery module is equipped with multi-layer thermal conductive sheets to improve heat dissipation efficiency, especially during high-rate charging, which can effectively control the battery temperature and extend battery life. The design is suitable for various electric vehicles and renewable energy storage systems, with better charging efficiency and longer service life.

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The global transition toward electrification, driven by carbon-reduction policies, rising fossil fuel costs, and urban mobility demand, has accelerated the adoption of electric vehicles (EVs), electric motorcycles, and distributed energy storage systems. Battery performance—particularly fast-charging capability, cycle life, thermal stability, and safety—has become a critical economic differentiator rather than a purely technical parameter.

Conventional lithium-ion battery modules based solely on 18650 or 21700 cells face increasing total cost of ownership (TCO) pressures due to capacity degradation under high-rate charging, thermal management complexity, and shortened service life. These issues translate into higher replacement frequency, increased warranty costs, and reduced consumer confidence, especially in applications such as electric motorcycles, fleet vehicles, and high-utilization energy storage systems.

The proposed battery module integrating silicon capacitors with embedded micro-batteries addresses these economic challenges by introducing localized energy buffering, redundancy, and improved thermal control. By reducing peak current stress on primary cells and stabilizing operation during high-C charging, the system extends effective battery lifespan and maintains usable capacity over a higher number of cycles. This directly lowers lifecycle costs for manufacturers, operators, and end users.

From a manufacturing and market perspective, the design leverages existing 21700 cell supply chains while adding value through modular silicon-based components, avoiding the need for entirely new cell chemistries or large-scale production line replacement. This enables faster commercialization, controlled cost increments, and scalable deployment across multiple product tiers—from electric motorcycles to stationary energy storage.

Overall, the invention aligns with current economic trends emphasizing longer service life, fast-charge compatibility, safety, and cost efficiency, positioning it as a commercially viable solution in a rapidly expanding global electrification market.

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polochung (Taiwan)

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