Multiple chemistry battery systems for electric vehicles

• US 10,661,679 B2
• Filed: 10/26/2018
• Issued: 05/26/2020
• Est. Priority Date: 10/26/2018
• Status: Active Grant

• Current Assignee: Premergy, Inc.
• Original Assignee: Premergy, Inc.
• Inventors: Botts, Richard Edward, Fabiani, Blakely Lane, Merrill, David S.
• Primary Examiner(s): Santana, Eduardo Colon
• Assistant Examiner(s): Agared, Gabriel
• Application Number:
  US16/172,300
• Publication Number:
  US 20200130511A1
• Time in Patent Office: 578 Days
• Field of Search: 318139
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60L 58/19 Switching between serial connection and parallel connection of battery modules
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• 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 4/485 of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy H01M4/505, H01M4/525 take precedence
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

Multiple chemistry battery systems and methods for using such systems in electric vehicles are disclosed. In one embodiment, an example electric vehicle may include a drive motor configured to impart motion to one or more wheels of the electric vehicle, a plurality of batteries configured to power the drive motor, and one or more controllers. The plurality of batteries may include a first battery including a first cell having a first chemistry, and a second battery including a second cell having a second chemistry different from the first chemistry. The one or more controllers may be configured to cause the first battery and the second battery to power the drive motor, and to cause the drive motor to charge the first battery and the second battery.

Claims

1. An electric drive system comprising:

a first drive motor configured to impart motion to one or more wheels of the electric drive system;

a plurality of batteries configured to power the first drive motor, the plurality of batteries comprising;

a first battery comprising a first cell having a first chemistry; and

a second battery comprising a second cell having a second chemistry different from the first chemistry;

one or more DC-DC converters electrically coupled to the first battery and the second battery; and

one or more controllers configured to;

cause the first battery and the second battery to power the first drive motor;

cause the first drive motor to charge or discharge the first battery and the second battery;

determine a first state of charge of the first battery;

determine a second state of charge of the second battery;

cause, based at least in part on the first state of charge and the second state of charge, the one or more DC-DC converters to transfer energy between the first battery and the second battery; and

cause the first battery to reconfigure internal cells between a series and parallel arrangement via one or more switches to optimally match voltage between a first battery pack and a second battery pack when the first battery pack and the second battery pack are in a parallel arrangement, and to optimally match current when the first battery pack and the second battery pack are in a series arrangement.

2. The electric drive system of claim 1, wherein the first cell has a first energy density, wherein the second cell has a second energy density less than the first energy density, wherein the first cell has a first power density, and wherein the second cell has a second power density greater than the first power density.

3. The electric drive system of claim 1, wherein the first cell is a lithium-ion cell, and wherein the second cell is a lithium-titanate cell.

4. The electric drive system of claim 1, further comprising one or more switches or transistors electrically coupled to the first battery and the second battery, the one or more switches or transistors configured to transition between a first state in which the one or more switches or transistors form a series connection between the first battery and the second battery and a second state in which the one or more switches or transistors form a parallel connection between the first battery and the second battery.

5. The electric drive system of claim 4, wherein the one or more controllers are further configured to:

determine an electric load on the plurality of batteries; and

cause, based at least in part on the electric load, the one or more switches or transistors to form the series connection or the parallel connection between the first battery and the second battery.

6. The electric drive system of claim 4, wherein the one or more controllers are further configured to:

cause the one or more switches or transistors to form the series connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery; and

cause the first drive motor to charge the first battery and the second battery while the first battery and the second battery are connected in parallel.

7. The electric drive system of claim 1, further comprising a second drive motor, wherein the one or more controllers are further configured to:

cause the first battery and the second battery to power the second drive motor; and

cause the second drive motor to charge the first battery and the second battery.

8. The electric drive system of claim 7, further comprising one or more switches or transistors electrically coupled to the first battery and the second battery, the one or more switches or transistors configured to transition between a first state in which the one or more switches or transistors form a series connection between the first battery and the second battery, a second state in which the one or more switches or transistors form a parallel connection between the first battery and the second battery, and a third state in which the first battery and the second battery are disconnected from one another, wherein the one or more controllers are further configured to:

cause the one or more switches or transistors to form the series connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another.

