Electric vehicle battery packs

Bold Valuable Tech may have formally materialized just about 3 years ago, but our ever-growing team has well over 10 years of experience in the world of electrification of vehicles spanning from F1 to hypercars to micro mobility.

We are an engineering services supplier for our trusted clients that hail from companies of 100 to 1,500 strong. Our multi-disciplinary team works tirelessly with conviction and determination of the potential advances to be made in battery packs for use in all types of vehicles as well as the structural advantages of lightweight structures for various applications. We have no barriers nor qualms: if it moves, we will take it on. If it involves technology to store and access energy safely and efficiently while reducing our carbon footprint, we will design, test and manufacture it – all in-house. Our company has one aim: to radically unleash electrification with highly optimized energy storage systems and light weight structures.

Helping our partners

While our range of high performing solutions give us great pride, discretion prevents us from making direct references to them. What we can share is how our solutions have contributed to the success of our clients’ projects. While Bold will remain faithfully discreet on the stupendous projects we participate in, it stands to reason that we are not in search of prestige or public accolade. We aim to continue creating first-rate technology for our valued partners which will eventually give way to exceptional products, higher efficiency, a lower impact on resources utilized and greater savings. Besides this, when we create a partnership, we essentially become additional teammates, working side by side until we are all satisfied with the outcome. Afterall, our clients’ success is our success.

Expertise

One common attribute among the hard-working professionals on the Bold team is that they are self-professed problem-solving addicts. They love a challenge and pushing beyond the invisible limits of technology today. One thing is for sure, Bold has built a team with extensive experience in thermal simulation programs. Take for example the project in which Bold developed a battery concept for a high-end motorsport electric series. The scope of work comprised the development of a battery, based on a pre-selected cell, to perform mechanical packaging and cooling system design. Multiple iterations are required to develop the cooling system for a battery pack. Even with large amounts of data from previous designs, there is no one-size-fits-all solution. Each pack is different. Simulation software offer the possibility to test and iterate a design numerous times before a pack is ready to be manufactured as a prototype.  

Two tools Bold uses are Simscale and Altair CFD for battery simulation. Specifically, the cooling system is where the thermal simulations were required. The difficulties in accurately predicting the thermal behavior and pumping losses in the cooling system were only possible to tackle using CFD tools. The main advantage we find in simulation is the speed at which we can try different ideas and design parameters. On top of that, the post processing tools allow us to understand the behavior of the system so our engineers can come up with improvements or discover issues before building prototypes. This translates to savings in time, money and resources that would have otherwise been wasted in the testing phase.

In another project, one of the biggest challenges in the process was to create a mesh for our models, a vital step in all CFD simulations and crucial for obtaining valid results. The size of some solid components was only 0,3 mm thick and there were a number of thin fluid channels. Our simulation know-how and experience are what led us to overcome these complex factors. It is not only important to evaluate the thermal stress, but also to perform a structural analysis. For this, we use Hypermesh with optistruct software which can simulate anisotropic materials, which is required for studying composite structures. Furthermore, it includes adequate failure criteria (Hill Tsai, Tsai-Wu, and Hashin) for post-processing analysis matrix and fibers of individual plies. 

Featured battery example

composite materials 1 large

Just to give an example of Bold’s capabilities, we would like to share some figures on a battery we have worked on to be used in the world of motorsport.  With the use of advanced materials, our team developed a battery that was 15% lighter than the original. The new battery Bold designed and tested had a specific energy at the module level of 205 Wh/kg and a specific peak power at module level at 2371 W/kg. The overall battery capacity was 42 kWh. Naturally, we reached these numbers working side by side with our partners by listening to their objectives and giving them valuable feedback. The result is a satisfied client with a powerful battery for their application. Do not let these numbers limit your imagination, there is no job too small nor too big. With Bold by your side, you can let innovation run free.

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