Secondary battery housing with control electronics
First Claim
1. An apparatus for electronically controlling and mechanically coupling cells together within a battery housing comprising:
- a plurality of cells having a cylindrical shape and a diameter;
two end frames each having a plurality of cell-receiving cups arranged in rows, wherein adjacent rows are staggered from each other by one-half of the cell diameter so that said cells are retained within the end frames in a honeycomb configuration to form a cell pack, wherein said cell-receiving cups have an annular ring capped on one end with a circular bottom having an aperture therethrough;
connecting tabs extending across adjacent cups and electrically soldered to said cells through said apertures to sandwich the end frames between said cells and said connecting tabs; and
a control circuit including an LC steered resonant flyback converter with a zero voltage MOSFET switch for switching of sinusoidal waveforms at the self-resonant frequency of the LC steered resonant flyback converter to maintain all of said cells at the same potential voltage and state of charge.
1 Assignment
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Accused Products
Abstract
Rechargeable cells in cylindrical form are arranged within frames in a honeycomb structure and coupled by connecting straps outside the frames to form cell pack. Several cell packs, an electronic switch and control circuit are integrated into the battery housing. A bus bar extends around the perimeter of the housing. A high density MOSFET switch is coupled between the bur bar and the battery contact. A high power electronic clamp disposed across the battery terminals absorbs or redirects transients. An active, high-efficiency, low-noise cell balance converter or a LC based resonant converter may also be provided. For advanced battery applications a +5V CAN bus interface is provided via two circular connectors. Thermistors are provided for use in a thermal protection scheme.
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Citations
24 Claims
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1. An apparatus for electronically controlling and mechanically coupling cells together within a battery housing comprising:
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a plurality of cells having a cylindrical shape and a diameter; two end frames each having a plurality of cell-receiving cups arranged in rows, wherein adjacent rows are staggered from each other by one-half of the cell diameter so that said cells are retained within the end frames in a honeycomb configuration to form a cell pack, wherein said cell-receiving cups have an annular ring capped on one end with a circular bottom having an aperture therethrough; connecting tabs extending across adjacent cups and electrically soldered to said cells through said apertures to sandwich the end frames between said cells and said connecting tabs; and a control circuit including an LC steered resonant flyback converter with a zero voltage MOSFET switch for switching of sinusoidal waveforms at the self-resonant frequency of the LC steered resonant flyback converter to maintain all of said cells at the same potential voltage and state of charge. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. An apparatus for electronically controlling and mechanically coupling cells together within a battery housing comprising:
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a plurality of cells having a cylindrical shape and a diameter; two end frames each having a plurality of cell-receiving cups arranged in rows, wherein adjacent rows are staggered from each other by one-half of the cell diameter so that said cells are retained within the end frames in a honeycomb configuration to form a cell pack, wherein said cell-receiving cups have an annular ring capped on one end with a circular bottom having an aperture therethrough; connecting tabs extending across adjacent cups and electrically soldered to said cells through said apertures to sandwich the end frames between said cells and said connecting tabs; and a control circuit including an isolated steered current resonant converter to provide a high side power supply for a MOSFET switch where energy will be transferred back and forth between an inductor (L) and a first capacitor (C);
wherein said cells, said MOSFET switch and said inductor (L) are in a series loop and a first diode and said first capacitor (C) are in parallel with said MOSFET switch. - View Dependent Claims (15)
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16. An apparatus for electronically controlling and mechanically coupling cells together within a battery housing comprising:
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a plurality of cells having a cylindrical shape and a diameter; two end frames each having a plurality of cell-receiving cups arranged in rows, wherein adjacent rows are staggered from each other by one-half of the cell diameter so that said cells are retained within the end frames in a honeycomb configuration to form a cell pack, wherein said cell-receiving cups have an annular ring capped on one end with a circular bottom having an aperture therethrough; connecting tabs extending across adjacent cups and electrically soldered to said cells through said apertures to sandwich the end frames between said cells and said connecting tabs; an electronic switch and a control circuit including and LC resonant converter to maintain all of said cells at the same potential and state of charge; and isolation mounts and a five-sided pocket, wherein said end frame includes slots along its periphery which have a height equal to the height of said annular rings, wherein said isolation mounts are installed in said slots to absorb shock and vibration by distancing the cell pack from the internal surfaces of the five-sided pocket when the cell pack is disposed therein to form a pocketed cell pack. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23)
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24. An apparatus for electronically controlling and mechanically coupling cells together within a battery housing comprising
a plurality of cells having a cylindrical shape and a diameter; - two end frames each having a plurality of cell-receiving cups arranged in rows, wherein adjacent rows are staggered from each other by one-half of the cell diameter so that said cells are retained within the end frames in a honeycomb configuration to form a cell pack, wherein said cell-receiving cups have an annular ring capped on one end with a circular bottom having an aperture therethrough,
connecting tabs extending across adjacent cups and electrically soldered to said cells through said apertures to sandwich the end frames between said cells and said connecting tabs; and an electronic switch and a control circuit including;
an LC resonant converter to maintain all of said cells at the same potential voltage and state of charge; and
a clamp having a second switch and a capacitor arranged in series with said cells, wherein said capacitor comprises an energy reservoir to absorb currents when said second switch is open;
said clamp further includes a diode in parallel with said capacitor and coupled across the positive and negative terminals of said cell so that current continues to flow while the voltage across the battery is clamped.
- two end frames each having a plurality of cell-receiving cups arranged in rows, wherein adjacent rows are staggered from each other by one-half of the cell diameter so that said cells are retained within the end frames in a honeycomb configuration to form a cell pack, wherein said cell-receiving cups have an annular ring capped on one end with a circular bottom having an aperture therethrough,
Specification