Battery and capacitor assembly for a vehicle and a method for heating and cooling the battery and capacitor assembly

• US 10,886,583 B2
• Filed: 07/12/2016
• Issued: 01/05/2021
• Est. Priority Date: 03/02/2016
• Status: Active Grant

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: Ciaccio, Michael Peter, Moorhead, Brian
• Primary Examiner(s): Crepeau, Jonathan
• Assistant Examiner(s): Buchanan, Jacob
• Application Number:
  US15/208,143
• Publication Number:
  US 20170256833A1
• Time in Patent Office: 1,638 Days
• CPC Class Codes: B60L 2240/525 Temperature of converter or components thereof
• CPC Class Codes: B60L 2240/526 Operating parameters
• CPC Class Codes: B60L 2240/527 Voltage
• 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 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: B60L 7/10 Dynamic electric regenerative braking B60L7/22 takes precedence
• CPC Class Codes: H01G 11/08 Structural combinations, e.g. assembly or connection, of hybrid or EDL capacitors with other electric components, at least one hybrid or EDL capacitor being the main component
• CPC Class Codes: H01G 11/18 against thermal overloads, e.g. heating, cooling or ventilating
• CPC Class Codes: H01G 11/82 Fixing or assembling a capacitive element in a housing, e.g. mounting electrodes, current collectors or terminals in containers or encapsulations
• CPC Class Codes: H01M 10/0481 Compression means other than compression means for stacks of electrodes and separators
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/4264 with capacitors
• 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 10/615 : Heating or keeping warm
• CPC Class Codes: H01M 10/617 : for achieving uniformity or desired distribution of temperature
• 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 10/6555 : arranged between the 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 10/6572 : Peltier elements or thermoelectric devices
• CPC Class Codes: H01M 16/00 : Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 2010/4271 : Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• CPC Class Codes: H01M 2200/20 : Pressure-sensitive devices
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/20 : Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders structural combination of accumulators with charging apparatus H01M10/46
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/224 : Metals
• CPC Class Codes: H01M 50/227 : Organic material
• 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

In one example, the present disclosure describes a battery and capacitor assembly for a hybrid vehicle that includes a plurality of battery cells, a plurality of capacitor cells, a cooling plate, a pair of end brackets, and a housing. The plurality of capacitor cells are arranged adjacent to the plurality of battery cells such that the plurality of battery cells and the plurality of capacitor cells form a cell stack. The pair of end brackets are disposed at opposite ends of the cell stack and are attached to the cooling plate. The pair of end brackets compress the plurality of battery cells and the plurality of capacitor cells. The housing is attached to the cooling plate and encloses the cell stack and the pair of end brackets.

Claims

1. A system comprising:

an enclosure formed by a housing and a cooling plate, the housing forming a bottom wall of the enclosure and sidewalls of the enclosure, the cooling plate forming a top wall of the enclosure;

a plurality of battery cells disposed within a first zone in the enclosure;

a plurality of capacitor cells disposed within a second zone in the enclosure;

a first temperature sensor that measures the temperature of the first zone in which the plurality of battery cells are disposed;

a second temperature sensor that measures the temperature of the second zone in which the plurality of capacitor cells are disposed; and

a control module that controls an amount of at least one of current, voltage, and power supplied to a plurality of thermoelectric devices to heat and cool the plurality of battery cells based on the first zone temperature and to heat and cool the plurality of capacitor cells based on the second zone temperature and independent of heating and cooling the plurality of battery cells.

2. The system of claim 1 wherein the control module:

controls the amount of at least one of current, voltage, and power supplied to a first one of the plurality of thermoelectric devices disposed within the first zone to one of heat and cool the plurality of battery cells; and

controls the amount of at least one of current, voltage, and power supplied to a second one of the plurality of thermoelectric devices disposed within the second zone to one of heat and cool the plurality of capacitor cells.

3. The system of claim 2 wherein the control module:

heats the plurality of battery cells when the first zone temperature is less than a first temperature threshold; and

cools the plurality of battery cells when the first zone temperature is greater than a second temperature threshold.

4. The system of claim 3 wherein the control module:

heats the plurality of capacitor cells when the second zone temperature is less than a third temperature threshold; and

cools the plurality of capacitor cells when the second zone temperature is greater than a fourth temperature threshold.

5. The system of claim 4 wherein at least one of:

the third temperature threshold is different than the first temperature threshold; and

the fourth temperature threshold is different than the second temperature threshold.

6. The system of claim 5 wherein:

the third temperature threshold is less than the first temperature threshold; and

the fourth temperature threshold is less than the second temperature threshold.

7. The system of claim 4, wherein each of the first, second, third, and fourth temperature thresholds is predetermined.

8. The system of claim 4, wherein the control module:

determines the first temperature threshold based on at least one of a target resistance of the plurality of battery cells, a target amount of power supplied by the plurality of battery cells, and a target capacity of the plurality of battery cells; and

determines the third temperature threshold based on at least one of a target resistance of the plurality of capacitor cells, a target amount of power supplied by the plurality of capacitor cells, and a target capacity of the plurality of capacitor cells for a single discharge cycle.

9. The system of claim 8 wherein the control module:

determines the first temperature threshold based on the target capacity of the plurality of battery cells when the target capacity of the plurality of battery cells is equal to a maximum capacity; and

does not determine the first temperature threshold based on the target capacity of the plurality of battery cells when the target capacity of the plurality of battery cells is less than the maximum capacity.

10. The system of claim 8 wherein the control module:

adjusts the first temperature threshold to a first value to maintain the capacity of the plurality of battery cells at a maximum capacity when the target capacity of the plurality of battery cells is equal to the maximum capacity; and

adjusts the first temperature threshold to a second value to prevent damage to the plurality of battery cells when the target capacity of the plurality of battery cells is less than the maximum capacity, the second value being less than the first value.

