Energy storage system for hybrid electric vehicle

• US 10,322,627 B2
• Filed: 04/11/2016
• Issued: 06/18/2019
• Est. Priority Date: 12/07/2010
• Status: Active Grant

• Current Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Original Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Inventors: Maskew, Brian J., Bennett, Scott K., Baxter, II, Leonard F., Youngs, Daniel J., Biehl, Kurt, Bass, Edward, Schneider, Eric D., Bailey, Felice E., Reyburn, Steven T., Ford, Dean M., Johnson, Clyde E., Miller, Bruce E., Bletsis, Richard, Delrymple, Derek A., Naegell, Markus, Wendling, Jerry, Gasaway, Timothy A., Hopkins, Russell B., Morrow, Brian C., Lawrence, Robert A.
• Primary Examiner(s): Jimenez, Anthony R
• Application Number:
  US15/095,217
• Publication Number:
  US 20160226112A1
• Time in Patent Office: 1,163 Days
• CPC Class Codes: B60K 2006/4825 Electric machine connected or connectable to gearbox input shaft
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/26 Vehicle weight
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0084 relating to control modules
• CPC Class Codes: B60L 3/108 whilst braking, i.e. ABS
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 : using propulsion power stored mechanically, e.g. in fly-wheels
• 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 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 58/20 : having different nominal voltages
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: F28F 9/00 : Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
• CPC Class Codes: G01K 1/146 : arrangements for moving thermometers to or from a measuring position
• CPC Class Codes: H01M 10/425 : Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/482 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/617 : for achieving uniformity or desired distribution of temperature
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/637 : characterised by the use of reversible temperature-sensitive devices, e.g. NTC, PTC or bimetal devices; characterised by control of the internal current flowing through the cells, e.g. by switching means for preventing undesired use or discharge H01M50/572
• CPC Class Codes: H01M 10/6551 : Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6554 : Rods or plates
• CPC Class Codes: H01M 10/6563 : with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/658 : by thermal insulation or shielding
• CPC Class Codes: H01M 2010/4278 : Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2200/00 : Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/204 : Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/244 : Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: H01M 50/264 : for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 : Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/289 : characterised by spacing elements or positioning means within frames, racks or packs spacing elements inside cells other than separators, membranes or diaphragms H01M50/471
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/317 : Re-sealable arrangements
• CPC Class Codes: H01M 50/569 : Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H01M 50/574 : Devices or arrangements for the interruption of current
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• 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 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor

Abstract

An energy storage system comprising at least one energy storage module adapted to supply electrical energy to a hybrid vehicle. The energy storage module comprises an enclosure, at least one battery array located within the enclosure, and an energy storage controller module located within the enclosure and electrically connected to the battery array. The energy storage module further comprises a compliant tipped thermistor which may be installed within a flexible clip. The thermistor is positioned to monitor the temperature of one or more of the batteries within the energy storage system.

Claims

1. An energy storage system, comprising:

a first energy storage module adapted to supply electrical energy to a hybrid vehicle, the first energy storage module comprising;

a primary enclosure with a battery array located within the primary enclosure, the battery array having multiple battery cells;

a vent in the primary enclosure, and a pressure relief panel held adjacent to the vent, the pressure relief panel operable to limit internal pressure of the primary enclosure, wherein at least one of the battery cells in the battery array has a battery vent for releasing battery gases into the primary enclosure;

a compliant seal positioned around the vent and at least one spring operable to maintain the pressure relief panel adjacent the vent in the primary enclosure;

a heat sink disposed on an exterior surface of the primary enclosure, the heat sink comprising a plurality of fins disposed angularly outward with respect to a longitudinal axis of the heat sink, a first portion of the plurality of fins having a first height, and a second portion of the plurality of fins having a second height;

wherein the first height is lower than the second height; and

wherein a central cavity is defined by the first height and the second height of the plurality of fins, the central cavity directing a flow of air from a first end of the heat sink toward a second end.

