Isolated high voltage battery charger and integrated battery pack

• US 7,253,584 B2
• Filed: 08/08/2003
• Issued: 08/07/2007
• Est. Priority Date: 09/12/2002
• Status: Expired due to Fees

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: General Motors Corporation (General Motors Company)
• Inventors: Henze, Christopher P., Conroy, Karl D., Steele, Eugene M., Radys, Raymond G., Souther, James P.
• Primary Examiner(s): Easthom; Karl
• Assistant Examiner(s): Berhanu; Samuel
• Application Number:
  US10/637,815
• Publication Number:
  US 20040130288A1
• Time in Patent Office: 1,460 Days
• Field of Search: 320/104, 320/119, 320/139, 320/162, 307/9.1, 307/10.6, 322/28
• US Class Current: 320/104
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

Methods and apparatus are provided for charging a high-voltage battery of a hybrid electric vehicle. The high-voltage battery charging apparatus comprises a battery charger configured to provide electrical energy, a battery module configured to store the electrical energy provided by the battery charger, and a high-voltage bus coupled to the battery charger and the battery module, which is configured to transmit the electrical energy from the battery charger and battery module to the electrical system of the hybrid electric vehicle. In addition, the high-voltage battery charging apparatus comprises a bus contactor interposed between the high-voltage bus and the battery charger, which is bus contactor configured to provide a first substantial electrical isolation between the battery charger and the high-voltage bus during a charging period of the battery module. Furthermore, the high-voltage battery charging apparatus comprises an isolation mechanism interposed between the battery charger and the high-voltage bus and also interposed between battery charger and the battery module, which is configured to provide a second substantial electrical isolation between the battery charger, the battery module, and the high voltage bus during a non-charging period of the battery module.

Claims

1. A high-voltage battery charging apparatus for a hybrid electric vehicle having an electrical system, comprising:

a battery charger configured to provide electrical energy;

a battery module configured to store said electrical energy provided by said battery charger;

a high-voltage bus coupled to said battery charger and said battery module, said high voltage bus configured to transmit said electrical energy from said battery charger and battery module to the electrical system of the hybrid electric vehicle;

a bus contactor interposed between said high voltage bus and said battery charger, said bus contactor configured to provide a first substantial electrical isolation between said battery charger and said high-voltage bus and to thereby allow a charging period of said battery module during which said battery charger transmits electrical energy to said battery and not to said high-voltage bus; and

an isolation mechanism interposed between said battery charger and said high-voltage bus and also interposed between said battery charger and said battery module, said isolation mechanism configured to provide a second substantial electrical isolation between said battery charger and said high-voltage bus, and also between said battery charger and said battery module during a non-charging period of said battery module.

2. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said bus contactor is further configured to provide a substantial electrical connection between said battery module and said high-voltage bus during said non-charging period.

3. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said isolation mechanism is further configured to provide a substantial electrical connection between said battery module and said battery charger during said charging period.

4. The high-voltage battery-charging apparatus far the hybrid electric vehicle of claim 1, wherein said isolation mechanism comprises an electra-mechanical contactor.

5. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said isolation mechanism comprises a solid-state switch.

6. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said battery module comprises a plurality of lead-acid batteries.

7. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said battery module comprises a plurality of nickel-metal-hydride batteries.

8. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said battery module comprises a plurality of lithium batteries.

9. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said battery module further comprises:

a conductive coupling component That is configured to couple a power source external to the hybrid electric vehicle with said battery charger for charging said battery module.

10. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 9, wherein said power source external to the hybrid electric vehicle is Electric Vehicle Service Equipment (EVSE).

11. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, further comprising a charge control module coupled to said battery charger, said charge control module being configured to selectively energize or de-energize said battery charger.

12. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, further comprising an isolation monitor coupled to said bus contactor, to said battery module and to said isolation mechanism, said isolation monitor configured to control said isolation mechanism and said bus controller in order to provide a substantial isolation between said vehicle bus, said battery module, and said battery charger upon detection of an undesirable connection in the electrical system of the electric hybrid vehicle.

13. The high-voltage battery-charging apparatus for the hybrid electric vehicle of claim 1, wherein said isolation mechanism is an integrated component of said battery charger.

14. A high-voltage battery-charging apparatus for a hybrid electric vehicle having an electrical system, comprising:

an Electric Vehicle Service Equipment (EVSE) configured to provide an off-vehicle source of electrical energy for charging an on-board battery of said hybrid electric vehicle;

a conductive coupling component that is configured to couple said EVSE to said on-board battery of said electric vehicle;

an on-board high-voltage charging system that is coupled to said conductive coupling component and configured to control said charging of said on-board battery during a charging period and a non-charging period, said on-board high-voltage charging system comprising;

a battery charger that is coupled to said conductive coupling component and configured to receive said electrical energy from said EVSE;

a high-voltage bus coupled to said battery charger and said on-board battery of the hybrid vehicle, said high voltage bus configured to transmit said electrical energy from said battery charger and also configured to transmit said electrical energy stored by said on-board battery;

a bus contactor interposed between said high voltage bus and said battery charger, said bus contactor configured to provide a first substantial electrical isolation between said battery charger and said high-voltage bus and to thereby allow said charging period during which said battery charger transmits electrical energy to said battery and not to said high-voltage bus; and

an isolation mechanism interposed between said battery charger and said bus contactor and interposed between battery charger and said on-board battery, said isolation mechanism configured to provide a second substantial electrical isolation between said battery charger and said high-voltage bus, and also between said battery charger and said battery module during said non-charging period.

