Integrated battery unit with cooling and protection expedients for electric vehicles

• US 8,816,645 B2
• Filed: 07/20/2005
• Issued: 08/26/2014
• Est. Priority Date: 07/20/2005
• Status: Active Grant

• Current Assignee: Webasto SE (Webasto Beteiligungs Verwaltung Gbr)
• Original Assignee: Aerovironment
• Inventors: Dickinson, Blake E., Hayashigawa, Larry
• Primary Examiner(s): WILLIAMS, ARUN C
• Application Number:
  US11/186,730
• Publication Number:
  US 20070090810A1
• Time in Patent Office: 3,324 Days
• Field of Search: 320/107, 320/150, 320/154, 361/690, 361/695, 361/696, 361/694, 361/676, 361/678
• US Class Current: 320/150
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B66F 9/07595 Cooling arrangements for device or operator
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/63 Control systems charging or discharging in response to temperature H01M10/44 , H01M10/443; measurement of temperature H01M10/48 , H01M10/486
• CPC Class Codes: H01M 10/6557 arranged between the cells
• CPC Class Codes: H01M 10/6563 with forced flow, e.g. by blowers
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

Methods of and apparatus for removing heat generated by cells of a battery pack. The method and apparatus may employ one or more fan modules disposed between or next to cells of the battery pack, or one or more fans directly mounted to the battery pack or battery pack case housing the cells. Further, a motor controller isolation system operates to electricity isolate the motor controller of the electric vehicle when the battery pack is being charged. The motor controller isolation system may be integrated with the integrated battery pack and thermal and ventilation system. The integrated system, or “integrated battery unit (IBU),” is preferably manufactured in a manner that requires no, modifications to the electric vehicle in which the IBU is installed.

Claims

1. A method for removing heat generated by multiple cells of a battery pack, comprising:

interposing, between a set of cells of the battery pack, a fan module having side panels that define an interior portion and having inlet and outlet ports formed in communication with the interior portion, at least two of the side panels defining the interior portion being disposed against the set of cells of the battery pack in contact therewith; and

using a fan to circulate air from the ambient environment into the interior portion of the fan module, the circulating including drawing air into the interior portion of the fan module through an inlet port and expelling air from the fan module through an outlet port.

2. The method of claim 1, further comprising controlling the fan using a thermostat.

3. The method of claim 1, further comprising controlling the fan using a key switch or a charger interlock.

4. The method of claim 1, further comprising disposing additional fan modules between different battery cells of the battery pack.

5. The method of claim 1, further comprising controlling the one or more fans using a battery mounted monitor and controller associated with the battery pack.

6. The method of claim 1, further comprising controlling the one or more fans using a charger interlock.

7. The method of claim 1, wherein the circulating air is brought into contact with at least one battery cell by way of at least one cut-out formed in a side panel of the fan module.

8. The method of claim 1, further including filtering the air entering the interior portion of the fan module.

9. The method of claim 1, further including providing filtering air at the outlet port.

10. The method of claim 1, further including extending the inlet port.

11. The method of claim 1, wherein circulating comprises using multiple fans.

12. The method of claim 1, wherein the fan is selectively operated during one or more of battery charging, vehicle operation, vehicle driving, or scheduled time period.

13. The method of claim 1, wherein the fan is selectively operated in forward or reverse rotation.

14. An integrated battery unit for an electric vehicle, comprising:

a plurality of cells; and

at least one fan module interposed between at least two cells, the fan module comprising a fan, a plurality of side panels defining an interior portion in which air circulates when the fan is in operation, and inlet and outlet ports formed in communication with the interior portion, wherein at least two of the side panels defining the interior portion are disposed against the at least two cells of the battery pack in contact therewith.

15. The integrated battery unit of claim 14 wherein the side panels are made from a heat conducting material.

16. The integrated battery unit of claim 14, further including cut-outs provided in the side panels, so that air circulating through said fan module is able to come in direct contact with the walls of at least two cells.

17. The integrated battery unit of claim 14, further comprising a battery pack container configured to house the plurality of cells and the fan module in a manner that does not require any modifications to an electric vehicle into which the battery pack container is to be installed.

18. A method of manufacturing an integrated battery unit, comprising:

providing a battery pack container;

installing a plurality of cells in the battery pack container;

interposing one or more removable fan modules between two or more cells in the battery pack container, each fan module comprising at least one fan and a plurality of side panels defining an interior portion in which air circulates when the fan is in operation, wherein at least two of the side panels defining the interior portion are disposed against the two or more cells of the battery pack in contact therewith; and

electrically connecting the plurality of cells.

19. The method of claim 18 wherein each fan module comprises:

an air inlet port configured to draw in air from the ambient environment into the interior portion of the fan module; and

an air outlet port configured to eject heated air from the fan module interior portion away from the plurality of cells.

20. The method of claim 18 wherein the side panels are made from a heat conducting material.

21. The method of claim 18 wherein the side panels of said one or more fan modules are provided with cut-outs, so that air circulating through said one or more fan modules is able to come in direct contact with external surfaces of said two or more cells.

22. An integrated battery pack and thermal and ventilation management system for an electric vehicle, comprising:

a plurality of electrically connected cells housed in a battery pack tray; and

one or more removable fan modules disposed between two or more of said plurality of cells, each fan module comprising a fan and a plurality of side panels defining an interior in which air circulates when the fan is in operation, at least one side panel being in contact with at least one cell.

23. The system of claim 22 wherein the battery pack tray, cells and fan module can all be installed in the electric vehicle without requiring any, or substantially any, modifications to the electric vehicle.

24. The system of claim 22 wherein the side panels are in contact with a surface of at least one of said plurality of cells.

25. The system of claim 24 wherein the side panels are made from a heat conducting material.

26. The system of claim 24 wherein cut-outs are made through the side panels, so that air circulating through said one or more fan modules is able to come in direct contact with a surface of at least one of said plurality of cells.

27. The system of claim 22, further comprising a thermostat or battery mounted monitor and controller that is operable to control operation of said one or more fan modules.

28. The system of claim 22, further comprising an key switch or charger interlock that is operable to control operation of said one or more fan modules.

29. A fan module configured for interposing between cells of a battery pack, the fan module comprising:

a plurality of side panels defining an interior portion and inlet and outlet ports in communication with the interior portion, wherein the side panels are configured to contact two different cells of the battery pack; and

a fan operable to move air in and out of the interior portion, the air entering the interior portion through the inlet port and exiting the interior portion, with heat drawn from the contacted cells, through the outlet port an additional fan operable to move air in and out of the interior portion.

30. An integrated battery unit for an electric vehicle, comprising:

at least first and second cells, the first cell having a first wall having first and second orthogonal dimensions, the second cell having a second wall having first and second orthogonal dimensions; and

at least one fan module interposed between the first and second cells, the fan module comprising a fan, first and second side panels defining an interior portion in which air circulates when the fan is in operation, and inlet and outlet ports formed in communication with the interior portion, wherein the first side panel is disposed against the first wall and extends for at least a majority of the first and second dimensions of the first wall, and the second side panel is disposed against the second wall and extends for at least a majority of the first and second dimensions of the second wall.