Large scale battery systems and method of assembly

• US 20110213509A1
• Filed: 08/31/2010
• Published: 09/01/2011
• Est. Priority Date: 09/01/2009
• Status: Active Grant

• Current Assignee: Boston-Power Inc.
• Original Assignee: Boston-Power Inc.
• Inventors: Jansen, Eckart, Warner, John, Onnerud, Per, Linna, Jan-Roger, Souza, Chad
• Granted Patent: US 8,483,886 B2
• Time in Patent Office: Days
• US Class Current: 700/297
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• 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 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/505 comprising a single busbar
• CPC Class Codes: H01M 50/512 Connection only in parallel
• CPC Class Codes: H01M 50/516 by welding, soldering or brazing
• CPC Class Codes: H01M 50/522 Inorganic material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49004 including measuring or testing of device or component part
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

The methods in this disclosure allow for the identification, selection, and arrangement of cells, blocks, and modules in large scale battery systems, such as electric vehicle battery systems. An example embodiment of the present invention allows for the identification of the cells, blocks, and modules with a unique identifier or associated parameter (e.g., internal resistance contributions or capacity). Additionally, to form a block, cells may be selected from a group of capacity-range sorting bins. Based on a parameter of the cell, a pseudo-number generator may be also be used to select cells from an available inventory of cells as maintained in a cell database based. Cells may also be placed in a block for uniform effective cell impedance and even cell aging while minimizing overall block capacity degradation caused by cycling. Block capacities may also be computed based on a known average temperature gradient during operation.

Claims

1. A method of identifying components of a large scale battery, comprising:

attaching an identification designation to each of plural cells included within the large scale battery;

attaching an identification designation to each of plural blocks of cells included within the large scale battery;

maintaining a database of the identification designations and associated parameters for the cells and blocks; and

selecting cells and blocks based on the associated parameters.

2. The method as claimed in claim 1, wherein the associated parameters include capacities of the cells and blocks.

3. The method as claimed in claim 1, wherein the associated parameters include internal resistances of the cells and blocks.

4. The method as claimed in claim 1, further comprising, using a pseudo-random number generator, selecting cells and blocks for placement within the large scale battery.

5. The method as claimed in claim 4, wherein the pseudo-random number generator selects cells based on a normal distribution of cells available for placement within the large scale battery. 25

6. The method as claimed in claim 1, further comprising:

attaching identification designations to each of plural modules of blocks included within the large scale battery; and

updating the database with the identification designations and associated parameters for the modules.

7. The method as claimed in claim 6, wherein the associated parameters include capacities of the modules.

8. The method as claimed in claim 6, wherein the associated parameters include internal resistances of the modules.

9. The method as claimed in claim 6, further comprising, using a pseudo-random number generator, selecting modules for placement within the large scale battery.

10. A method of selecting cells for construction of a battery system, comprising:

measuring capacity of battery cells;

associating, in a database, each battery cell with its respective capacity measurement;

calculating a statistical distribution of the capacity of measured battery cells;

selecting battery cells, from across the statistical distribution, for placement in the battery system; and

placing selected battery cells in parallel within the battery system.

11. The method as claimed in claim 10, wherein the battery cells are selected to result in capacity of the battery system tending toward a mean of the statistical distribution.

12. The method as claimed in claim 10, wherein the battery cell capacities are within a range of 4000 mAh to 4500 mAh.

13. The method as claimed in claim 10, wherein the battery cell capacities are within a range of 4420 mAh to 4480 mAh.

14. The method as claimed in claim 10, wherein selecting battery cells includes selecting battery cells at random from particular segments along the statistical distribution.

15. The method as claimed in claim 10, further comprising, if battery cells within a particular segment of the statistical distribution are depleted, selecting battery cells from a neighboring segment that is closer to a mean of the statistical distribution.

16. A battery system comprising:

a plurality of electrically coupled blocks of battery cells, including parallel connected battery cells within each block; and

capacity of the battery cells in each block following a statistical distribution of a population of the battery cells from which the battery cells are selected.

17. The battery system as claimed in claim 16, wherein the battery cells are selected to result in capacity of the battery system tending toward a mean of the statistical distribution.

18. The battery system as claimed in claim 16, wherein the battery cell capacities are within a range of 4000 mAh to 4500 mAh.

19. The battery system as claimed in claim 16, wherein the battery cell capacities are within a range of 4420 mAh to 4480 mAh.

20. The battery system as claimed in claim 16, wherein the block includes battery cells selected at random from particular segments along the statistical distribution.

21. A method of selecting cells for a battery system, comprising:

measuring internal resistance for components of the battery system;

maintaining a database that includes internal resistance measurements; and

placing cells in the battery system based on the internal resistance measurements.

22. The method as claimed in claim 21, wherein placing cells includes placing cells having a low internal resistance measurement in areas of high internal resistance contributed from other components of the battery system relative to battery terminals.

23. The method as claimed in claim 21, wherein placing cells includes placing cells having a high internal resistance measurement in areas of low internal resistance contributed from other components of the battery system relative to battery terminals.

24. The method as claimed in claim 21, wherein the database includes identification designations and associated parameters, including the internal resistances, for the cells and components of the battery system.

25. The method as claimed in claim 21, wherein the associated parameters include capacities of the cells and components of the battery system.

26. A battery system comprising:

a plurality of electrically coupled blocks of plural battery cells, including parallel connected battery cells within each block; and

in each block, battery cells having a low internal resistance are placed in areas of high internal resistance contributed from other components of the battery system relative to battery terminals.

27. The battery system as claimed in claim 26, wherein, in each block, battery cells having a high internal resistance are placed in areas of low internal resistance contributed from other components of the battery system relative to battery terminals.

28. A method of selecting desired capacities for components of a battery system, comprising:

determining a temperature profile within the battery system;

estimating a temperature dependent capacity of components of the battery system; and

selecting components of the battery system using the temperature dependent capacities and temperature profile.

29. The method as claimed in claim 28, further comprising:

selecting a reference block to establish an acceptable temperature for blocks within the battery system;

determining a temperature differential based on the reference block temperature and temperature of other blocks within the battery system;

determining desired capacity of blocks within the battery system based on the temperature dependent capacities and temperature differential; and

placing blocks within the battery system based on the calculated desired capacity.

30. A battery system comprising:

a plurality of electrically coupled battery system components; and

battery system components having low capacity are selected to be placed farthest away from a heat source.

31. The battery system as claimed in claim 30, wherein the battery components include a plurality of electrically coupled blocks of battery cells.

32. The battery system as claimed in claim 30, wherein the battery components include a plurality of electrically coupled modules of blocks of battery cells.

33. A method of identifying components of a large scale battery, comprising:

attaching an identification designation to each of plural cells included within the large scale battery;

attaching an identification designation to each of plural blocks of cells included within the large scale battery;

attaching an identification designation to each of plural modules of blocks included within the large scale battery; and

maintaining a database of the identification designations and associated parameters for the cells, blocks, and modules.

34. The method as claimed in claim 33, wherein the associated parameters include capacities of the cells, blocks, and modules. 25

35. The method as claimed in claim 33, wherein the associated parameters include internal resistances of the cells, blocks, and modules.

36. The method as claimed in claim 33, further comprising, using a pseudo-random number generator, selecting cells, blocks, and modules for placement within the large scale battery.

37. The method as claimed in claim 36, wherein the pseudo-random number generator selects cells based on a normal distribution of cells available for placement within the large scale battery.