Battery pack including electronic power saver

• US 5,204,608 A
• Filed: 11/07/1989
• Issued: 04/20/1993
• Est. Priority Date: 11/07/1989
• Status: Expired due to Term

• Current Assignee: Unova Incorporated (Honeywell International Inc.)
• Original Assignee: Norand Corporation (Baker Hughes Company)
• Inventors: Koenck, Steven E.
• Primary Examiner(s): Hickey, R. J.
• Application Number:
  US07/433,076
• Time in Patent Office: 1,260 Days
• Field of Search: 307/150, 320/2, 320/39, 320/13, 429/99, 429/100, 429/7
• US Class Current: 320/112
• CPC Class Codes: H01M 10/42 Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• 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 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/269 Mechanical means for varying the arrangement of batteries or cells for different uses, e.g. for changing the number of batteries or for switching between series and parallel wiring methods or arrangements for servicing or maintenance H01M6/50, H01M10/42
• CPC Class Codes: H01M 50/284 with incorporated circuit boards, e.g. printed circuit boards [PCB]
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 6/50 Methods or arrangements for servicing or maintenance, e.g. for maintaining operating temperature 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: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00308 Overvoltage protection
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A housing of a battery pack contains in addition to standard power cell elements a voltage converter. The voltage converter is interposed between the power cell elements and external output contacts of the housing. The voltage converter regulates the output voltage applied to the output contacts of the battery pack, such that the supply voltage of the battery pack remains at a predetermined value which is independent of the voltage supplied by the power cell elements to the voltage converter and does not vary over the discharge cycle of the power cell elements. Excess battery voltage available particularly during the initial portion of the discharge cycle of the power cell elements is efficiently converted to the predetermined output voltage value which reduces the overall current delivered by the power cells to extend the useful life of the battery pack between charges.

Claims

1. A battery pack comprising:

a power cell having positive and negative terminals, the positive terminal having a positive voltage with respect to the voltage at the negative terminal, such positive voltage having values subject to measurable variations over a first range during a discharge cycle of the power cell;

housing means encasing the power cell, said housing means including external positive and negative contacts; and

means, coupled respectively between the positive terminal of the power cell and the positive contact of the housing means, and between the negative terminal of the power cell and the negative contact of the housing means, for regulating the voltage at the positive terminal with respect to the voltage at the negative terminal of the power cell to values within a predetermined second range with values of a similar magnitude as the first range, and for applying such regulated voltage values to the positive contact with respect to the negative contact of the housing means, whereby the power cell appears to have between such positive and negative contacts a characteristic voltage variation of the predetermined, second range of values over the discharge cycle of the power cell.

a power cell having a plurality positive and negative terminals, the positive terminal having a positive voltage with respect to the voltage at the negative terminal, such positive voltage having values subject to measurable variations over a first range during a discharge cycle of the power cell;

2. A battery pack according to claim 1, wherein the voltage converter is a voltage converter module comprising a circuit board, and wherein said selective power application means is mounted on said circuit board, the voltage converter module further comprising means, mounted on said circuit board and coupled to said selective power application means for controlling the operation of the selective power application means.

3. A battery pack according to claim 2, further comprising a switch for selectively isolating the positive terminal of the power cell from being coupled to the voltage converter.

4. A battery pack comprising a power cell having a plurality of power cell elements with positive and negative terminals, the positive terminal having a positive voltage with respect to the voltage at the negative terminal, such positive voltage having values subject to measurable variations over a first range during a discharge cycle of the power cell;

housing means encasing the power cell, said housing means including external positive and negative contacts;

a switching type voltage converter, coupled respectively between the positive terminal of the power cell and the positive contact of the housing means, and between the negative terminal of the power cell and the negative contact of the housing means, for modifying the voltage at the positive terminal with respect to the voltage at the negative terminal of the power cell to values within a predetermined second range, and for applying such modified voltage values to the positive contact with respect to the negative contact of the housing means, whereby the power cell appears to have between such positive and negative contacts a characteristic voltage variation of the predetermined, second range of values over the discharge cycle of the power cell; and

means for coupling a battery charger across the positive and negative terminals of the power cell, such that a voltage applied to the terminals of the power cell is applied to the voltage converter for conversion to values within said predetermined second range for application to said external contacts of the housing means.

