Universal battery module and controller therefor

• US 20070080662A1
• Filed: 02/06/2006
• Published: 04/12/2007
• Est. Priority Date: 10/11/2005
• Status: Active Grant

• Current Assignee: Delaware Power Systems Corporation
• Original Assignee: Delaware Power Systems Corporation
• Inventors: Wu, Deping
• Granted Patent: US 7,772,799 B2
• Time in Patent Office: Days
• US Class Current: 320/110
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• 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 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• 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 10/48 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 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 10/625 Vehicles
• CPC Class Codes: H01M 10/633 characterised by algorithms, flow charts, software details or the like
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/6556 : Solid parts with flow channel passages or pipes for heat exchange closed pipes H01M10/6552
• CPC Class Codes: H01M 10/6567 : Liquids
• CPC Class Codes: H02J 7/00036 : Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 : with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0014 : Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0048 : Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• 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

Abstract

A battery pack is provided including universal battery modules and a master control module. By selecting proper rated universal battery modules and connecting them either in series and/or parallel, a high performance and long life battery pack is assembled that is suitable for high power applications such as electrical vehicles whereby the master control module acts as the battery pack control and interface module.

Claims

1. A universal battery module comprising:

a plurality of series connected battery cells;

sensor means coupled to the cells, the sensor means configured to transmit physical parameters of the cells;

a battery control unit in communication with the sensor means to control the cells based on physical parameters from the sensor means;

wherein the battery control unit, the sensor means and the cells are packaged together as a single integral module.

2. The universal battery module as set forth in claim 1, further comprising a shell for retaining the battery cells therein.

3. The universal battery module as set forth in claim 1, further comprising a thermal frame in thermal communication with the cells to provide cell thermal equalization.

4. The universal battery module as set forth in claim 2, further comprising a base plate coupled to the shell in a hermetically sealing relationship and in thermal communication with the thermal frame to enhance heat dissipation from the thermal frame.

5. The universal battery module as set forth in claim 4, wherein the base plate has an inlet, an outlet and a plurality of passes fluidly connected to the inlet and outlet for transmitting cooling liquid between the inlet and the outlet.

6. The universal battery module as set forth in claim 4, wherein the base plate is hermetically coupled to the shell in a sealing relationship.

7. The universal battery module as set forth in claim 1, further comprising cell electric equalization means.

8. The universal battery module as set forth in claim 1, further comprising an electrical connector coupled to the battery control unit, the electrical connector being configured to provide electric connections for serial communication, power on/off signal, control output signals and input signals.

9. The universal battery module as set forth in claim 8, wherein the serial communication bus is a CAN bus.

10. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to generate control output signals relating to charge/discharge power control and warning light control.

11. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to monitor the module current from the differential input signals.

12. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to monitor the cell voltages, module current and module thermal frame temperature.

13. The universal battery module as set forth in claim 1, wherein the battery control unit configured to control the cell electrical equalization.

14. The universal battery module as set forth in claim 1, wherein the battery control unit isn configured to control the arbitration of the cell sequence numbers.

15. A battery pack comprising:

at least two universal battery modules in a string of connected universal battery modules, each universal battery module including a plurality of series connected battery cells, sensor means coupled to the cells and configured to monitor and transmit physical parameters of the cells, a battery control unit in communication with the sensor means to control the cells based on physical parameters from the sensor means;

a master control module coupled to the string of universal battery modules, the master control module configured to control the battery pack power on/off and including internal electrical connector means to interface with each universal battery modules and control means to control electric equalization of the string of universal battery modules;

wherein the string of universal battery modules and the master control module are packaged together as a single integral battery pack.

16. The battery pack as set forth in claim 15, wherein the universal battery modules are electrically connected in series.

17. The battery pack as set forth in claim 15, wherein the universal battery modules are electrically connected in parallel.

18. The battery pack as set forth in claim 15, wherein the master control module further comprises an external electrical connector means to interface with an external system controller via a serial communication bus to transmit charge/discharge power control, warning light control and safety interlock signals.

19. The battery pack as set forth in claim 15, wherein the master control module further includes ground fault sensor means that monitors di-electric impedance of the battery pack.

20. The battery pack as set forth in claim 15, wherein the master control module further includes a current shunt that monitors the battery pack current.

21. The battery pack as set forth in claim 15, wherein the master control module further includes a fuse to protect the battery pack from short circuit.