Battery Pack Block Replacement With Refreshed Module Grouping

Solution Overview

Problem

Existing battery module replacement processes are complicated and costly due to the need to impart a memory effect to replacement battery modules, leading to potential erroneous replacements and increased costs, and voltage differences between modules with and without memory effect.

Innovation Solution

Replace battery blocks with pre-refreshed modules that do not have a memory effect, rearrange non-replacement blocks to minimize voltage differences, and use a control device to issue warnings based on threshold voltage differences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If memory effect is imparted to replacement battery modules in advance, then voltage characteristics uniformity is improved, but replacement process complexity and cost increase

Engineering Contradiction:

Improvevoltage characteristics uniformityVSAvoidreplacement process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by refreshing replacement battery blocks before installation to a predetermined charge state, which eliminates the need for complex memory effect imparting procedures during replacement while ensuring voltage characteristics uniformity between replacement and non-replacement blocks

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If replacement battery modules are installed without memory effect, then replacement process is simplified, but voltage difference between adjacent modules increases causing erroneous replacement determination

Engineering Contradiction:

Improvereplacement process simplicityVSAvoidreplacement determination accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent applies preliminary action by refreshing replacement battery blocks before installation to a predetermined charge state, which eliminates the need for complex memory effect imparting procedures during replacement while ensuring voltage characteristics uniformity between replacement and non-replacement blocks

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If battery blocks are replaced without refreshing, then replacement work is simplified, but voltage difference causes erroneous determination of needed replacement

Engineering Contradiction:

Improvereplacement work easeVSAvoidreplacement determination accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent applies preliminary action by refreshing replacement battery blocks before installation to a predetermined charge state, which eliminates the need for complex memory effect imparting procedures during replacement while ensuring voltage characteristics uniformity between replacement and non-replacement blocks

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12476320B2Battery pack, vehicle equipped with battery pack, and replacement method of battery blocks in battery pack

Publication Date: 2025.11.18 TOYOTA JIDOSHA KK

AI summary

A battery pack according to the present disclosure includes a plurality of battery blocks, the battery blocks being arrayed adjacent to each other in a stacking direction that is set in advance. After two or more of the battery blocks are replaced with multiple replacement battery blocks that have been refreshed in advance, multiple non-replacement battery blocks, among the battery blocks, that have not been replaced with the replacement battery blocks, are adjacent to each other in the stacking direction, and the replacement battery blocks are adjacent to each other in the stacking direction.