METHODS AND APPARATUSES FOR ELECTROCHEMICAL CELL MONITORING AND CONTROL

• US 20120094150A1
• Filed: 10/14/2010
• Published: 04/19/2012
• Est. Priority Date: 10/14/2010
• Status: Active Grant

• Current Assignee: Northrop Grumman Systems Corporation (Northrop Grumman Corporation)
• Original Assignee: Alliant Techsystems Incorporated (Northrop Grumman Corporation)
• Inventors: Troutman, Joseph M.
• Granted Patent: US 8,470,464 B2
• Time in Patent Office: Days
• US Class Current: 429/50
• CPC Class Codes: G01R 19/16542 for batteries charge condition monitoring in G01R31/36
• CPC Class Codes: G01R 31/396 Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery
• 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 10/482 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 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 50/505 comprising a single busbar
• CPC Class Codes: H01M 50/509 characterised by the type of connection, e.g. mixed connections
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/512 Connection only in parallel
• CPC Class Codes: H01M 6/42 Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H02J 7/007194 of the battery
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Battery sub-arrays are configured for electrical and mechanical coupling with each other to form a multi-cell battery. A sub-array may be an individual cell or a group of cells. Each sub-array includes a bypass switch to connect the sub-array within the multi-cell battery or bypass the sub-array. Monitoring and control circuitry controls the bypass switch in response to voltage measurements, temperature measurements or a combination thereof for the sub-array. Each sub-array is contained in a holder including a housing and a thermal container encompassing a substantial portion of the housing. The housing includes a cell cavity, a sensor cavity, and a circuit cavity. Positive terminals and negative terminals are positioned on sides of the holder such that when holders are mechanically abutted in an array, various electrical connections can be made to connect the cells in series, parallel, or a combination thereof.

Claims

1. A battery sub-array, comprising:

a sub-array electrochemical cell configured for coupling with other sub-array electrochemical cells to form a multi-cell battery;

a temperature sensor configured for disposition in a holder for the sub-array electrochemical cell and proximate the sub-array electrochemical cell;

a bypass switch operably coupled to switch a first holder terminal to either a second holder terminal or a cell terminal of the sub-array electrochemical cell; and

monitor and control circuitry operably coupled to the sub-array electrochemical cell, the bypass switch, and the temperature sensor and configured for;

monitoring a temperature of the sub-array electrochemical cell; and

responsive to the monitoring, selectively opening the bypass switch to couple the electrochemical cell between the first holder terminal and the second holder terminal or selectively closing the bypass switch to bypass the electrochemical cell.

3. The battery sub-array of claim 1, wherein the sub-array electrochemical cell includes at least two single electrochemical cells operably coupled in series.

4. The battery sub-array of claim 1, wherein the monitor and control circuitry is further configured for:

sampling the temperature sensor to determine the temperature of the sub-array electrochemical cell; and

closing the bypass switch when the temperature is greater than a predetermined maximum temperature or less than a predetermined minimum temperature.

5. The battery sub-array of claim 4, wherein the monitor and control circuitry is further configured for opening the bypass switch when the temperature is less than the predetermined maximum temperature and greater than the predetermined minimum temperature.

6. The battery sub-array of claim 4, wherein the monitor and control circuitry is further configured for determining a rate of change of the temperature of the sub-array electrochemical cell, closing the bypass switch when the rate of change exceeds a predetermined rate threshold and opening the bypass switch when the rate of change is less than the predetermined rate threshold.

7. The battery sub-array of claim 1, wherein the monitor and control circuitry is further configured for:

sampling a voltage across the sub-array electrochemical cell; and

closing the bypass switch when the voltage is greater than a predetermined maximum voltage or less than a predetermined minimum voltage.

8. The battery sub-array of claim 7, wherein the monitor and control circuitry is further configured for opening the bypass switch a predetermined time delay after the closing the bypass switch.

9. The battery sub-array of claim 1, further comprising a communication bus operably coupled to the monitor and control circuitry and configured for conveying at least one of temperature information for the sub-array electrochemical cell and voltage information for the sub-array electrochemical cell to an external controller.

2. The battery sub-array 1, wherein the sub-array electrochemical cell is a single electrochemical cell.

10. A multi-cell battery, comprising:

two or more electrochemical cell circuits operably coupled to form the multi-cell battery, wherein each of the two or more electrochemical cell circuits comprises;

a single electrochemical cell;

a bypass switch operably coupled to switch a first holder terminal to either a second holder terminal or a cell terminal of the single electrochemical cell; and

monitor and control circuitry operably coupled to the single electrochemical cell and the bypass switch and configured for;

monitoring a voltage across the single electrochemical cell; and

selectively operating the bypass switch to connect or disconnect the cell terminal from the second holder terminal responsive to the monitoring.

11. The multi-cell battery of claim 10, wherein each of the two or more electrochemical cell circuits further comprises a temperature sensor operably coupled to the monitor and control circuitry and configured for disposition in a holder for the single electrochemical cell and proximate the single electrochemical cell and wherein the monitor and control circuitry is further configured for:

sampling the temperature sensor to determine temperature information; and

selectively operating the bypass switch to connect or disconnect the cell terminal from the second holder terminal responsive to the temperature information.

12. The multi-cell battery of claim 10, wherein the two or more electrochemical cell circuits are operably coupled in series.

