Apparatus and method for discharging electrical energy storage cells

• US 20060244427A1
• Filed: 04/28/2005
• Published: 11/02/2006
• Est. Priority Date: 04/28/2005
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Maxwell Technologies Incorporated (Tesla Inc.)
• Inventors: Thrap, Guy
• Granted Patent: US 7,560,903 B2
• Time in Patent Office: Days
• US Class Current: 323/210
• CPC Class Codes: G05F 1/70 Regulating power factor; Regulating reactive current or power

Abstract

A power module includes double layer capacitors, a voltage booster, a charging circuit, and a switching assembly. In discharging mode, the switching assembly connects the voltage booster to the output of the power module. The voltage booster enhances the voltage of the cells as needed for operation of a load at the output of the module. In charging mode, the switching assembly connects the charging circuit to the output of the module to receive electric energy from an external charger connected to the output of the module. The charging circuit converts the received energy into energy suitable for recharging the cells. In end-of-cycle discharging mode, the switching assembly connects the voltage booster to the charging circuit, causing these devices to loop into each other. Inefficiencies in the voltage booster and the charging circuit dissipate the energy in the cells, rendering the battery fail-safe.

Claims

1. A power module for use with one or more electrical energy storage device comprising:

a voltage converter comprising an input and an output, the input of the voltage converter being coupled to the one or more cells to receive voltage of the one or more cells, the voltage converter being configured to convert the voltage at the input of the voltage converter into a converted voltage at the output of the voltage converter;

a charging circuit comprising an input and an output, the output of the charging circuit being coupled to the one or more energy storage cells and to the input of the voltage converter, the charging circuit being configured to convert electrical voltage at the input of the charging circuit into charging circuit output voltage for charging the one or more cells at the output of the charging circuit; and

a switching assembly connected to the input of the charging circuit and to the output of the voltage converter, the switching assembly being capable of selectively coupling the output of the voltage converter to the input of the charging circuit;

wherein, when the switching assembly couples the output of the voltage converter to the input of the charging circuit, the power losses in the voltage converter and in the charging circuit dissipate energy in the one or more cells.

2. A power module in accordance with claim 1, wherein the one or more cells comprise at least one double layer capacitor.

3. A power module in accordance with claim 2, wherein the switching assembly comprises a plurality of solid-state switches.

4. A power module in accordance with claim 2, wherein the voltage converter comprises a DC-to-DC voltage booster.

5. A power module in accordance with claim 2, further comprising a housekeeping power supply coupled to the output of the DC-to-DC voltage booster.

6. A power module in accordance with claim 4, wherein the charging circuit comprises a DC-to-DC constant power circuit capable of increasing current at the output of the charging circuit in response to decrease of voltage of the one or more cells.

7. A power module in accordance with claim 2, wherein the voltage converter comprises a DC-to-DC voltage converter with interleaved operation.

8. A power module in accordance with claim 2, wherein the charging circuit comprises a DC-to-DC constant power circuit with interleaved operation.

9. A power module in accordance with claim 2, wherein:

the charging circuit comprises an AC-to-DC charging voltage converter; and

the voltage converter comprises a DC-to-AC voltage booster.

10. A power module in accordance with claim 2, further comprising a switch controller coupled to the switching assembly for controlling state of the switching assembly.

11. A power module in accordance with claim 2, wherein the switching assembly comprises a distributed mechanism that selectively enables and disables the voltage booster and the charger.

12. A method for discharging one or more electrical energy storage cells, the method comprising:

connecting the one or more cells to a voltage booster and to a charging circuit; and

connecting an output of the voltage booster to an input of the charging circuit so that the voltage booster and the charging circuit loop into each other dissipating energy stored in the one or more cells.

13. A system comprising:

one or more energy dissipation circuit coupled to one or more energy storage capacitor to actively dissipate energy stored in the one or more energy storage capacitor.

14. The system of claim 13, wherein an energy dissipation circuit comprises a voltage converter circuit.

15. The system of claim 13, wherein an energy dissipation circuit comprises a charging circuit.

16. The system of claim 13, wherein an energy dissipation circuit comprises a switch controller.

17. The system of claim 13, wherein the one or more energy dissipation circuit comprises a voltage converter, a charging, circuit, and a switching assembly for selectively coupling the output of the voltage converter to the input of the charging circuit power, and wherein losses in the voltage converter and in the charging circuit can be used dissipate the energy in the one or more energy storage capacitor.

18. The system of claim 13, wherein and the one or more energy dissipation circuit is coupled to a load, and wherein the energy dissipation circuit dissipates the energy such that a voltage at the load is lowered to a safe level environmental level.

19. The system of claim 18, wherein the safe level is a voltage that is less than about 1 volt.

20. The system of claim 13, wherein when the one or more energy storage capacitor comprises one or more 48 volt 400 Farad double-layer capacitor, the one or more energy dissipation circuit can discharge the one or more double-layer capacitor to a safe level in less than one hour.