Battery Block Support Structure and Cascade Charging
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Solution Overview
Problem
The assembly and operation of rechargeable batteries face challenges such as electrode failures leading to high current density and heat generation, which can damage adjacent electrodes, and the inefficiency of charging processes that draw significant energy from the grid.
Innovation Solution
A support structure for assembling battery blocks, electronic switches or fuses to bypass failing electrodes, and a cascade charging system that utilizes energy from charged batteries to minimize grid power usage, along with a cooling system to protect adjacent cells from overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are assembled into battery blocks without support structures, then assembly complexity is reduced, but manufacturing precision and protection of battery cells deteriorate
Solution Approach 1:
A support structure serves as an intermediary component between the battery cells and the battery block housing. This support structure includes positioning features that precisely locate battery cells during assembly, ensuring correct orientation and spacing while protecting cells from damage during the assembly process.
Solution Approach 2:
The support structure is prepared in advance with pre-formed positioning features and protective elements before battery cells are assembled. This preliminary preparation ensures that when cells are installed, they are automatically positioned with high precision and protected from mechanical damage without requiring complex assembly operations.
2Reliability
If electronic switches or fuses are added to bypass failing electrodes, then reliability of battery blocks improves, but device complexity increases
Solution Approach 1:
The bypass functionality is extracted as a separate, optional feature that can be added only when needed. Electronic switches or fuses are incorporated into specific battery cells that require bypass capability, rather than adding this complexity to all cells. This allows the battery block to maintain high reliability through bypass protection in critical cells while keeping overall device complexity manageable.
3Loss of energy
If cascade charging system is used to charge batteries, then energy efficiency improves, but loss of time in charging process increases
Solution Approach 1:
The cascade charging system maintains continuous useful action by chaining multiple battery cells together in a sequence where each cell charges the next. Instead of charging all cells simultaneously from the grid (which would be faster but less efficient), the system continuously transfers energy through the chain, achieving high energy efficiency by minimizing grid power consumption while maintaining an ongoing charging process across all cells.
4Object-affected harmful factors
If cooling systems are added to protect adjacent battery cells from heat, then protection of battery cells improves, but device complexity increases
Solution Approach 1:
Cooling capability is applied locally only to areas where heat protection is most critical - specifically around battery cells that are adjacent to cells with bypass electronics or in high-density packing configurations. This localized approach provides necessary thermal protection to vulnerable areas while avoiding the added complexity and cost of cooling systems throughout the entire battery pack.
Data Source
AI summary
The assembly of battery cells, battery blocks and battery packs may benefit from a support structure for receiving and positioning battery cells, electronic switches and/or fuses that protect electrodes and/or battery cells or battery blocks from damage, a method for charging and discharging batteries that decreases the amount of energy needed from the power company and cooling system that directs the flow of a coolant to reduce damage from excessive heat.