Process

Battery Module Development Process

This section provides an overview of the battery module development lifecycle, from initial concept and requirements gathering to design freeze and readiness for manufacturing. It emphasizes the multidisciplinary nature of module engineering, involving electrical, mechanical, thermal, and safety considerations. The goal is to design a module that meets performance, cost, reliability, safety, and manufacturability targets.

Info Current and Verified

Updated 06/2025

1 Cell Selection

The early battery module design phase begins with selecting the right cell format (pouch, prismatic, cylindrical) and chemistry (NMC, LFP, NCA) based on performance, cost, and availability. Next, the series-parallel configuration is defined, shaping voltage, capacity, size, and system complexity.

Content:

1.1 Battery Cell Selection

1.2 Battery Module Configuration

2 Mechanical Design

This design phase defines the battery module’s mechanical structure—ensuring cell protection, structural integrity, and ease of assembly. Key outputs include the enclosure design, cell retention, BoM, and detailed manufacturing and assembly documentation.

2.5 Burst Disc & Pressure Relief

2.6 Compliance

3 Busbar & Electrical Design

This stage designs the module’s electrical architecture—cell interconnects, connectors, CSC integration, and LV harnesses—to ensure safe current flow, accurate monitoring, and reliable external connections, while meeting electrical safety standards for creepage and clearance.

Content:

3.1 Cell-to-Cell Interconnects

3.2 Power & Signal Connectors

3.3 CSC Integration

3.4 Low-Voltage Harness

3.5 Electrical Simulation

4 Thermal Management

This stage focuses on thermal management to keep cells within safe operating temperatures, ensuring performance, safety, and longevity. It includes selecting TR-resistant materials, planning cell venting, designing cooling/heating systems, and optimizing thermal interfaces.

Content:

4.1 Module Cooling/Heating

4.2 Thermal Runaway

4.3 Cell Venting

5 Safety & Validation Testing

This stage tests prototype and pre-production modules to confirm performance, reliability, and safety. Validation ensures design meets requirements; safety testing exposes modules to abuse to confirm safe behavior. Both physical tests and simulations are used to predict real-world performance.