5. A battery pack comprising:

a power cell having a plurality of power cell elements with positive and negative terminals, the positive terminal having a positive voltage with respect to the voltage at the negative terminal, such positive voltage having values subject to measurable variations over a first range during a discharge cycle of the power cell;

housing means encasing the power cell, said housing means including external positive and negative contacts, wherein the housing means comprises a molded housing, said housing supporting the external negative contact disposed at a base of the housing and centered on a central axis through the housing and the external positive contact disposed in spaced relationship along said base adjacent a side wall of the housing, the housing further comprising guide means for receiving the voltage converter and the power cell elements, the housing means further comprising header means for electrically coupling the power cell elements to the voltage converter and means for electrically coupling the converted voltage values to the external contacts of the housing means;

a switching type voltage converter, coupled respectively between the positive terminal of the power cell and the positive contact of the housing means, and between the negative terminal of the power cell and the negative contact of the housing means, for modifying the voltage at the positive terminal with respect to the voltage at the negative terminal of the power cell to values within a predetermined second range, and for applying such modified voltage values to the positive contact with respect to the negative contact of the housing means, whereby the power cell appears to have between such positive and negative contacts a characteristic voltage variation of the predetermined, second range of values over the discharge cycle of the power cell, wherein said voltage converter comprises means, controlled by the output voltage appearing between the positive and negative contacts of the housing means, for selectively applying power available at the respective terminals of the power cell elements to the contacts of the housing means, said selective power application means including a first capacitor coupled across the positive and negative terminals of the housing means, and a second capacitor coupled across the positive and negative terminals of the power cell elements.

6. A battery pack according to claim 5, wherein the positive external contact is a first positive external contact, the housing further supporting a second positive external contact spaced from the centered negative contact in symmetry to said first positive external contact.

7. A battery pack comprising:

a housing having power terminals including positive and negative external contacts, said contacts adapted to be coupled to a utilization device;

a power cell disposed within the housing, the power cell having positive and negative terminals and having a positive voltage at the positive terminal with respect to the negative terminal, such positive voltage being of a variable value within a known range over a discharge cycle of the power cell;

means contained within the housing and coupled between the positive and negative external contacts and the positive and negative terminals of the power cell for converting the positive voltage at the positive terminal with respect to the negative terminal of the power cell to a predetermined, constant value over the discharge cycle of the power cell and for applying the converted voltage between the positive and negative external contacts; and

a power input terminal disposed in the housing and extending through the housing, an external portion of the power input terminal being adapted to be coupled to a positive power terminal of a battery charging device, the negative external contact being adapted to be coupled to the negative power terminal of the battery charging device, such that a positive input voltage at a voltage level in excess of the voltage level of the power cell applied to the positive terminal with respect to the negative terminal of the power cell for charging the power cell is converted by the voltage converting means prior to the voltage converting means applying the voltage to the positive external contact of the battery pack.

8. A battery pack according to claim 7, wherein the housing has two opposite side walls spaced apart by a predetermined width, a base extending between the two side walls, the positive and negative external contacts and the power input terminal being spacedly disposed along the base, wherein at least one of the positive and negative external contacts is centered along the base between the two opposite side walls and the remaining at least one of the positive and negative external contacts is spacedly located adjacent one of the side walls at a first predetermined distance from the centered external contact, and the power input terminal is spacedly located at a second predetermined distance from the centered external contact.

