Battery packs with cell module assemblies usable in multiple applications

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Solution Overview

Problem

Battery packs face challenges in maximizing the useful life of lithium-ion cells due to degradation over cycles, temperature changes, and varying energy demands, leading to premature end-of-life disposal rather than reuse in applications with lower energy requirements.

Innovation Solution

Implementing a cell module assembly with lithium-ion battery cells connected in parallel and an electronic controller that tracks useful life data, determines end-of-life thresholds, and allows for reconditioning and reuse in different applications based on remaining capacity, enabling multiple life cycles and extended use in equipment with lower energy needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If lithium-ion battery cells are used in high energy demand applications, then power and energy output are improved, but the cells reach end-of-life faster due to degradation from cycles and temperature changes

Engineering Contradiction:

Improveenergy outputVSAvoiduseful life

Core Design Contradiction:

PowerVSDuration of action of stationary object

Solution Approach 1:

The system changes the operational parameters of battery cells by transitioning them from high-demand to low-demand applications. The controller monitors cell health metrics (capacity, cycle count, temperature history) and adjusts the application assignment accordingly, allowing cells to serve in appropriate applications as their capacity degrades over time

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system dynamically reassigns battery cells between different applications based on their real-time health status. Cells are not statically assigned to a single application but are moved between high-demand and low-demand applications as their useful life progresses, optimizing both power utilization and lifespan extension

Inventive Principle:

Principle #15Dynamics

2Reliability

If battery cells are disposed of at first end-of-life threshold, then safety and performance reliability are ensured, but resource waste occurs due to premature disposal of cells with remaining capacity

Engineering Contradiction:

Improveperformance reliabilityVSAvoidbattery cell capacity

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Instead of discarding cells at the first end-of-life threshold, the system recovers them for continued use in applications with lower energy demands. The controller identifies cells that have reached the first threshold but still possess usable capacity and redistributes them to suitable applications, thereby recovering value that would otherwise be lost

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The system converts the harmful effect of cell degradation into a benefit by creating a multi-tiered utilization strategy. Cells that degrade from high-demand applications are not wasted but are redeployed to low-demand applications where their reduced capacity is still adequate, turning a negative (degradation) into a positive (extended resource utilization)

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If battery cells are reused in multiple applications, then resource utilization is improved, but tracking and managing cell history becomes more complex

Engineering Contradiction:

Improveresource utilizationVSAvoidcell tracking system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The controller implements a feedback mechanism that continuously monitors and records cell health metrics (capacity, cycle count, temperature history) and uses this information to make intelligent reassignment decisions. This automated feedback loop manages the complexity of tracking multiple cells through multiple applications without requiring manual intervention

Inventive Principle:

Principle #23Feedback

4Duration of action of stationary object

If multiple end-of-life thresholds are implemented, then cell reuse opportunities are maximized, but the control system becomes more complex

Engineering Contradiction:

Improveuseful lifeVSAvoidcontrol system

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The system uses parameter changes (multiple thresholds on capacity retention) to create distinct utilization tiers. The first threshold (e.g., 80% capacity) triggers reassignment to lower-demand applications, and the second threshold (e.g., 60% capacity) triggers further reassignment or retirement, allowing extended useful life through structured parameter-based management

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11682800B2Battery packs with cell module assemblies usable in multiple applications

Publication Date: 2023.06.20 BRIGGS & STRATTON CORP

AI summary

A cell module assembly includes multiple lithium-ion battery cells connected in parallel and an electronic controller. The electronic 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.