Solid-state energy storage module employing integrated interconnect board

• US 6,146,778 A
• Filed: 07/25/1997
• Issued: 11/14/2000
• Est. Priority Date: 07/25/1997
• Status: Expired due to Term

• Current Assignee: 3M Innovative Properties Company (3M Company), Avestor (Bolloré SE), Bathium Canada Inc. (Bolloré SE)
• Original Assignee: 3M Innovative Properties Company (3M Company), HYDRO-Quebec Corporation
• Inventors: Ranger, Michel, Sudano, Anthony, Knudson, Orlin B., Rouillard, Roger, Morin, Andre, Comte, Christophe, Ross, Guy, Daigle, Dominik, St-Germain, Philippe, Turgeon, Thomas A., Rouillard, Jean, Hagen, Ronald A.
• Primary Examiner(s): Maples, John S.
• Application Number:
  US08/900,427
• Time in Patent Office: 1,208 Days
• Field of Search: 429/121, 429/7, 429/159, 361/434
• US Class Current: 429/7
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/0445 Multimode batteries, e.g. containing auxiliary cells or electrodes switchable in parallel or series connections
• 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 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/653 characterised by electrically insulating or thermally conductive materials
• CPC Class Codes: H01M 10/6553 Terminals or leads
• CPC Class Codes: H01M 10/6554 Rods or plates
• 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 10/656 characterised by the type of heat-exchange fluid
• CPC Class Codes: H01M 10/659 by heat storage or buffering, e.g. heat capacity or liquid-solid phase changes or transition
• CPC Class Codes: H01M 10/667 the system being an electronic component, e.g. a CPU, an inverter or a capacitor
• CPC Class Codes: H01M 2200/00 Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2200/103 Fuse
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/264 for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/293 characterised by the material
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 50/50 : Current conducting connections for cells or batteries
• CPC Class Codes: H01M 50/503 : characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/569 : Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H01M 50/583 : in response to current, e.g. fuses
• CPC Class Codes: H01M 6/181 : with polymeric electrolytes
• CPC Class Codes: H01M 6/5016 : Multimode utilisation
• CPC Class Codes: H05K 1/117 : Pads along the edge of rigid circuit boards, e.g. for pluggable connectors
• CPC Class Codes: H05K 1/18 : Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• 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: Y10T 29/4911 : including sealing

Abstract

The present invention is directed to an improved electrochemical energy storage device. The electrochemical energy storage device includes a number of solid-state, thin-film electrochemical cells which are selectively interconnected in series or parallel through use of an integrated interconnect board. The interconnect board is typically disposed within a sealed housing which also houses the electrochemical cells, and includes a first contact and a second contact respectively coupled to first and second power terminals of the energy storage device. The interconnect board advantageously provides for selective series or parallel connectivity with the electrochemical cells, irrespective of electrochemical cell position within the housing. In one embodiment, a sheet of conductive material is processed by employing a known milling, stamping, or chemical etching technique to include a connection pattern which provides for flexible and selective interconnecting of individual electrochemical cells within the housing, which may be a hermetically sealed housing. Fuses and various electrical and electro-mechanical devices, such as bypass, equalization, and communication devices for example, may also be mounted to the interconnect board and selectively connected to the electrochemical cells.

Claims

1. A solid-state energy storage device, comprising:

a sealed housing through which a first terminal and a second terminal pass;

a plurality of thin-film electrochemical cells disposed in the housing; and

an interconnect board disposed in the housing and having a first contact and a second contact respectively coupled to the first and second terminals, the interconnect board including an electrically conductive surface comprising a connection pattern that provides selective series and parallel connectivity with the electrochemical cells.

2. The device of claim 1, wherein:

a first group of electrochemical cells of the plurality of electrochemical cells is connected through the interconnect board in parallel to form a first cell pack;

a second group of electrochemical cells of the plurality of electrochemical cells is connected through the interconnect board in parallel to form a second cell pack; and

the first and second cell packs are connected through the interconnect board in series.

3. The device of claim 1, further comprising a plurality of fuses affixed to the interconnect board, each of the fuses connected in series with one of the electrochemical cells.

4. The device of claim 2, further comprising a first fuse pack and a second fuse pack each affixed to the interconnect board, the first and second fuse packs each comprising a plurality of fuses, each of the plurality of fuses of the first fuse pack being connected in series with one of the electrochemical cells of the first group, and each of the plurality of fuses of the second fuse pack being connected in series with one of the electrochemical cells of the second group.

5. The device of claim 2, wherein a first bypass device and a first equalizer device are affixed to the interconnect board and respectively coupled in series and parallel with the electrochemical cells of the first group, and a second bypass device and a second equalizer device are affixed to the interconnect board and respectively coupled in series and parallel with the electrochemical cells of the second group.

