Integrated battery unit for electric vehicles

• US 20070090810A1
• Filed: 07/20/2005
• Published: 04/26/2007
• Est. Priority Date: 07/20/2005
• Status: Active Grant

• Current Assignee: Webasto SE (Webasto Beteiligungs Verwaltung Gbr)
• Original Assignee: Aerovironment
• Inventors: Hayashigawa, Larry, Dickinson, Blake
• Granted Patent: US 8,816,645 B2
• Time in Patent Office: Days
• US Class Current: 320/150
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B66F 9/07595 Cooling arrangements for device or operator
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/63 Control systems charging or discharging in response to temperature H01M10/44 , H01M10/443; measurement of temperature H01M10/48 , H01M10/486
• CPC Class Codes: H01M 10/6557 arranged between the cells
• CPC Class Codes: H01M 10/6563 with forced flow, e.g. by blowers
• 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 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• 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 90/14 Plug-in electric vehicles

Abstract

Methods of and apparatus for removing heat generated by cells of a battery pack. The method and apparatus may employ one or more fan modules disposed between or next to cells of the battery pack, or one or more fans directly mounted to the battery pack or battery pack case housing the cells. Further, a motor controller isolation system operates to electricity isolate the motor controller of the electric vehicle when the battery pack is being charged. The motor controller isolation system may be integrated with the integrated battery pack and thermal and ventilation system. The integrated system, or “integrated battery unit (IBU),” is preferably manufactured in a manner that requires no, modifications to the electric vehicle in which the IBU is installed.

Claims

1. A method of removing heat generated by cells of a battery pack, comprising

drawing air from an ambient environment toward cells of a battery pack;

directing the drawn-in air toward one or more surfaces of the cells; and

displacing air heated by contact with the one or more surfaces away from the battery pack.

2. The method of claim 1 wherein drawing in air comprises drawing in air into an air inlet port of one or more fan modules interposed between or next to one or more cells of the battery pack.

3. The method of claim 2, further comprising:

circulating the drawn-in air through the one or more fan modules; and

ejecting the heated air out an air outlet port of the one or more fan modules.

4. The method of claim 3 wherein circulating the drawn-in air is performed by operation of one or more fans disposed in said one or more fan modules.

5. The method of claim 4 wherein the one or more fans are controlled by either a thermostat or a battery mounted monitor and controller associated with the battery pack.

6. The method of claim 4 wherein the one or more fans are controlled by either a key switch or a charger interlock.

7. The method of claim 1 wherein drawing in air is performed by one or more fans directly mounted to the battery pack or a battery pack container.

8. The method of claim 7 wherein the one or more direct-mounted fans are controlled by either a thermostat or a battery mounted monitor and controller associated with the battery pack.

9. The method of claim 7 wherein the one or more direct-mounted fans are controlled by either a key switch or a charger interlock.

10. An integrated battery unit for an electric vehicle, comprising:

a plurality of cells; and

a fan module interposed between walls of at least two adjacent cells.

11. The integrated battery unit of claim 10 wherein said fan module includes:

an air inlet port configured to draw in air from the ambient environment into an interior of the fan module;

an air outlet port configured to eject heated air from the fan module interior and away from the plurality of cells; and

a fan operable to circulate the drawn-in air from the air inlet port and force the heated air out the air outlet port.

12. The integrated battery unit of claim 10 wherein the fan module has side panels in contact with the walls of at least two adjacent cells.

13. The integrated battery unit of claim 12 wherein the side panels are made from a heat conducting material.

14. The integrated battery unit of claim 12 wherein cut-outs are made through the side panels, so that air circulating through said fan module is able to come in direct contact with the walls of at least two adjacent cells.

15. The integrated battery unit of claim 10, further comprising a battery pack container configured to house the plurality of cells and the fan module in a manner that does not require any modifications to an electric vehicle into which the battery pack container is to be installed.

16. The integrated battery unit of claim 10, further comprising a motor controller isolator operable to selectively isolate electrical terminals of a motor controller of an electric vehicle from one or more electrical terminals of the battery pack when the integrated battery unit and cooling system is installed in the electric vehicle.

17. A motor controller isolation system for an electric vehicle, comprising:

a first set of connectors having positive and negative terminals electrically coupled to positive and negative terminals of a battery pack and electrically connectable to positive and negative terminals of a battery charger;

a second set of connectors having positive and negative terminals electrically connectable to positive and negative terminals of a motor controller; and

an isolator operable to selectively couple the positive and negative terminals of said second set of connectors to the positive and negative terminals of the battery pack.

18. The motor controller isolation system of claim 17 wherein said isolator electrically isolates either or both the positive and negative terminals of said second set of connectors from the positive and negative terminals of the battery pack when the positive and negative terminals of said first set of connectors is connected to positive and negative terminals of the battery charger.

