Battery pack with cell module assemblies
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Solution Overview
Problem
Battery packs experience degradation in charge capacity over time, leading to reduced energy rating and equipment performance, with existing technologies often discarding used components rather than reusing them effectively.
Innovation Solution
Implementing an electronic controller in cell module assemblies to track useful life indicators, allowing for multiple end-of-life thresholds and reconditioning of battery cells for reuse in applications with lower energy demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are discarded after reaching end-of-life threshold, then manufacturing simplicity is maintained, but resource waste increases and environmental harm worsens
Solution Approach 1:
The patent implements a system that recovers and reuses battery cells after they reach their initial end-of-life threshold. The electronic controller monitors useful life indicators and, upon detecting the threshold is met, redirects cells to secondary applications rather than discarding them. This recovery process extends the operational lifecycle of battery cells, reducing resource waste while maintaining manufacturing efficiency through automated classification and redistribution systems.
Solution Approach 2:
The system changes the operational parameters of battery cells by reclassifying them from primary to secondary applications based on their degraded performance characteristics. Instead of discarding cells that no longer meet original specifications, the system adapts them for lower-demand applications where their reduced capacity is still sufficient, thereby extending their useful life and reducing waste.
2Loss of substance
If battery cells are reused in secondary applications, then resource utilization is improved and waste is reduced, but system complexity increases
Solution Approach 1:
The electronic controller continuously monitors useful life indicators of battery cells and provides feedback to the system. When a cell reaches its end-of-life threshold, the controller triggers a redistribution process that automatically reassigns the cell to appropriate secondary applications. This feedback mechanism manages system complexity by automating the classification and redistribution process, reducing the need for manual intervention while optimizing resource utilization.
Solution Approach 2:
The patent creates a universal system that handles multiple functions: monitoring, classification, redistribution, and tracking of battery cells across different applications. The electronic controller and database system serve as multi-functional components that manage the entire cell lifecycle, from initial deployment to secondary application assignment, thereby managing complexity through integrated design.
3Duration of action of moving object
If multiple end-of-life thresholds are implemented, then cell reuse opportunities are maximized, but monitoring and control complexity increases
Solution Approach 1:
The electronic controller automatically performs monitoring, evaluation, and redistribution of battery cells without requiring external intervention. The system self-manages the complexity of tracking multiple useful life indicators and determining when cells should be redirected to secondary applications. This automation reduces the operational burden despite the increased monitoring requirements, allowing the system to maximize cell reuse opportunities independently.
Data Source
AI summary
A cell module assembly includes battery cells and a controller. The controller is programmed to receive useful life data for a useful life indicator of the battery cells, save the life data to memory to create a life data history, determine a life measurement based on the life data history, compare the life measurement to a first end of life threshold, determine if the life measurement has met the first end of life threshold, provide a first end of life output indicating that the life measurement has met the first end of life threshold, compare the life measurement to a second end of life threshold, determine if the life measurement has met the second end of life threshold, and provide a second end of life output indicating that the life measurement has met the second end of life threshold.