2. The energy storage system of claim 1, comprising:

a junction box mounted to the primary enclosure, the junction box having one or more external terminals and one or more internal terminals electrically connected to the battery array in the primary enclosure; and

a plug-in bussed electrical center, comprising;

a connector formed of electrically insulative material having a plurality of internal terminal connectors and a plurality of external terminal connectors; and

a plurality of high voltage contactors configured to electrically connect at least one of the internal terminal connectors with at least one of the external terminal connectors;

wherein the plurality of internal terminal connectors of the plug-in bussed electrical center are configured to electrically connect to corresponding internal terminals of the junction box; and

wherein the plurality of external terminal connectors of the plug-in bussed electrical center are configured to electrically connect to corresponding external terminals of the junction box.

3. An energy storage system of claim 1, comprising:

a plurality of parallel side rails with mounting holes at each end, wherein the multiple battery cells in the first energy storage module are positioned along the side rails;

a plurality of end plates positioned adjacent the side rails, each plate having a plurality of plate mounting flanges, and;

a plurality of mounting pins;

wherein plate mounting flanges and rail mounting holes are arranged so that a mounting pin can be inserted through a rail mounting hole and adjacent a plate mounting flange to secure the battery cells within the side rails and end plates.

4. The energy storage system of claim 1, comprising:

a thermistor mounted to a thermistor mount by a thermistor clip adjacent a battery cell of the multiple battery cells in the first energy storage module, the thermistor configured to sense a temperature of the battery cell, the thermistor clip comprising;

a central portion coupled to the thermistor, the central portion separated from the thermistor mount and passing through a central hole of the thermistor mount; and

one or more lateral portions extending away from the central portion, the one or more lateral portions coupled to the thermistor mount;

wherein the lateral portions of the thermistor clip are flexible and configured to retain the thermistor against the battery cell.

5. The energy storage system of claim 1, comprising:

a fan mounted to a first end of the primary enclosure;

wherein the fan is operable to direct the flow of air across the heat sink from the first end to the second end.

6. The energy storage system of claim 1, comprising:

a thermal pad disposed between the battery array and an interior surface of the primary enclosure, the thermal pad being constructed of a thermally conductive and electrically insulating material.

7. The energy storage system of claim 1, comprising:

a plate mounted to the heat sink, the plate defining an airflow cavity between the primary enclosure and the plate, wherein the plate directs air through the airflow cavity and across the multiple fins of the heat sink.

8. The heat sink of claim 1, wherein the first portion of the plurality of fins defines a floor of the central cavity and the second portion of the multiple fins defines walls of the central cavity.

9. The energy storage system of claim 1, wherein a length of the second portion of the plurality of fins increases with the direction of the flow of air up to a first longitudinal distance from a first end of the heat sink, and wherein the length of the first portion of the plurality of fins decreases with the direction of air flow beyond the first longitudinal distance.

10. The energy storage system of claim 1, wherein the plurality of fins are disposed on a first side of the heat sink, the heat sink configured to conduct heat from a heat source disposed on a second side of the heat sink through the fins on the first side of the heat sink.

11. The energy storage system of claim 10, wherein the plurality of fins is integral to the exterior surface of the first energy storage module.

12. The energy storage system of claim 1, comprising:

a voltage sense board including multiple bus bars extending from the voltage sense board, the bus bars configured to electrically connect in series separate groups of the multiple battery cells in the battery array, wherein the voltage sense board is configured to insulate the separate groups of battery cells from one another; and

multiple overlapping insulative covers including final bus bars, wherein the final bus bars are configured to electrically connect together the separate groups of battery cells.

13. The energy storage system of claim 12, wherein the voltage sense board comprises a plurality of voltage sensors positioned adjacent the multiple battery cells and configured to sense a corresponding plurality of voltages of the multiple battery cells.

14. The energy storage system of claim 1, wherein the pressure relief panel is operable to move away from the vent, the pressure relief panel moving from a sealed first position to an unsealed second position when pressure inside the primary enclosure exceeds a predetermined threshold.

15. The energy storage system of claim 1, comprising:

a second energy storage module having a primary enclosure with a second battery array located within the primary enclosure, the second battery array having multiple battery cells, wherein the battery array of the first energy storage module is electrically connected to the second battery array of the second energy storage module, and wherein the battery arrays of the first and second energy storage modules are configured to electrically connect to an electric motor.

