Battery Pack Cell Replacement Layout for Heat and Wall Stress
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Solution Overview
Problem
Conventional methods for replacing anomalous batteries in assembled batteries do not optimize the properties of the assembled battery post-replacement and can lead to degradation of the battery container's strength, particularly at the ends, due to improper placement of new batteries in high-temperature regions.
Innovation Solution
A method for replacing unsatisfactory rechargeable batteries by removing them from the ends of the assembled battery and installing satisfactory batteries with minimal deterioration, ensuring proper temperature distribution and reducing stress on the battery container walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If new batteries are installed in the central high-temperature region to replace anomalous batteries, then the capacity difference between batteries is reduced and assembly battery performance is optimized, but the battery container wall strength at the ends deteriorates due to increased stress concentration
Solution Approach 1:
The patent applies local quality by differentiating the placement strategy for new batteries based on their position in the assembly. New batteries are specifically placed at the end positions rather than uniformly distributed, creating a non-uniform arrangement that addresses the local stress concentration issue at the ends while maintaining overall assembly performance.
Solution Approach 2:
The patent inverts the conventional replacement strategy by placing new batteries at the ends rather than in the central high-temperature region. This inversion resolves the strength issue by preventing further stress concentration at the ends, while the removed anomalous batteries from the central region allow for potential optimization of the remaining battery arrangement.
2Productivity
If anomalous batteries are replaced following conventional methods without considering position optimization, then replacement speed is maintained, but the assembled battery properties are not optimized and variations in battery properties increase
Solution Approach 1:
The patent applies preliminary action by pre-determining the optimal placement positions for new batteries (specifically at the ends) before the actual replacement occurs. This planning step ensures that when replacement happens, the new batteries are immediately positioned to optimize assembly properties, achieving both speed and optimization without requiring post-replacement adjustments.
3Device complexity
If batteries are arranged without considering temperature distribution, then the replacement process is simplified, but the capacity difference between batteries increases and assembly battery performance deteriorates
Solution Approach 1:
The patent applies local quality by recognizing that different positions in the battery assembly have different thermal characteristics and performance requirements. By placing new batteries specifically at the end positions, the patent creates a differentiated arrangement that accounts for local temperature distribution patterns, thereby maintaining capacity consistency without requiring complex real-time temperature monitoring during replacement.
Data Source
AI summary
A method is for replacing a rechargeable battery that is considered as an unsatisfactory rechargeable battery that needs replacing in an assembled battery in which rechargeable batteries are stacked and restrained in a row and electrically connected in series or in parallel. The method includes removing of finding at least one of the rechargeable batteries to be an unsatisfactory rechargeable battery in the assembled battery and removing the unsatisfactory rechargeable battery, and installing a satisfactory rechargeable battery, which has little deterioration, on at least one end of the row of the rechargeable batteries, in a row direction, in the assembled battery from which the unsatisfactory rechargeable battery has been removed.