9. The electric drive system of claim 8, wherein the first motor and the second motor are mechanically coupled to one another, and wherein the one or more controllers are further configured to:

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second drive motor to charge the second battery while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.

10. An electric drive system comprising:

a first drive motor;

a second drive motor;

a plurality of batteries configured to power the first drive motor, the plurality of batteries comprising;

a first battery comprising a first cell having a first chemistry; and

a second battery comprising a second cell having a second chemistry different from the first chemistry;

one or more switches or transistors electrically coupled to the first battery and the second battery, the one or more switches or transistors configured to transition between a first state in which the one or more switches or transistors form a series connection between the first battery and the second battery, a second state in which the one or more switches or transistors form a parallel connection between the first battery and the second battery, and a third state in which the first battery and the second battery are disconnected from one another; and

one or more controllers configured to;

cause the one or more switches or transistors to form the series connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another.

11. The electric drive system of claim 10, wherein the first cell has a first energy density, wherein the second cell has a second energy density less than the first energy density, wherein the first cell has a first power density, and wherein the second cell has a second power density greater than the first power density.

12. The electric drive system of claim 10, wherein the first cell is a lithium-ion cell, and wherein the second cell is a lithium-titanate cell.

13. The electric drive system of claim 10, wherein the one or more controllers are further configured to:

determine an electric load on the plurality of batteries; and

cause, based at least in part on the electric load, the one or more switches or transistors to form the series connection or the parallel connection between the first battery and the second battery.

14. The electric drive system of claim 10, wherein the one or more controllers are further configured to:

cause the first battery and the second battery to power the first drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery; and

cause the first drive motor to charge the first battery and the second battery while the first battery and the second battery are connected in parallel.

15. The electric drive system of claim 10, further comprising one or more DC-DC converters electrically coupled to the first battery and the second battery, wherein the one or more controllers are further configured to:

determine a first state of charge of the first battery;

determine a second state of charge of the second battery; and

cause, based at least in part on the first state of charge and the second state of charge, the one or more DC-DC converters to transfer energy between the first battery and the second battery.

16. The electric drive system of claim 10, further comprising a second drive motor, wherein the one or more controllers are further configured to:

cause the first battery and the second battery to power the second drive motor; and

cause the second drive motor to charge the first battery and the second battery.

17. The electric drive system of claim 10, wherein the first motor and the second motor are mechanically coupled to one another, and wherein the one or more controllers are further configured to:

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second drive motor to charge the second battery while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.

18. The electric drive system of claim 10, wherein the first motor and the second motor are electrically independent and mechanically coupled to one another, and wherein the one or more controllers are further configured to:

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second drive motor to charge the second battery while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.

19. The electric drive system of claim 10, wherein the one or more controllers are further configured to:

cause the first battery to reconfigure internal cells between a series and parallel arrangement via one or more switches to optimally match voltage between a first battery pack and a second battery pack when the first battery pack and the second battery pack are in a parallel arrangement, and to optimally match current when the first battery pack and the second battery pack are in a series arrangement.

20. A method comprising:

determining, by one or more computer processors coupled to at least one memory, an electric load on a plurality of batteries of an electric drive system, the plurality of batteries comprising;

a first battery comprising a first cell having a first chemistry; and

a second battery comprising a second cell having a second chemistry different from the first chemistry;

causing, based at least in part on the electric load, one or more switches or transistors to form a series connection or a parallel connection between the first battery and the second battery;

causing one or more switches or transistors to form a series connection between the first battery and the second battery;

causing the first battery and the second battery to power the first drive motor and a second drive motor of the electric drive system while the first battery and the second battery are connected in series;

causing the one or more switches or transistors to form a parallel connection between the first battery and the second battery; and

causing the first drive motor and the second drive motor to charge the first battery and the second battery while the first battery and the second battery are connected in parallel.