6. The device of claim 1, wherein voltage and current characteristics of the solid-state energy storage device are alterable by altering the connection pattern of the sheet of conductive material.

7. The device of claim 1, wherein the electrically conductive surface comprises one of a machine milled connection pattern, a stamped connection pattern, or a chemically etched connection pattern.

8. The device of claim 1, wherein the electrically conductive surface comprises copper or aluminum.

9. The device of claim 1, wherein the connection pattern of the sheet of conductive material provides selective series or parallel connectivity with the electrochemical cells.

10. The device of claim 1, wherein each of the electrochemical cells comprises first and second terminals which are electrically coupled to the connection pattern of the electrically conductive surface.

11. The device of claim 1, wherein the first and second terminals of each of the electrochemical cells are ultrasonically welded to the connection pattern of the electrically conductive surface.

12. The device of claim 1, wherein a current of up to approximately 400 amperes passes through the interconnect board.

13. The device of claim 1, wherein the housing is a hermetically sealed housing.

14. An energy storage device, comprising:

a sealed housing through which a first terminal and a second terminal pass;

an interconnect board disposed in the housing and having a first contact and a second contact respectively coupled to the first and second terminals, the interconnect board including an electrically conductive surface comprising a connection pattern that provides selective connectivity with a plurality of electrochemical cells;

a first group of electrochemical cells of the plurality of electrochemical cells connected through the interconnect board in parallel to form a first cell pack;

a second group of electrochemical cells of the plurality of electrochemical cells connected through the interconnect board in parallel to form a second cell pack; and

the first and second cell packs connected through the interconnect board in series.

15. The device of claim 14, further comprising a first fuse pack and a second fuse pack each affixed to the interconnect board, the first and second fuse packs each comprising a plurality of fuses, each of the plurality of fuses of the first fuse pack being connected in series with one of the electrochemical cells of the first group, and each of the plurality of fuses of the second fuse pack being connected in series with one of the electrochemical cells of the second group.

16. The device of claim 14, wherein a first bypass device is affixed to the interconnect board and coupled in series with the electrochemical cells of the first group, and a second bypass device is affixed to the interconnect board and coupled in series with the electrochemical cells of the second group.

17. The device of claim 14, wherein a first equalizer device is affixed to the interconnect board and coupled in parallel with the electrochemical cells of the first group, and a second equalizer device is affixed to the interconnect board and coupled in parallel with the electrochemical cells of the second group.

18. A solid-state energy storage device, comprising:

a sealed housing through which a first terminal and a second terminal pass;

a plurality of thin-film electrochemical cells disposed in the housing;

an interconnect board disposed in the housing and having a first contact and a second contact respectively coupled to the first and second terminals of the housing, the interconnect board including a surface comprising a plurality of connection regions each being connected to particular ones of the plurality of electrochemical cells;

a plurality of series connected current bypass devices that electrically couple the connection regions together and to the first and second contacts of the interconnect board.

19. A solid-state energy storage device, comprising:

a sealed housing through which a first terminal and a second terminal pass;

a plurality of thin-film electrochemical cells disposed in the housing;

an interconnect board disposed in the housing and having a first contact and a second contact respectively coupled to the first and second terminals of the housing, the interconnect board including a surface comprising a plurality of connection regions each being connected to particular ones of the plurality of electrochemical cells; and

a plurality of parallel connected equalizer devices that electrically couple the connection regions together and to the first and second contacts of the interconnect board.

20. A solid-state energy storage device, comprising:

a sealed housing through which a first terminal and a second terminal pass;

a plurality of thin-film electrochemical cells disposed in the housing;

an interconnect board disposed in the housing and having a first contact and a second contact respectively coupled to the first and second terminals of the housing, the interconnect board including a surface comprising a plurality of connection regions each being connected to particular ones of the plurality of electrochemical cells; and

a plurality of parallel connected integrated equalizer and current bypass units that electrically couple the connection regions together and to the first and second contacts of the interconnect board.

21. A solid-state energy storage device, comprising:

a sealed housing through which a first terminal and a second terminal pass;

a plurality of thin-film electrochemical cells disposed in the housing;

an interconnect board disposed in the housing and having a first contact and a second contact respectively coupled to the first and second terminals of the housing, the interconnect board including a surface comprising a plurality of connection regions each being connected to particular ones of the plurality of electrochemical cells;

a plurality of electrically conductive elements that electrically couple the connection regions together and to the first and second contacts of the interconnect board; and

at least one communications connector affixed to the interconnect board that receives a mating connector disposed on a communication line that passes through the sealed housing.

22. The device of claim 21, wherein each of the electrically conductive elements comprises a series connected current bypass device.

23. The device of claim 21, wherein each of the electrically conductive elements comprises a parallel connected equalizer device.

24. The device of claim 21, wherein each of the electrically conductive elements comprises a parallel connected integrated equalizer and current bypass unit.