Dr. John Naylor

Dr. John Naylor

Dr. John Naylor is a Battery Pack & Energy Storage Systems Engineer specialising in pack architecture and system integration. His work covers enclosure and IP design, vibration resistance, series-parallel configuration, busbar design, UPS systems, portable power stations, and solar energy storage applications.

Laminated Busbar Design for PCS Sub-Modules: Stray Inductance Optimization and Supplier Qualification

TL;DR Switching from a 3-layer to a 2-layer laminated busbar structure with centered IGBT placement and longitudinally arranged capacitor terminals reduces stray inductance by 29% — from 18.23 nH down to 13 nH — in energy storage PCS sub-modules. For…

Read article →Laminated Busbar Design for PCS Sub-Modules: Stray Inductance Optimization and Supplier Qualification

Serpentine Liquid Cooling Channel Orientation for LiFePO₄ Battery Packs: Transverse vs. Longitudinal Performance Trade-offs

TL;DR Longitudinal serpentine liquid cooling channels deliver 0.093 °C better peak temperature control than transverse layouts in LiFePO₄ storage packs, but incur 0.683 Pa higher pressure drop and 122 mm longer flow path. Buyers sourcing packs for high-duty-cycle stationary storage…

Read article →Serpentine Liquid Cooling Channel Orientation for LiFePO₄ Battery Packs: Transverse vs. Longitudinal Performance Trade-offs

1500V Battery Pack Enclosure Insulation: Field Intensity Data, Material Selection, and Supplier Qualification

TL;DR At DC 1500V system voltage, electric field simulation confirms the cell bottom-corner as the weakest insulation point, with a calculated peak field intensity of 6.75 kV/mm against a withstand test voltage of only 5.37 kV — a margin that…

Read article →1500V Battery Pack Enclosure Insulation: Field Intensity Data, Material Selection, and Supplier Qualification

BESS Enclosure Structural Integrity: Tri-Axial Vibration Stress Analysis and Supplier Qualification Guide

TL;DR Under Z-axis vibration loading at 100 Hz, FEA simulation of a 300 kg battery module assembly recorded a peak stress response of 209 MPa — concentrated at the junction between stiffener ribs and fixed beams, well into plastic deformation…

Read article →BESS Enclosure Structural Integrity: Tri-Axial Vibration Stress Analysis and Supplier Qualification Guide

Solar Generator Storage Sizing: Dispatch Optimization and Capacity Specification for Residential BESS

TL;DR A grid-connected residential solar-plus-storage system with a 24 kWh battery bank and PV array achieves a system utilization rate of 88% — versus 70% for PV-only configurations — directly reducing long-term operating costs through optimized charge/discharge scheduling against real-time…

Read article →Solar Generator Storage Sizing: Dispatch Optimization and Capacity Specification for Residential BESS

Harmonic Plate Air-Cooling for 280 Ah LFP Packs: Thermal Uniformity Data for Procurement Teams

TL;DR Maximum temperature differential of just 3.2°C across a 280 Ah battery pack at 1.5C discharge—with peak temperature held to 42.26°C—demonstrates that harmonic plate air-cooling geometry directly solves the thermal uniformity problem that trips up large-format energy storage deployments. For…

Read article →Harmonic Plate Air-Cooling for 280 Ah LFP Packs: Thermal Uniformity Data for Procurement Teams

CFD-Validated Immersion Cooling Design for 280 Ah Battery Cabinets: Cell Spacing, Port Geometry, and Dielectric Fluid Selection

TL;DR Computational fluid dynamics analysis of 280 Ah battery modules in immersion cooling systems reveals that 5 mm cell spacing reduces peak temperature differential by 1.57°C versus direct contact, while deionized water coolant outperforms silicone oil by 5.99°C in maximum…

Read article →CFD-Validated Immersion Cooling Design for 280 Ah Battery Cabinets: Cell Spacing, Port Geometry, and Dielectric Fluid Selection

Aluminum Busbar Laser Welding: Process Parameters, Tensile Strength, and Supplier Qualification for Energy Storage Modules

TL;DR Annular dual-beam laser welding of 1060 aluminum busbars achieves optimal tensile strength at a precise parameter window: 80/20 inner-to-outer energy ratio, 4,000 W total power, 80 mm/s welding speed, and 0 mm defocus — validated across 10,000+ production modules…

Read article →Aluminum Busbar Laser Welding: Process Parameters, Tensile Strength, and Supplier Qualification for Energy Storage Modules

Immersion Cooling for Battery ESS: Oil-Based Dielectric Fluid Specification, Material Compatibility, and Thermal Runaway Test Data

TL;DR Immersion cooling in oil-based dielectric fluid reduced battery surface temperature during nail penetration from above 400°C to 280°C while keeping coolant bulk temperature at just 48°C — a thermal containment result that air-cooled and cold-plate systems cannot match. For…

Read article →Immersion Cooling for Battery ESS: Oil-Based Dielectric Fluid Specification, Material Compatibility, and Thermal Runaway Test Data

LFP Battery Module Swelling Force: Lifecycle Data, Peak Inversion, and Structural Design Limits for 280 Ah Prismatic Cells

TL;DR In a constrained-condition lifecycle test of 280 Ah LFP modules, swelling force at the 30% SOC charge peak overtakes the 100% SOC peak as the dominant structural load once SOH drops below ~94%, and a 1P12S module reaches 2365…

Read article →LFP Battery Module Swelling Force: Lifecycle Data, Peak Inversion, and Structural Design Limits for 280 Ah Prismatic Cells