21. The method of claim 20, wherein the first cell has a first energy density, wherein the second cell has a second energy density less than the first energy density, wherein the first cell has a first power density, and wherein the second cell has a second power density greater than the first power density, wherein the first cell is a lithium-ion cell, and wherein the second cell is a lithium-titanate cell.

22. The method of claim 20, further comprising:

causing one or more switches or transistors to form a series connection between the first battery and the second battery, wherein causing the first battery and the second battery to power the first drive motor comprises causing the first battery and the second battery to power the first drive motor while the first battery and the second battery are connected in series;

causing the one or more switches or transistors to form a parallel connection between the first battery and the second battery; and

causing the first drive motor to charge the first battery and the second battery while the first battery and the second battery are connected in parallel.

23. The method of claim 20, further comprising:

causing one or more switches or transistors to form a parallel connection between the first battery and the second battery, wherein causing the first battery and the second battery to power the first drive motor comprises causing the first battery and the second battery to power the first drive motor while the first battery and the second battery are connected in parallel; and

causing the first drive motor to charge the first battery and the second battery while the first battery and the second battery are connected in parallel.

24. The method of claim 20, further comprising:

determining a first state of charge of the first battery;

determining a second state of charge of the second battery; and

causing, based at least in part on the first state of charge and the second state of charge, one or more DC-DC converters to transfer energy between the first battery and the second battery.

25. The method of claim 20, further comprising:

causing one or more switches or transistors to form a parallel connection between the first battery and a second battery of the electric drive system;

causing the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel; and

causing the first drive motor and the second drive motor to charge the first battery and the second battery while the first battery and the second battery are connected in parallel.

26. The method of claim 20, further comprising:

causing one or more switches or transistors to disconnect the first battery and a second battery of the electric drive system from one another;

causing the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

causing the second battery to power a second drive motor of the electric drive system while the first battery and the second battery are disconnected from one another, wherein causing the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another comprises causing the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.

27. An electric drive system comprising:

a first drive motor configured to impart motion to one or more wheels of the electric drive system;

a second drive motor;

a plurality of batteries configured to power the first drive motor, the plurality of batteries comprising (i) a first battery comprising a first cell having a first chemistry, and (ii) a second battery comprising a second cell having a second chemistry different from the first chemistry;

one or more switches or transistors electrically coupled to the first battery and the second battery, the one or more switches or transistors configured to transition between a first state in which the one or more switches or transistors form a series connection between the first battery and the second battery, a second state in which the one or more switches or transistors form a parallel connection between the first battery and the second battery, and a third state in which the first battery and the second battery are disconnected from one another;

one or more controllers configured to;

cause the second drive motor to charge the first battery and the second battery;

cause the one or more switches or transistors to form the series connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another.

28. An electric drive system comprising:

a first drive motor configured to impart motion to one or more wheels of the electric drive system;

a second drive motor, wherein the first motor and the second motor are mechanically coupled to one another;

a plurality of batteries configured to power the first drive motor, the plurality of batteries comprising (i) a first battery comprising a first cell having a first chemistry, and (ii) a second battery comprising a second cell having a second chemistry different from the first chemistry;

one or more switches or transistors electrically coupled to the first battery and the second battery, the one or more switches or transistors configured to transition between a first state in which the one or more switches or transistors form a series connection between the first battery and the second battery, a second state in which the one or more switches or transistors form a parallel connection between the first battery and the second battery, and a third state in which the first battery and the second battery are disconnected from one another; and

one or more controllers configured to;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another;

cause the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another;

cause the first drive motor to charge or discharge the first battery and the second battery;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second drive motor to charge the second battery while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.

29. An electric drive system comprising:

a first drive motor;

a second drive motor, wherein the first motor and the second motor are mechanically coupled to one another;

a plurality of batteries configured to power the first drive motor, the plurality of batteries comprising (i) a first battery comprising a first cell having a first chemistry, and (ii) a second battery comprising a second cell having a second chemistry different from the first chemistry;

one or more switches or transistors electrically coupled to the first battery and the second battery, the one or more switches or transistors configured to transition between a first state in which the one or more switches or transistors form a series connection between the first battery and the second battery, a second state in which the one or more switches or transistors form a parallel connection between the first battery and the second battery, and a third state in which the first battery and the second battery are disconnected from one another; and

one or more controllers configured to;

cause the one or more switches or transistors to form the series connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another;

cause the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another;

cause the first drive motor to charge the first battery and the second battery;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second drive motor to charge the second battery while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.