16. The energy storage system of claim 15, wherein the battery array of the first energy storage module is electrically connected in series to the battery array of the second energy storage module.

17. The energy storage system of claim 15, wherein the battery array of the first energy storage module is electrically connected in parallel to the battery array of the second energy storage module.

18. The energy storage system of claim 15, wherein the primary enclosure of the first energy storage module is mounted to the primary enclosure of the second energy storage module.

19. The energy storage system of claim 15, comprising:

a third energy storage module having a primary enclosure with a third battery array located within the primary enclosure, the third battery array having multiple battery cells, wherein the third battery array of the third energy storage module is electrically connected to the battery arrays of the first and second energy storage modules, and wherein the battery arrays of the first, second, and third energy storage modules are configured to electrically connect to an electric motor.

20. The energy storage system of claim 19, wherein the battery array of the first, second, and third energy storage modules are electrically connected in series.

21. The energy storage system of claim 19, wherein the battery array of the first, second, and third energy storage modules are electrically connected in parallel.

22. The energy storage system of claim 19, wherein the battery array of the first and second energy storage modules are electrically connected in parallel, and the third energy storage module is connected in series with the first and second energy storage modules.

23. The energy storage system of claim 15, comprising:

a first controller and a first signal connector in the first energy storage module, the first signal connector electrically connected to the first controller;

a second controller and a second signal connector in the second energy storage module, the second signal connector electrically connected to the second controller;

wherein the first signal connector and the second signal connector are electrically connected together so that the first controller is in communication with the second controller; and

wherein the first controller is configured to operate as a master controller controlling the second controller configured to operate as a slave controller.

24. An energy storage system, comprising:

a first and a second energy storage module adapted to supply electrical energy to a hybrid vehicle, the first and second energy storage modules comprising;

a primary enclosure with a battery array located within the primary enclosure, the battery array having multiple battery cells;

a heat sink disposed on an exterior surface of the primary enclosure, the heat sink comprising a plurality of fins disposed angularly outward with respect to a longitudinal axis of the heat sink, a first portion of the plurality of fins having a first height, and a second portion of the plurality of fins having a second height, wherein the first height is lower than the second height, and wherein a central cavity is defined by the first height and the second height of the plurality of fins, the central cavity directing a flow of air from a first end of the heat sink toward a second end;

a thermistor mounted within the primary enclosure adjacent a battery cell of the multiple battery cells in the primary enclosure operable to sense a temperature of the battery cell;

a controller mounted within the primary enclosure, the controller responsive to the thermistor; and

a signal connector electrically connected to the controller;

wherein the battery array of the first energy storage module is electrically connected to the battery array of the second energy storage module; and

wherein the signal connectors of the first and second energy storage modules are electrically connected together to form a hybrid data link between the controllers of the first and second energy storage modules.

25. The energy storage system of claim 24, wherein the battery array of the first energy storage module is electrically connected in series to the battery array of the second energy storage module.

26. The energy storage system of claim 24, wherein the battery array of the first energy storage module is electrically connected in parallel to the battery array of the second energy storage module.

27. The energy storage system of claim 24, wherein the primary enclosure of the first energy storage module is mounted to the primary enclosure of the second energy storage module.

28. The energy storage system of claim 24, wherein the controller of the first energy storage module is configured to operate as a master controller, and the controller of the second energy storage module is configured to operate as a slave controller.

29. The energy storage system of claim 24, comprising:

a third energy storage module having a primary enclosure with a battery array located within the primary enclosure, the battery array having multiple battery cells, wherein the battery array of the third energy storage module is electrically connected to the battery arrays of the first and second energy storage modules, and wherein the signal connectors of the first, second, and third energy storage modules are electrically connected together.

30. The energy storage system of claim 29, wherein the battery array of the first, second, and third energy storage modules are electrically connected in series.

31. The energy storage system of claim 29, wherein the battery array of the first, second, and third energy storage modules are electrically connected in parallel.

32. The energy storage system of claim 29 wherein battery array of the first and second energy storage modules are electrically connected in parallel, and the third energy storage module is connected in series with the first and second energy storage modules.