Battery Cell Buffer Structure for Uniform Stack Pressure
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Solution Overview
Problem
Existing power supply devices for vehicles face issues with uneven stress distribution on secondary battery cells due to variations in height caused by expansion and contraction during charging and discharging, leading to potential deterioration and damage.
Innovation Solution
A power supply device with a buffer system comprising resin covers and flexible connecting parts that absorb height differences between battery cells, distributing stress uniformly across the cells using metal plates for reinforcement and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large-capacity buffer is disposed of in a vehicle, then the buffer occupies a large installation space, but the vehicle has limited space for installing the buffer
Solution Approach 1:
The buffer is disposed of inside the fuel tank, utilizing the existing fuel tank space. The buffer is positioned in the fuel tank such that it can receive excess fuel while the fuel tank maintains its normal fuel storage function. This nesting arrangement allows the buffer to be accommodated within the vehicle's existing fuel storage volume without requiring additional installation space.
Solution Approach 2:
The fuel tank serves multiple functions: it stores fuel for the engine and simultaneously houses the buffer for excess fuel management. The buffer system integrates with the fuel tank structure, allowing the fuel tank to function both as a fuel reservoir and as a containment structure for the buffer, thereby eliminating the need for separate dedicated buffer installation space.
2Quantity of substance
If the buffer is filled with fuel, then the buffer cannot receive more fuel, but the vehicle must maintain proper fuel levels for engine operation
Solution Approach 1:
The system employs a sensor that detects the fuel level in the buffer and provides feedback to the control unit. When the buffer reaches its maximum fuel level, the sensor signals the control unit to close the inlet valve, preventing further fuel inflow. This feedback mechanism ensures the buffer operates within safe limits while allowing maximum fuel storage capacity.
Solution Approach 2:
The buffer system dynamically adjusts its fuel reception capacity based on real-time fuel level conditions. The inlet valve transitions between open and closed states according to buffer fuel level, enabling the system to maximize fuel storage when capacity is available and prevent overflow when the buffer is full, thereby maintaining operational flexibility.
3Productivity
If the inlet valve is always open, then fuel can freely flow into the buffer, but fuel may overflow when the buffer is full
Solution Approach 1:
The control unit receives real-time feedback from the sensor monitoring buffer fuel level and automatically controls the inlet valve operation. When the buffer fuel level reaches the maximum threshold, the sensor triggers the control unit to close the inlet valve, preventing overflow. This automated feedback control ensures both efficient fuel transfer during normal operation and reliable overflow prevention when the buffer is full.
Solution Approach 2:
The system uses its own sensor and control unit to automatically monitor and regulate fuel inflow to the buffer. The inlet valve is controlled by the system's internal feedback mechanism rather than external intervention, enabling self-regulating fuel transfer that maintains both productivity and reliability without requiring additional safety systems.
Data Source
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AI summary
In order to distribute a stress applied to upper surfaces of secondary battery cells and protect them, power supply device (100) includes a plurality of secondary battery cells (1), a pair of end plates (20) that cover both end faces of battery stack (10) in which the plurality of secondary battery cells (1) are stacked, a plurality of fastening members (15) that fasten end plates (20) to each other, a plurality of pressing parts (15d) that press upper surfaces of the plurality of secondary battery cells (1) respectively, and buffer (30) interposed between pressing parts (15d) and the upper surfaces of secondary battery cells (1). Buffer (30) includes a plurality of covers made of resin, and a connecting part, having flexibility, for connecting two of the plurality of covers. Buffer (30) is configured such that each of the plurality of covers is disposed on the upper surface of corresponding one of secondary battery cells (1), and each of pressing part (15d) abuts on the upper surface of the corresponding cover.