Methods and systems for assembling batteries

• US 20060076923A1
• Filed: 08/10/2005
• Published: 04/13/2006
• Est. Priority Date: 08/13/2004
• Status: Active Grant

• Current Assignee: Enersys Energy Products, Inc. (EnerSys)
• Original Assignee: Modular Energy Devices, Inc. (EnerSys)
• Inventors: Eaves, Stephen S.
• Granted Patent: US 7,304,453 B2
• Time in Patent Office: Days
• US Class Current: 320/112
• CPC Class Codes: A61B 6/037 Emission tomography
• CPC Class Codes: G01T 1/244 Auxiliary details, e.g. casings, cooling, damping or insulation against damage by, e.g. heat, pressure or the like
• CPC Class Codes: G01T 1/249 specially adapted for use in SPECT or PET SPECT imaging G01T1/1642; PET imaging G01T1/2985; detecting prohibited goods, e.g. weapons, explosives, hazardous substances, contraband or smuggled objects G01V5/20
• CPC Class Codes: G01T 1/2985 In depth localisation, e.g. using positron emitters; Tomographic imaging (longitudinal and transverse section imaging; apparatus for radiation diagnosis sequentially in different planes, steroscopic radiation diagnosis); using external radiation sources A61B6/02
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• 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 50/107 having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A large battery pack of specified voltage and capacity can be assembled from a plurality of identical small cells by dividing the specified capacity by a nominal battery module capacity to determine a desired number of parallel modules to be provided, dividing the nominal battery module capacity by a nominal cell card capacity, to determine the number of cell cards required in each module, connecting the call cards in parallel to a common buswork to form the battery module, and connecting the modules in parallel to obtain the specified battery pack capacity and in series to obtain the specified battery pack voltage Protection circuitry can be implemented at the module level, by disconnecting one or more modules or the entire battery pack if a fault at the module level is identified; at the cell card level, by disconnecting a cell card if a cell within it is determined to be faulty; and/or internally, in each cell.

Claims

1. A method for assembling a battery pack of specified voltage and capacity from a plurality of cells, comprising the steps of:

dividing the specified capacity by a nominal battery module capacity to determine a desired number of parallel modules to be provided,

dividing the nominal battery module capacity by a nominal cell card capacity, to determine the number of cell cards required in each module,

dividing the nominal cell card capacity by the cell capacity, to determine the number of cells to be provided in each cell card,

assembling the cell cards to comprises the desired nmber ocells in a sutaible series/parallel circuit,

connecting the call cards in parallel to a common buswork to form the battery module(s), and

connecting the modules(s) in parallel to obtain the specified battery pack capacity and in series to obtain the specified battery pack voltage

2. The method of claim 1, wherein the cell cards making up the battery module are substantially identical planar members having the cells assembled thereto to comprise the cell cards, and having bus connections on outer edges thereof, and said cell cards are arranaged parallel to one another, so that the cell cards can be electrically and mechanically interconnected by elongated bus bars secured to said bus connections on the cell cards.

3. The method of claim 2, wherein the cells are generally cylindrical such that when they are assembled to the planar cell cards, spaces are left therebetween which are suitable for the assembly of protection circuitry and also form channels for flow of ventilating air.

4. A battery pack made up of a number of cells, the cells being organized in series/parallel format to make up cell cards of desired capacity, and the cell cards being organized in parallel to form modules of desired capacity, the modules being connected in series and parallel to form the battery pack, wherein each module comprises a protection circuit which monitors operational parameters of the cell cards making up the module, the protection circuit being arranged to disconnect the faulty module or the entire battery pack upon detection of a flaw, and wherein each cell card further comprises cell card protection circuitry for disconnection of a particular cell card upon detection of a fault in one or more of the cells thereof.

5. The battery module of claim 4, wherein the cells making up each cell card are disposed on a circuit board, the cell cards being essentially identical and having bus connections on their edges, so that when the cell cards are arranged parallel to one another they can be connected mechanically and electrically by elongated bus bars.

6. The battery module of claim 5, wherein the cells are generally cylindrical, such that when they are assembled to the planar cell cards, spaces are left therebetween which are suitable for the assembly of protection circuitry and also form channels for flow of ventilating air.