13. The multi-cell battery of claim 10, wherein the two or more electrochemical cell circuits are operably coupled in parallel.

14. The multi-cell battery of claim 10, wherein the two or more electrochemical cell circuits comprise four or more electrochemical cell circuits and at least two of the four or more electrochemical cell circuits are operably coupled in parallel and at least two of the four or more electrochemical cell circuits are operably coupled in series.

15. A method for monitor and control, comprising:

monitoring at least one of a temperature of an electrochemical cell and a voltage across the electrochemical cell;

coupling a first terminal of the electrochemical cell to a first terminal of a holder for the electrochemical cell; and

responsive to the monitoring, selectively coupling a second terminal of the holder either to a second terminal of the electrochemical cell or to the first terminal of the holder.

16. The method of claim 15, wherein:

the selectively coupling comprises disconnecting the second terminal of the electrochemical cell from the second terminal of the holder upon an occurrence of a first voltage event or an occurrence of a second voltage event;

the first voltage event occurs when the voltage across the electrochemical cell exceeds a predetermined maximum voltage; and

the second voltage event occurs when the voltage across the electrochemical cell is less than a predetermined minimum voltage.

17. The method of claim 15, wherein:

the selectively coupling comprises disconnecting the second terminal of the electrochemical cell from the second terminal of the holder upon an occurrence of a first temperature event or upon an occurrence of a second temperature event;

the first temperature event occurs when the temperature of the electrochemical cell exceeds a predetermined maximum temperature; and

the second temperature event occurs when the temperature of the electrochemical cell is less than a predetermined minimum temperature.

18. The method of claim 17, wherein the monitoring further comprises determining a rate of change of the temperature of the electrochemical cell and the selectively coupling further comprises disconnecting the second terminal of the electrochemical cell from the second terminal when the rate of change exceeds a predetermined rate threshold.

19. A method for monitoring and control, comprising:

monitoring at least one of a temperature of an electrochemical cell and a voltage across the electrochemical cell;

electrically coupling terminals of the electrochemical cell to corresponding terminals of a holder for the electrochemical cell; and

responsive to the monitoring, selectively bypassing the electrochemical cell by coupling the terminals of the holder together and decoupling at least one terminal of the electrochemical cell from a corresponding terminal of the holder.

20. A holder for an electrochemical cell holder, comprising:

a housing;

comprising;

a first serial side;

a second serial side opposite from the first serial side;

a first parallel side;

a second parallel side opposite from the first parallel side;

a cell cavity within the housing configured to receive an electrochemical cell;

a sensor cavity within the housing configured to receive a temperature sensor; and

a circuit cavity within the housing configured to receive circuitry for monitoring and controlling the electrochemical cell;

a positive terminal on the first serial side and for operable coupling to the electrochemical cell; and

a negative terminal on the second serial side and for operable coupling to the electrochemical cell;

wherein the housing is configured for;

mechanical and electrical engagement with a first other electrochemical cell holder on the first serial side; and

mechanical and electrical engagement with a second other electrochemical cell holder on the first serial side.

21. The holder of claim 20, wherein at least one of the positive terminal and the negative terminal is configured for selective retraction such that the terminal is retracted within a terminal cavity of the holder so it will not electrically connect to a corresponding terminal of an adjacent holder or is coplanar with or slightly protruding from an exterior surface of the holder so it will electrically connect with the corresponding terminal of the adjacent holder.

22. The holder of claim 20, wherein at least one of the positive terminal and the negative terminal is disposed in a terminal cavity of the holder such that it will not electrically connect to a corresponding terminal of an adjacent holder and further comprising a connection plug for disposition in the terminal cavity such that the connection plug will have a surface coplanar with or slightly protruding from an exterior surface of the holder and electrically connect the terminal with the corresponding terminal of the adjacent holder.

23. The holder of claim 20, further comprising first protrusions on the first serial side and second protrusions on the second serial side wherein the first protrusions of the holder are configured to mesh with the second protrusions of an adjacent holder.

24. The holder of claim 23, further comprising third protrusions on the first parallel side and fourth protrusions on the second parallel side wherein the third protrusions of the holder are configured to mesh with the fourth protrusions of another adjacent holder.

25. The holder of claim 20, further comprising:

a second positive terminal configured for exposure on the first parallel side and for operable coupling to the electrochemical cell;

a second negative terminal configured for exposure on the first parallel side and for operable coupling to the electrochemical cell;

a third positive terminal configured for exposure on the second parallel side and for operable coupling to the electrochemical cell; and

a third negative terminal configured for exposure on the second parallel side and for operable coupling to the electrochemical cell;

wherein the housing is further configured for;

mechanical and electrical engagement with a third other electrochemical cell holder on the first parallel side; and

mechanical and electrical engagement with a fourth other electrochemical cell holder on the second parallel side.

26. The holder of claim 25, further comprising:

a fourth positive terminal configured for exposure on the second serial side and for operable coupling to the electrochemical cell; and

a fourth negative terminal configured for exposure on the first serial side and for operable coupling to the electrochemical cell.

27. The holder of claim 20, further comprising a thermal container encompassing a substantial portion of the housing.

28. The holder of claim 27, wherein the thermal container comprises a flexible graphite material.