15. The high-voltage battery-charging apparatus for the hybrid electric vehicle having the electrical system of claim 14, wherein said bus contactor is further configured to provide a substantial electrical connection between said on-board battery and said high-voltage bus during said non-charging period.

16. The high-voltage battery-charging apparatus for the hybrid electric vehicle having the electrical system of claim 14, wherein said isolation mechanism is further configured to provide a substantial electrical connection between said on-board battery and said battery charger during said charging period.

17. The high-voltage battery-charging apparatus for the hybrid electric vehicle having the electrical system of claim 14, wherein said isolation mechanism comprises an electro-mechanical contactor.

18. The high-voltage battery-charging apparatus for the hybrid electric vehicle having the electrical system of claim 14, wherein said battery module comprises a plurality of lead-acid batteries.

19. The high-voltage battery-charging apparatus for the hybrid electric vehicle having the electrical system of claim 14, wherein said on-board high-voltage charging system further comprising a charge control module coupled to said battery charger, said charge control module being configured to selectively energize or de-energize said battery charger.

20. The high-voltage battery-charging apparatus for the hybrid electric vehicle having the electrical system of claim 14, said on-board high-voltage charging system further comprising an isolation monitor coupled to said bus contactor, to said on-board battery and to said isolation mechanism, said isolation monitor configured to provide a substantial electrical isolation of said high-voltage vehicle bus with said isolation mechanism and said bus contactor upon detection of an undesirable connection in electrical system of the electric hybrid vehicle.

21. A method for charging a high-voltage battery of a hybrid electric vehicle having an electrical system, comprising:

providing electrical energy with a battery charger;

storing said electrical energy in a battery module to said hybrid electric vehicle;

transmitting said electrical energy with a high-voltage bus from said battery module and from said power source to said electrical system;

activating an isolation mechanism interposed between said battery charger and said battery module to provide a first substantial electrical isolation between said battery charger and said high voltage bus during a non-charging period of the battery module; and

activating a bus contactor interposed between said high voltage bus and said battery charger to provide a second substantial electrical isolation between said battery charger and said high-voltage bus and to thereby allow a charging period of said battery module during which said battery charger transmits electrical energy to said battery and not to said high-voltage bus.

22. The method of charging a battery module in a hybrid electric vehicle having the electrical system of claim 21, wherein said activating said bus contactor further provides a substantial electrical connection between said battery module and said high-voltage bus during said non-charging period of said battery module.

23. The method of charging a battery module in a hybrid electric vehicle having the electrical system of claim 21, wherein said activating said isolation mechanism further provides a substantial electrical connection between said battery module and battery charger during said charging period of said battery module.

24. The method of charging a battery module in a hybrid electric vehicle having the electrical system of claim 21, further comprising coupling a power source external to the hybrid electric vehicle with said battery charger.

25. The method of charging a battery module in a hybrid electric vehicle having the electrical system of claim 21, further comprising:

detecting an undesirable connection in the electrical system of the electric hybrid vehicle; and

activating said isolation mechanism and said bus controller in order to provide a substantial isolation between said vehicle bus, said battery module, and said battery charger.

26. An Integrated Battery Pack (IPB) for a hybrid electric vehicle having an electrical system, which is coupled to a conductive coupling component and configured to control charging of a battery module with an EVSE during a charging and a non-charging period;

comprising;

a battery charger integrally formed in the IPB and coupled to the conductive coupling component, said battery charger configured to receive electrical energy from the EVSE;

a high-voltage bus integrally formed in the IPB and coupled to said battery charger and the battery module, said high voltage bus configured to transmit said electrical energy received from said EVSE and also configured to transmit said electrical energy stored by the battery module;

a bus contactor integrally formed in the IPB and interposed between said high-voltage bus and said battery charger, said bus contactor configured to provide a first substantial electrical isolation between said battery charger and said high voltage bus during the charging period;

an isolation mechanism integrally formed in the IPB and interposed between said battery charger and said bus contactor and interposed between battery charger and said on-board battery, said isolation mechanism configured to provide a second substantial electrical isolation between said battery charger, said battery module and said high voltage bus during said non-charging period; and

a cooling system integrally formed in the IPB, said cooling system configured to cool said battery charger during said charging period.