11. The system of claim 4 wherein the control module:

determines the second temperature threshold based on at least one of a target resistance of the plurality of battery cells, a target amount of power supplied by the plurality of battery cells, and a target capacity of the plurality of battery cells; and

determines the fourth temperature threshold based on at least one of a target resistance of the plurality of capacitor cells, a target amount of power supplied by the plurality of capacitor cells, and a target capacity of the plurality of capacitor cells for a single discharge cycle.

12. The system of claim 4 wherein the control module determines the second temperature threshold based on at least one of a target amount of power supplied by the plurality of battery cells and a target life of the plurality of battery cells.

13. The system of claim 12 wherein the control module:

adjusts the second temperature threshold to a first value when the target amount of power of the plurality of battery cells is less than a maximum power amount; and

adjusts the second temperature threshold to a second value when the target amount of power of the plurality of battery cells is equal to the maximum power amount, the second value being greater than the first value.

14. The system of claim 1 wherein the control module:

heats the plurality of battery cells when the first zone temperature is less than a first temperature threshold if the plurality of battery cells are charging; and

does not heat the plurality of battery cells when the first zone temperature is less than the first temperature threshold if the plurality of battery cells are discharging.

15. A method comprising:

enclosing a plurality of battery cells and a plurality of capacitor cells within a common enclosure formed by a housing and a cooling plate, the plurality of battery cells being disposed within a first zone of the enclosure, the plurality of capacitor cells being disposed within a second zone of the enclosure, the housing forming a bottom wall of the enclosure and sidewalls of the enclosure, the cooling plate forming a top wall of the enclosure, the cooling plate isolating the plurality of battery cells and the plurality of capacitor cells from cooling fluid flowing through the cooling plate;

measuring the temperature of the first zone in which the plurality of battery cells are disposed;

measuring the temperature of the second zone in which the plurality of capacitor cells are disposed; and

controlling an amount of at least one of current, voltage, and power supplied to a plurality of thermoelectric devices to heat and cool the plurality of battery cells based on the first zone temperature and to heat and cool the plurality of capacitor cells based on the second zone temperature and independent of heating and cooling the plurality of battery cells.

16. The method of claim 15 further comprising:

controlling the amount of at least one of current, voltage, and power supplied to a first one of the plurality of thermoelectric devices disposed within the first zone to one of heat and cool the plurality of battery cells; and

controlling the amount of at least one of current, voltage, and power supplied to a second one of the plurality of thermoelectric devices disposed within the second zone to one of heat and cool the plurality of capacitor cells.

17. The method of claim 16 further comprising:

heating the plurality of battery cells when the first zone temperature is less than a first temperature threshold; and

cooling the plurality of battery cells when the first zone temperature is greater than a second temperature threshold.

18. The method of claim 17 further comprising:

heating the plurality of capacitor cells when the second zone temperature is less than a third temperature threshold; and

cooling the plurality of capacitor cells when the second zone temperature is greater than a fourth temperature threshold.

19. The method of claim 18 wherein at least one of:

the third temperature threshold is different than the first temperature threshold; and

the fourth temperature threshold is different than the second temperature threshold.

20. The method of claim 19 wherein:

the third temperature threshold is less than the first temperature threshold; and

the fourth temperature threshold is less than the second temperature threshold.

21. The method of claim 18, wherein each of the first, second, third, and fourth temperature thresholds is predetermined.

22. The method of claim 18, further comprising:

determining the first temperature threshold based on at least one of a target resistance of the plurality of battery cells, a target amount of power supplied by the plurality of battery cells, and a target capacity of the plurality of battery cells; and

determining the third temperature threshold based on at least one of a target resistance of the plurality of capacitor cells, a target amount of power supplied by the plurality of capacitor cells, and a target capacity of the plurality of capacitor cells for a single discharge cycle.

23. The method of claim 22 further comprising:

determining the first temperature threshold based on the target capacity of the plurality of battery cells when the target capacity of the plurality of battery cells is equal to a maximum capacity; and

not determining the first temperature threshold based on the target capacity of the plurality of battery cells when the target capacity of the plurality of battery cells is less than the maximum capacity.

24. The method of claim 22 further comprising:

adjusting the first temperature threshold to a first value to maintain the capacity of the plurality of battery cells at a maximum capacity when the target capacity of the plurality of battery cells is equal to the maximum capacity; and

not adjusting the first temperature threshold to a second value to prevent damage to the plurality of battery cells when the target capacity of the plurality of battery cells is less than the maximum capacity, the second value being less than the first value.

25. The method of claim 18 further comprising:

determining the second temperature threshold based on at least one of a target resistance of the plurality of battery cells, a target amount of power supplied by the plurality of battery cells, and a target capacity of the plurality of battery cells; and

determining the fourth temperature threshold based on at least one of a target resistance of the plurality of capacitor cells, a target amount of power supplied by the plurality of capacitor cells, and a target capacity of the plurality of capacitor cells for a single discharge cycle.

26. The method of claim 18 further comprising determining the second temperature threshold based on at least one of a target amount of power supplied by the plurality of battery cells and a target life of the plurality of battery cells.

27. The method of claim 26 further comprising:

adjusting the second temperature threshold to a first value when the target amount of power of the plurality of battery cells is less than a maximum power amount; and

adjusting the second temperature threshold to a second value when the target amount of power of the plurality of battery cells is equal to the maximum power amount, the second value being greater than the first value.

28. The method of claim 16, further comprising:

heating the plurality of battery cells when the first zone temperature is less than a first temperature threshold if the plurality of battery cells are charging; and

not heating the plurality of battery cells when the first zone temperature is less than the first temperature threshold if the plurality of battery cells are discharging.