Universal battery module and controller therefor

• US 7,772,799 B2
• Filed: 02/06/2006
• Issued: 08/10/2010
• Est. Priority Date: 10/11/2005
• Status: Expired due to Fees

• Current Assignee: Delaware Power Systems Corporation
• Original Assignee: Delaware Power Systems Corporation
• Inventors: Wu, Deping
• Primary Examiner(s): Vu; Bao Q
• Assistant Examiner(s): Tran; Nguyen
• Application Number:
  US11/348,056
• Publication Number:
  US 20070080662A1
• Time in Patent Office: 1,646 Days
• Field of Search: 320/109, 320/110, 320/112, 320/113, 320/104, 320/106, 320/107, 903/907, 903/903
• US Class Current: 320/104
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• 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 10/48 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 10/482 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 10/625 Vehicles
• CPC Class Codes: H01M 10/633 characterised by algorithms, flow charts, software details or the like
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• 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 10/6567 : Liquids
• CPC Class Codes: H02J 7/00036 : Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 : with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0014 : Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0048 : Detection of remaining charge capacity or state of charge [SOC]
• 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: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries

Abstract

A battery pack is provided including universal battery modules and a master control module. By selecting proper rated universal battery modules and connecting them either in series and/or parallel, a high performance and long life battery pack is assembled that is suitable for high power applications such as electrical vehicles whereby the master control module acts as the battery pack control and interface module.

Claims

1. A universal battery module configured as a generic building block for a battery pack, said battery pack including a plurality of universal battery modules, each universal battery module comprising:

a plurality of electrically connected battery cells;

sensor means coupled to the cells, the sensor means configured to transmit physical parameters of the cells; and

a battery control unit in communication with the sensor means to control the cells based on physical parameters from the sensor means, the battery control unit configured in serial communication with other universal battery modules in the battery pack to provide control signals directly to the other universal battery modules and receive control signals directly from the other universal battery modules, the battery control unit further configured to be responsive to an input signal wherein the input signal is configured to assign system control of the battery pack to one universal battery module of the plurality of universal battery modules in the battery pack, and wherein the battery control unit is configured to control all of the plurality of universal battery modules of the battery pack when assigned system control of the battery pack;

wherein the battery control unit, the sensor means and the cells are packaged together as a single integral module and wherein the universal battery module is configured for interchangeability within the battery pack.

2. The universal battery module as set forth in claim 1, further comprising a shell for retaining the battery cells therein.

3. The universal battery module as set forth in claim 1, further comprising a thermal frame in thermal communication with the cells to provide cell thermal equalization.

4. The universal battery module as set forth in claim 2, further comprising a base plate coupled to the shell in a hermetically sealing relationship and in thermal communication with a thermal frame to enhance heat dissipation from the thermal frame.

5. The universal battery module as set forth in claim 4, wherein the base plate has an inlet, an outlet and a plurality of passes fluidly connected to the inlet and outlet for transmitting cooling liquid between the inlet and the outlet.

6. The universal battery module as set forth in claim 4, wherein the base plate is hermetically coupled to the shell in a sealing relationship.

7. The universal battery module as set forth in claim 1, further comprising cell electric equalization means.

8. The universal battery module as set forth in claim 1, further comprising an electrical connector coupled to the battery control unit, the electrical connector being configured to provide electric connections for serial communication, power on/off signal, control output signals and input signals.

9. The universal battery module as set forth in claim 8, wherein a serial communication bus is a CAN bus.

10. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to generate control output signals relating to charge/discharge power control and warning light control.

11. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to monitor a module current from differential input signals.

12. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to monitor cell voltages, module current and module thermal frame temperature.

13. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to control the cell electrical equalization.

14. The universal battery module as set forth in claim 1, wherein the battery control unit is configured to control arbitration of sequence numbers of the universal battery modules in the battery pack.

15. The universal battery module as set forth in claim 14, wherein arbitration enables automatic numbering of each of the universal battery modules in the battery pack.

16. The universal battery module as set forth in claim 14, wherein the arbitration of the sequence numbers determines the universal battery module which will provide battery pack control.

17. The universal battery module as set forth in claim 14, wherein arbitration is initiated upon first time power up.

18. The universal battery module as set forth in claim 14, wherein arbitration is initiated upon an external service reset command.