Battery Stack Assemblies with Adjustable Retention Bands

Solution Overview

Problem

Existing battery stack assemblies in hybrid/electric vehicles make it difficult to replace individual faulty cells without replacing the entire battery pack, as they are secured by non-adjustable structures, leading to unnecessary battery pack replacements.

Innovation Solution

A battery stack assembly with sleeves and retention bands that allow for compression application and release, enabling easy access and replacement of individual battery cells by sliding the sleeves along the retention bands, facilitating the withdrawal and reinsertion of cells within the stack.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If non-adjustable structure (riveted retention bands) is used to keep battery stack under compression, then structural stability is improved, but ease of cell replacement deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidease of cell replacement

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The retention bands are changed from a fixed, non-adjustable structure to a dynamic, adjustable structure. The retention bands can be moved along the sleeves to different positions, allowing compression to be applied to the entire stack or released from specific areas to enable individual cell replacement while maintaining overall structural stability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The battery stack is divided into individually accessible cells through sleeves that can be independently manipulated. Each cell can be accessed and replaced separately by adjusting the retention bands, rather than treating the entire stack as a single unit that must be replaced together.

Inventive Principle:

Principle #1Segmentation

2Reliability

If entire battery pack is replaced when single cell fails, then reliability is maintained, but loss of substance and waste increase

Engineering Contradiction:

Improvebattery pack reliabilityVSAvoidbattery material waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The faulty battery cell is extracted and removed from the stack for replacement, while the remaining functional cells are retained. This allows selective replacement of only the defective component rather than discarding the entire battery pack, reducing material waste while maintaining system reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of discarding the entire battery pack when one cell fails, the system enables recovery and retention of functional cells. Only the specific defective cell is discarded and replaced, maximizing resource utilization and minimizing waste.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If entire battery pack is replaced when single cell fails, then reliability is maintained, but loss of time and cost increase

Engineering Contradiction:

Improvebattery pack reliabilityVSAvoidreplacement time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The faulty battery cell is extracted and removed from the stack for replacement, while the remaining functional cells are retained. This allows selective replacement of only the defective component rather than discarding the entire battery pack, reducing material waste while maintaining system reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The retention bands are changed from a fixed, non-adjustable structure to a dynamic, adjustable structure. The retention bands can be moved along the sleeves to different positions, allowing compression to be applied to the entire stack or released from specific areas to enable individual cell replacement while maintaining overall structural stability.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11502325B2Battery stack assemblies and methods for replacing a battery cell

Publication Date: 2022.11.15 TOYOTA JIDOSHA KK

AI summary

In one embodiment, a battery stack assembly includes a plurality of sleeves, a plurality of battery cells, and one or more retention bands. The plurality of sleeves is arranged in a stack along a common plane, each of the plurality of sleeves including a slot. The plurality of battery cells are positioned within the plurality of sleeves such that at least a portion of each battery cell is accessible when positioned within a dedicated sleeve. The one or more retention bands extend through each of the slots formed in the plurality of sleeves, wherein the one or more retention bands facilitate application of compression across the stack, and release of compression allows a chosen cell to be withdrawn from the dedicated sleeve.