Energy source devices and systems having a battery and an ultracapacitor

• US 10,290,912 B2
• Filed: 03/16/2012
• Issued: 05/14/2019
• Est. Priority Date: 03/16/2011
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Jiang, Junwei, Watson, Thomas M., Wyatt, Perry M.
• Primary Examiner(s): Ruddock, Ula C
• Assistant Examiner(s): Chuo, Tony S
• Application Number:
  US13/422,421
• Publication Number:
  US 20120237799A1
• Time in Patent Office: 2,615 Days
• Field of Search: None
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2240/662 Temperature
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: H01G 11/14 Arrangements or processes for adjusting or protecting hybrid or EDL capacitors emergency protective circuit arrangements specially adapted for capacitors, and effecting automatic switching in the event of an undesired change from normal working conditions H02H7/16; emergency protective circuit arrangements for limiting excess current or voltages without disconnection H02H9/00
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/4264 with capacitors
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/48 : Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 16/00 : Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/296 : characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H02J 7/0014 : Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0031 : using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/0048 : Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/005 : Detection of state of health [SOH]
• CPC Class Codes: H02J 7/1423 : with multiple batteries
• CPC Class Codes: H02J 7/345 : using capacitors as storage or buffering devices
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making

Abstract

A battery system includes an enclosure conforming to a standard form factor, such as a group specified by the Battery Council International. A battery and at least one ultracapacitor are disposed in the enclosure and interconnected to provide electrical energy at battery terminals. Control and/or regulation circuitry may also be provided in the enclosure and interconnected with the battery and ultracapacitor. The battery system may be designed to retrofit existing batteries, such as in vehicular and other applications. The use of a standard form factor allows for little or no alteration of the physical and electrical systems into which the battery system is placed.

Claims

1. A battery kit system comprising:

an assembly, comprising;

an enclosure having a first terminal and a second terminal configured to couple to a load;

a plurality of battery cells configured to be disposed within the enclosure and electrically coupled to the first and second terminals by a first switch, and wherein the first switch is capable of closing a first circuit between the plurality of battery cells and the load;

an ultracapacitor configured to be disposed within the enclosure and electrically coupled to the first and second terminals by a second switch, wherein the ultracapacitor is arranged in parallel to the plurality of battery cells, wherein the second switch is positioned in parallel to the first switch, and wherein the second switch is capable of closing a second circuit between the ultracapacitor and the load;

a DC-DC converter configured to be disposed within the enclosure and electrically coupled to the plurality of battery cells and the ultracapacitor;

a plurality of sensors configured to be disposed within the enclosure and to measure at least one parameter of the plurality of battery cells, the ultracapacitor, or a combination thereof; and

control logic configured to be disposed within the enclosure and to control the DC-DC converter and the first and second switches and programmed to meet a power demand of the load based on the at least one parameter by;

calculating a rate of change of the at least one parameter with respect to time;

comparing the rate of change to a preset threshold; and

controlling the first and second switches based on the comparison of the rate of change and the preset threshold; and

at least one adapter that adapts the enclosure for mounting in place of a lead-acid battery comprising one or more lead-acid electrochemical cells without an ultracapacitor and having a standard form factor.

2. The battery kit system of claim 1, wherein the standard form factor comprises a standard group specified by the Battery Council International.

3. The battery kit system of claim 2, wherein the standard form factor comprises at least one group selected from Battery Council International groups 21, 22F, 22HF, 22NF, 22R, 24, 24F, 24H, 24R, 24T, 25, 26, 26R, 27, 27F, 27H, 29NF, 31, 31A, 31T, 33, 34, 34/78, 34R, 35, 36R, 40R, 41, 42, 43, 45, 46, 47, 48, 49, 50, 51, 51R, 52, 53, 54, 55, 56, 57, 58, 58R, 59, 60, 61, 62, 63, 64, 65, 70, 71, 72, 73, 74, 75, 75/25, 76, 78, 85, 86, 90, 91, 92, 93, 95R, 96R, 97R, 98R, 1, 2, 2E, 2N, 17HF, 4D, 6D, 8D, 28, 29H, 30H, 31, GC2, and GC2H.

4. The battery kit system of claim 1, wherein the enclosure is smaller than the standard form factor for the battery in the place of which it is to be mounted.

5. The battery kit system of claim 1, wherein the enclosure is differently shaped than the standard form factor for the battery in the place of which it is to be mounted.

6. The battery kit system of claim 1, wherein the plurality of sensors comprises voltage sensors, current sensors, or a combination thereof.

7. The battery kit system of claim 1, wherein the at least one parameter comprises a voltage of the plurality of battery cells, a voltage of the ultracapacitor, or a combination thereof.

8. The battery kit system of claim 1, wherein the power demand is a voltage or current draw generated during start-up of a vehicle containing the battery kit system.

9. The battery kit system of claim 1, wherein the plurality of battery cells and the ultracapacitor are selected to provide output of 6 or 12 volts at the first and second terminals of the enclosure.

10. The battery kit system of claim 1, wherein the ultracapacitor is one of a plurality of ultracapacitors, and the control logic is configured to permit current flow from the plurality of battery cells to the plurality of ultracapacitors, but not from the plurality of ultracapacitors to the plurality of battery cells, and the control logic is coupled to each ultracapacitor of the plurality of ultracapacitors and provides overcharge protection and balancing of charge among the plurality of ultracapacitors as current flows from the plurality of battery cells to the plurality of ultracapacitors.

11. The battery kit system of claim 1, wherein the load comprises a light, a chassis electrification, or an electronic component.

12. The battery kit system of claim 1, wherein the plurality of sensors comprise a current sensor coupled to the first switch, the second switch, and the load.

13. The battery kit system of claim 12, wherein the at least one parameter comprises a current provided by the load measured by the current sensor.

14. The battery kit system of claim 1, wherein the second switch comprises a field effect transistor, and wherein controlling the first and the second switches comprises meeting the power demand of the load using the plurality of battery cells and the ultracapacitor using the first circuit and the second circuit.