30. An electric drive system comprising:

a first drive motor;

a second drive motor, wherein the first motor and the second motor are electrically independent and mechanically coupled to one another;

a plurality of batteries configured to power the first drive motor, the plurality of batteries comprising (i) a first battery comprising a first cell having a first chemistry, and (ii) a second battery comprising a second cell having a second chemistry different from the first chemistry;

one or more switches or transistors electrically coupled to the first battery and the second battery, the one or more switches or transistors configured to transition between a first state in which the one or more switches or transistors form a series connection between the first battery and the second battery, a second state in which the one or more switches or transistors form a parallel connection between the first battery and the second battery, and a third state in which the first battery and the second battery are disconnected from one another; and

one or more controllers configured to;

cause the one or more switches or transistors to form the series connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in series;

cause the one or more switches or transistors to form the parallel connection between the first battery and the second battery;

cause the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel;

cause the one or more switches or transistors to disconnect the first battery and the second battery from one another;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another;

cause the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another;

cause the first drive motor to charge the first battery and the second battery;

cause the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

cause the second drive motor to charge the second battery while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.

31. An electric drive system comprising:

a first drive motor;

a second drive motor, wherein the first motor and the second motor are electrically independent and mechanically coupled to one another;

a plurality of batteries configured to power the first drive motor, the plurality of batteries comprising (i) a first battery comprising a first cell having a first chemistry, and (ii) a second battery comprising a second cell having a second chemistry different from the first chemistry;

one or more switches or transistors electrically coupled to the first battery and the second battery; and

one or more controllers configured to;

cause the first battery and the second battery to power the first drive motor;

cause the first drive motor to charge the first battery and the second battery; and

cause the first battery to reconfigure internal cells between a series and parallel arrangement via one or more switches to optimally match voltage between a first battery pack and a second battery pack when the first battery pack and the second battery pack are in a parallel arrangement, and to optimally match current when the first battery pack and the second battery pack are in a series arrangement.

32. A method comprising:

determining, by one or more computer processors coupled to at least one memory, an electric load on a plurality of batteries of an electric drive system, the plurality of batteries comprising (i) a first battery comprising a first cell having a first chemistry, and (ii) a second battery comprising a second cell having a second chemistry different from the first chemistry;

causing the first battery and the second battery to power a first drive motor of the electric drive system;

causing the first drive motor to charge the first battery and the second battery;

causing, based at least in part on the electric load, one or more switches or transistors to form a series connection or a parallel connection between the first battery and the second battery;

causing one or more switches or transistors to form a parallel connection between the first battery and a second battery of the electric drive system;

causing the first battery and the second battery to power the first drive motor and the second drive motor while the first battery and the second battery are connected in parallel; and

causing the first drive motor and the second drive motor to charge the first battery and the second battery while the first battery and the second battery are connected in parallel.

33. A method comprising:

determining, by one or more computer processors coupled to at least one memory, an electric load on a plurality of batteries of an electric drive system, the plurality of batteries comprising (i) a first battery comprising a first cell having a first chemistry, and (ii) a second battery comprising a second cell having a second chemistry different from the first chemistry;

causing the first battery and the second battery to power a first drive motor of the electric drive system;

causing the first drive motor to charge the first battery and the second battery;

causing, based at least in part on the electric load, one or more switches or transistors to form a series connection or a parallel connection between the first battery and the second battery;

causing one or more switches or transistors to disconnect the first battery and a second battery of the electric drive system from one another;

causing the first battery to power the first drive motor while the first battery and the second battery are disconnected from one another; and

causing the second battery to power a second drive motor of the electric drive system while the first battery and the second battery are disconnected from one another, wherein causing the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another comprises causing the second battery to power the second drive motor while the first battery and the second battery are disconnected from one another and the first battery powers the first drive motor.