9. A battery pack according to claim 8, wherein the centered external contact is the negative contact, the positive power terminal is a first positive power terminal and the external portion thereof is a first positive contact, the housing including a second positive power terminal extending through the housing, a portion of the second positive terminal being disposed externally of the housing and forming a second positive contact, the second positive contact being spacedly located at the first predetermined distance from the negative external contact adjacent the opposite side wall of the housing, the second predetermined distance being less than the first predetermined distance such that the power input terminal is located between the negative and one of the positive contacts of the battery pack, the means for converting the voltage and for applying the converted voltage including means for applying the converted voltage to the second positive external contact of the battery pack.

10. A battery pack comprising:

a power cell having positive and negative terminals, the positive terminal having a positive voltage with respect to the voltage at the negative terminal, such positive voltage having values subject to measurable variations over a first range during a discharge cycle of the power cell;

housing means encasing the power cell, said housing means including external positive and negative contacts;

means, coupled respectively between the positive terminal of the power cell and the positive contact of the housing means, and between the negative terminal of the power cell and the negative contact of the housing means, for regulating the voltage at the positive terminal with respect to the voltage at the negative terminal of the power cell to values within a predetermined second range, and for applying such regulated voltage values to the positive contact with respect to the negative contact of the housing means, whereby the power cell appears to have between such positive and negative contacts a characteristic voltage variation of the predetermined, second range of values over the discharge cycle of the power cell;

wherein the power cell comprises at least two power cell elements each of the power cell elements having positive and negative terminals;

wherein the means for regulating is a switching type voltage converter and the regulated voltage values are converted voltage values;

wherein the voltage converter comprises means, controlled by the output voltage appearing between the positive and negative contacts of the housing means, for selectively applying power available at the respective terminals of the power cell elements to the contact of the housing means, said selective power application means including a first capacitor coupled across the positive and negative terminals of the housing means, and a second capacitor coupled across the positive and negative terminals of the power cell elements; and

wherein the housing means comprises means for receiving the power cell elements, means for supporting the voltage converter, and further including a circuit header board mounted within the housing, the circuit header board including terminals and conductive extensions for electrically coupling the power cell elements to the voltage converter and means for electrically coupling the converted voltage values to the external contacts of the housing means.

11. A battery pack according to claim 10, wherein the voltage converter is a voltage converter module comprising a circuit board, and wherein said selective power application means is mounted on said board, the voltage converter module further comprising means, mounted on said circuit board and coupled to said selective power application means for controlling the operation of the selective power application means.

12. A battery pack according to claim 11, further comprising a switch for selectively isolating the positive terminal of the power cell from being coupled to the voltage converter.

13. A battery pack comprising:

a power cell having positive and negative terminals, the positive terminal having a positive voltage with respect to the voltage at the negative terminal, such positive voltage having values subject to measurable variations over a first range during a discharge cycle of the power cell;

housing means encasing the power cell, said housing means including external positive and negative contacts;

means, coupled respectively between the positive terminal of the power cell and the positive contact of the housing means, and between the negative terminal of the power cell and the negative contact of the housing means, for regulating the voltage at the positive terminal with respect to the voltage at the negative terminal of the power cell to values within a predetermined second range, and for applying such regulated voltage values to the positive contact with respect to the negative contact of the housing means, whereby the power cell appears to have between such positive and negative contacts a characteristic voltage variation of the predetermined, second range of values over the discharge cycle of the power cell;

wherein the power cell comprises at least two power cell elements each of the power cell elements having positive and negative terminals;

wherein the means for regulating is a switching type voltage converter and the regulated voltage values are converted voltage values;

further comprising means for coupling a battery charger across the positive and negative terminals of the power cell such that a voltage applied to the terminals of the power cell is applied to the voltage converter for conversion to values within said predetermined second range for application to said external contacts of the housing means.

