BATTERY PACK ASSEMBLY WITH INTEGRATED HEATER

• US 20080226969A1
• Filed: 03/13/2008
• Published: 09/18/2008
• Est. Priority Date: 03/14/2007
• Status: Active Grant

• Current Assignee: EnerDel, Inc. (Ener1, Inc.)
• Original Assignee: EnerDel, Inc. (Ener1, Inc.)
• Inventors: Fattig, Robert N.
• Granted Patent: US 8,574,738 B2
• Time in Patent Office: Days
• US Class Current: 429/90
• 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 10/4207 for several batteries or cells simultaneously or sequentially
• 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 10/486 for measuring temperature
• CPC Class Codes: H01M 10/615 Heating or keeping warm
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/657 by electric or electromagnetic means
• CPC Class Codes: H01M 10/6571 Resistive heaters arrangements for heating the battery by its resistance to the internal current H01M10/637
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery pack assembly for providing electric power to a load includes a battery pack, preferably made up of a plurality of lithium ion cells. A heating device formed of a flexible material flexes and covers at least part of the battery pack. The heating device includes a meandering heating strip. A thermal sensor is surrounded by the heating strip to sense the temperature of the battery pack. Electric current is applied to the heating strip to heat the battery pack when its temperature falls too low, thus improving performance of the battery pack. The heating device also includes a plurality of tabs extending beyond the peripheral sides of the heating device for direct connection to the cells. Thus, electric current for the heating strip is provided directly from the cells of the battery pack.

Claims

1. A battery pack assembly comprising:

a battery pack having at least one cell;

a heating device having a first layer and a second layer of flexible non-conductive material and defining a plurality of peripheral sides;

said heating device positioned to overlap at least a portion of said battery pack;

a plurality of conductive traces of a conductive material sandwiched between said layers of said heating device wherein said conductive traces include a heating strip for heating the cells of the battery pack and at least one connection pad for conducting electric current; and

at least one connection tab electrically connected to said at least one connection pad and extending beyond said peripheral sides of said heating device for electrical connection of said connection pad to said at least one cells of said battery pack.

2. An assembly as set forth in claim 1 wherein said plurality of conductive traces further includes a thermal sensor for sensing temperature.

3. An assembly as set forth in claim 2 wherein said thermal sensor is generally surrounded by said heating strip for sensing the temperature of said heating strip and/or said battery pack.

4. An assembly as set forth in claim 3 wherein said thermal sensor is positioned generally adjacent a center of said battery pack.

5. An assembly as set forth in claim 1 further comprising a printed circuit board (PCB) for supporting and electrically connecting a plurality of electronic devices.

6. An assembly as set forth in claim 5 wherein conductive traces of said heating element are electrically connected to said PCB.

7. An assembly as set forth in claim 6 wherein said heating devices includes an electrical interface stub extending from one of said peripheral sides.

8. An assembly as set forth in claim 7 wherein each of said conductive traces terminates at said electrical interface stub for electrical connection of said conductive traces to said PCB.

9. An assembly as set forth in claim 1 wherein said battery pack includes a plurality of cells disposed adjacent one another and electrically interconnected together.

10. An assembly as set forth in claim 9 wherein said cells are lithium ion cells.

11. A battery pack assembly comprising:

a plurality of cells disposed adjacent one another and electrically interconnected to form a battery pack;

a heating device having a first layer and a second layer of flexible non-conductive material and defining a plurality of peripheral sides;

said heating device positioned to overlap at least a portion of said battery pack;

a plurality of conductive traces of a conductive material sandwiched between said layers of said heating device wherein said conductive traces include a heating strip meandering between said peripheral sides for producing heat in response to receiving an electric current; and

said plurality of conductive traces including a plurality of connection pads for receiving electric current from said cells of said battery pack such that said electric current is applied to said heating strip.

12. An assembly as set forth in claim 11 further comprising a plurality of connection tabs wherein each connection tab is electrically connected to one of said connection pads and at least one of said cells of said battery pack.

13. A battery pack assembly comprising:

a battery pack having at least one cell;

a heating device having a first layer and a second layer of flexible non-conductive material and defining a plurality of peripheral sides;

said heating device positioned to overlap at least a portion of said battery pack;

a plurality of conductive traces of conductive material sandwiched between said layers;

said conductive traces including a heating strip meandering between said peripheral sides for producing heat to heat said cells of said battery pack; and

said conductive traces also including a thermal sensor generally surrounded by said heating strip for sensing temperature.

14. An assembly as set forth in claim 13 wherein said thermal sensor is positioned generally adjacent a center of said battery pack.

15. An assembly as set forth in claim 13 further comprising a printed circuit board (PCB) for supporting and electrically connecting a plurality of electronic devices.

16. An assembly as set forth in claim 15 wherein conductive traces of said heating element are electrically connected to said PCB.

17. An assembly as set forth in claim 13 wherein said battery pack includes a plurality of cells disposed adjacent one another and electrically interconnected together.

18. An assembly as set forth in claim 17 wherein said cells are lithium ion cells.