19. The motor controller isolation system of claim 18 wherein the isolator is either mechanically or electrically controlled.

20. A method of manufacturing an integrated battery unit, comprising:

providing a battery pack container;

installing a plurality of cells in the battery pack container;

interposing one or more fan modules between two or more adjacent cells in the battery pack container; and

electrically connecting the plurality of cells.

21. The method of claim 20 wherein each fan module comprises:

an air inlet port configured to draw in air from the ambient environment into an interior of the fan module;

an air outlet port configured to eject heated air from the fan module interior and away from the plurality of cells; and

a fan operable to circulate the drawn-in air from the air inlet port and force the heated air out the air outlet port.

22. The method of claim 20 wherein side panels of said one or more fan modules are in contact with external surfaces of said two or more cells, when the one or more fan modules are disposed between said two or more adjacent cells.

23. The method of claim 22 wherein the side panels are made from a heat conducting material.

24. The method of claim 22 wherein the side panels of said one or more fan modules have cut-outs through them, so that air circulating through said one or more fan modules is able to come in direct contact with the external surfaces of said two or more cells.

25. The method of claim 20, further comprising installing a motor controller isolator to power terminals of the plurality of cells.

26. An integrated battery pack and thermal and ventilation management system for an electric vehicle, comprising:

a plurality of electrically connected cells housed in a battery pack tray; and

one or more fan modules disposed next to or between one or more of said plurality of cells.

27. The system of claim 26 wherein the battery pack tray, cells and fan module can all be installed in the electric vehicle without requiring any, or substantially any, modifications to the electric vehicle.

28. The system of claim 26 wherein said one or more fan module each have side panels in contact with a surface of at least one of said plurality of cells.

29. The system of claim 28 wherein the side panels are made from a heat conducting material.

30. The system of claim 28 wherein cut-outs are made through the side panels, so that air circulating through said one or more fan modules is able to come in direct contact with a surface of at least one of said plurality of cells.

31. The system of claim 26, further comprising a thermostat or battery mounted monitor and controller that is operable to control operation of said one or more fan modules.

32. The system of claim 26, further comprising an key switch or charger interlock that is operable to control operation of said one or more fan modules.

33. The system of claim 26, further comprising a motor controller isolator operable to isolate electrical terminals of a motor controller of the electric vehicle from electrical terminals of the battery pack when battery pack connectors are mated with connectors of a charger.

34. An electric vehicle including an integrated battery unit (IBU) comprising a fan box having one or more fans, said fan box mounted on a battery pack of the electric vehicle.

35. The electric vehicle of claim 34 wherein the IBU further comprises a motor controller isolator operable to selectively isolate electrical terminals of a motor controller of an electric vehicle from one or more electrical terminals of the battery pack.

36. The electric vehicle of claim 35 wherein the motor controller isolator is either electrically or mechanically controlled.

37. The electric vehicle of claim 35 wherein the IBU further comprises a charge port, said charge port including means for electrically isolating the electrical terminals of the motor controller from the electrical terminals of the battery pack when a charger connector is plugged into the charge port.

38. The electric vehicle of claim 37 further comprising a charge port configured to receive a fast charge connector from a fast charger.

39. The electric vehicle of claim 38 wherein the IBU further comprises a connector status indicator that indicates whether said fast charge connector is plugged into said charge port.

40. The electric vehicle of claim 34, further comprising a thermostat or a battery mounted monitor and controller that is operable to control the operation of said one or more fans of said fan box.

41. The electric vehicle of claim 40 wherein the IBU further comprises a battery mounted monitor and controller display.

42. The electric vehicle of claim 34, further comprising a key switch or charger interlock that is operable to control the operation of said one or more fans of said fan box.

43. An integrated battery unit (IBU) comprising a fan housing containing one or more fans, said fan housing configured to be attached to a battery pack of an electric vehicle, said IBU capable of being installed in an electric vehicle without having to make any modifications to the electric vehicle.

44. The IBU of claim 43, further comprising a charge port that is accessible through the fan housing.

45. The IBU of claim 43, further comprising a thermostat or a battery mounted monitor and controller that is operable to control the operation of said one or more fans.

46. The IBU of claim 45, further comprising a battery mounted monitor and controller display mounted on or in said fan housing.

47. The IBU of claim 43, further comprising a key switch or a charger interlock that is operable to control the operation of said one or more fans.

48. The IBU of claim 43, further comprising a watering solenoid mounted on or in said fan housing, said watering solenoid valve configured for coupling to a watering system.

49. The IBU of claim 43, further comprising a motor controller isolator operable to selectively isolate electrical terminals of a motor controller of the electric vehicle from one or more electrical terminals of the battery pack.

50. The IBU of claim 49 wherein said motor controller isolator is either mechanically or electrically controlled.