14. A battery pack comprising:

a power cell having positive and negative terminals, the positive terminal having a positive voltage with respect to the voltage at the negative terminal, such positive voltage having values subject to measurable variations over a first range during a discharge cycle of the power cell;

housing means encasing the power cell, said housing means including external positive and negative contacts;

means, coupled respectively between the positive terminal of the power cell and the positive contact of the housing means, and between the negative terminal of the power cell and the negative contact of the housing means, for regulating the voltage at the positive terminal with respect to the voltage at the negative terminal of the power cell to values within a predetermined second range, and for applying such regulated voltage values to the positive contact with respect to the negative contact of the housing means, whereby the power cell appears to have between such positive and negative contacts a characteristic voltage variation of the predetermined, second range of values over the discharge cycle of the power cell;

wherein the power cell comprises at least two power cell elements each of the power cell elements having positive and negative terminals;

wherein the means for regulating is a switching type voltage converter and the regulated voltage values are converted voltage values;

wherein the voltage converter comprises means, controlled by the output voltage appearing between the positive and negative contacts of the housing means, for selectively applying power available to the respective terminals of the power cell elements to the contact of the housing means, said selective power application means including a first capacitor coupled across the positive and negative terminals of the housing means, and a second capacitor coupled across the positive and negative terminals of the power cell elements; and

wherein the housing means comprises a molded housing, said housing supporting the external negative contact disposed at a base of the housing and centered on a central axis through the housing and the external positive contact disposed in spaced relationship along said base adjacent a side wall of the housing, the housing further comprising guide means for receiving the voltage converter and the power cell elements, the housing means further comprising header means for electrically coupling the power cell elements to the voltage converter and means for electrically coupling the converted voltage values to the external contacts of the housing means.

15. A battery pack according to claim 14, wherein the positive external contact is a first positive external contact, the housing further supporting a second positive external contact spaced apart from the centered negative contact in symmetry to said first positive external contact.

16. A battery pack comprising:

a housing having power terminals including positive and negative external contacts, said contacts adapted to be coupled to a utilization device;

a power cell disposed within the housing, the power cell having positive and negative terminals and having a positive voltage at the positive terminal with respect to the negative terminal, such positive voltage being of a variable value within a known range over a discharge cycle of the power cell;

means contained within the housing and coupled between the positive and negative external contacts and the positive and negative terminals of the power cell for converting the positive voltage at the positive terminal with respect to the negative terminal of the power cell to a predetermined, constant value over the discharge cycle of the power cell and for applying the converted voltage between the positive and negative external contacts; and

a power input terminal disposed in the housing and extending through the housing, an external portion of the power input terminal being adapted to be coupled to a positive power terminal of a battery charging device, the negative external contact being adapted to be coupled to the negative power terminal of the battery charging device such that a positive input voltage at a voltage level in excess of the voltage level of the power cell applied to the positive terminal with respect to the negative terminal of the power cell for charging the power cell is converted by the voltage converting means prior to the voltage converting means applying the voltage to the positive external contact of the battery pack.

17. A battery pack according to claim 16, wherein the housing has two opposite side walls spaced apart by a predetermined width, a base extending between the two side walls, the positive and negative external contacts and the power input terminal being spacedly disposed along the base, wherein at least one of the positive and negative external contacts is centered along the base between the two opposite side walls and the remaining at least one of the positive and negative external contacts is spacedly located adjacent one of the side walls at a first predetermined distance from the centered external contact, and the power input terminal is spacedly located at a second predetermined distance from the centered external contact.

18. A battery pack according to claim 17, wherein the centered external contact is the negative contact, the positive power terminal is a first positive power terminal and the external portion thereof is a first positive contact, the housing including a second positive power terminal extending through the housing, a portion of the second positive terminal being disposed externally of the housing and forming a second positive contact, the second positive contact being spacedly located at the first predetermined distance from the negative external contact adjacent the opposite side wall of the housing, the second predetermined distance being less than the first predetermined distance such that the power input terminal is located between the negative and one of the positive contacts of the battery pack, the means for converting the voltage and for applying the converted voltage including means for applying the converted voltage to the second positive external contact of the battery pack.