Flexible Battery Belt for Selective Cell Replacement
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Solution Overview
Problem
Current rechargeable battery systems face issues with thermal regulation, uneven charge distribution, and limited flexibility, leading to overheating, reduced efficiency, and premature wear, as well as the inability to rapidly replace or condition individual cells, which can result in permanent damage or waste.
Innovation Solution
A system that mechanically links batteries in a flexible serpentine belt arrangement, allowing for easy handling and selective replacement of individual cells, with an actuator for moving batteries in and out of an operational zone for electrical connection, enabling flexible power configurations and rapid change-out capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If batteries are connected in fixed rigid arrays, then electrical connection is stable, but flexibility for handling and selective replacement is poor
Solution Approach 1:
The battery array is segmented into individually replaceable battery units connected through a flexible belt system with discrete links. Each link can be independently manipulated, allowing selective replacement of individual cells while maintaining connection to the remaining array through the flexible belt structure.
Solution Approach 2:
A flexible belt structure replaces rigid mechanical linkages to connect battery units. The belt's flexibility enables easy handling, manipulation, and selective removal of individual cells, while maintaining electrical and mechanical connections to the remaining array through the continuous flexible medium.
2Reliability
If individual defective cells are replaced, then battery array reliability is improved, but mechanical linkage complexity increases
Solution Approach 1:
The battery system is divided into modular units where individual cells can be independently replaced. The flexible belt with discrete links provides a mechanical structure that facilitates this segmentation, allowing defective cells to be removed and replaced without affecting the entire array.
Solution Approach 2:
Defective battery cells can be selectively removed from the array and replaced with new or reconditioned cells. The flexible belt structure enables easy discarding of failed components and integration of replacement units, extending the overall system life through component-level maintenance.
3Productivity
If rapid battery change-out is enabled, then productivity is improved, but device complexity increases
Solution Approach 1:
The battery array system incorporates dynamic elements including a movable flexible belt and actuator mechanisms that enable rapid insertion and removal of battery units. The conduit system with operational zones provides a structured pathway for quick exchange while maintaining electrical connections during the transition.
Solution Approach 2:
The flexible belt acts as an intermediary mechanical structure between individual battery cells and the final array configuration. The conduit system serves as an intermediary pathway that guides batteries into and out of operational zones, facilitating rapid change-out while managing the complexity of electrical and mechanical connections.
4Reliability
If thermal regulation measures are implemented, then battery safety is improved, but energy loss increases
Solution Approach 1:
The battery array is segmented into individually monitorable and replaceable units, allowing thermal issues to be detected and addressed at the cell level rather than requiring thermal discharge of the entire array. This localized approach maintains safety while minimizing energy loss.
Solution Approach 2:
The system enables preliminary detection and replacement of cells showing signs of thermal stress before they cause overheating. By monitoring and maintaining individual cell health, the system prevents thermal runaway conditions without requiring full thermal discharge cycles that waste energy.
Data Source
AI summary
In one embodiment, a system for deploying batteries, for example in an electric vehicle, includes a battery belt for mechanically linking multiple batteries together, a conduit having one or more operational zones each with an output, the operational zones each establishing an electrical connection between the output and batteries in the operational zone, and an actuator for selectively moving batteries into and out of the operational zones. Resting zones may also be provided. The batteries can be connected in series or in parallel and can be individually removed and replaced by an exchanger.