Battery pack with multiple secure modules

• US 6,403,251 B1
• Filed: 01/31/2000
• Issued: 06/11/2002
• Est. Priority Date: 01/31/2000
• Status: Expired due to Term

• Current Assignee: Inspired Energy, Inc.
• Original Assignee: Moltech Power Systems Incorporated (City of Shanghai)
• Inventors: Jacobs, Alexander III, Baggaley, David C.
• Primary Examiner(s): Kalafut, Stephen
• Assistant Examiner(s): ALEJANDRO, RAYMOND
• Application Number:
  US09/494,990
• Time in Patent Office: 862 Days
• Field of Search: 429/149, 429/150, 429/156, 429/158, 429/160, 429/121, 429/123, 429/61, 429/90, 429/7, 429/96, 429/100, 429/9, 429/91, 429/92, 429/99, 320/127, 320/119, 320/121, 320/122, 320/128, 320/137, 320/138
• US Class Current: 429/61
• CPC Class Codes: H01M 10/42 Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• 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 50/209 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: H01M 50/271 Lids or covers for the racks or secondary casings
• 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

Abstract

A modularized power supply is presented employing individual electrochemical cells which are rendered inert when separated from a specified unlocking circuit. The cells are enclosed in a cell module having a disabling circuit which isolates the cell terminals and prevents release of significant cell energy. A switch in the disabling circuit is activated when the cell module is connected to the specified unlocking circuit in an external frame. The frame includes receptacles for receiving multiple modules, all of which must be connected before power is delivered to a host interface. The frame may include circuits and devices for monitoring the performance of the modules, for controlling cell charging and discharging, and protective elements to protect the modules and tray from aberrant conditions such as high temperatures, overcurrent, and similar events. By including these in the frame, fewer elements are required in the individual modules, reducing their complexity, weight and cost. The present concepts are embodied in both integrated power supplies and removable battery packs. Using thin rigid modules, a large flat battery pack is formed. The relatively smaller modules are less susceptible to damage from handling. This is particularly advantageous when the cell used in embodiments with a lithium ion, lithium ion polymer or similar cell having a potential for producing fires in the event of an internal short. Power supplies using both primary and secondary cells are provided.

Claims

1. A portable power supply comprising:

a predetermined number of cell modules, each module comprising;

at least one electrochemical cell;

a disabling circuit connected to the cell and preventing release of cell energy in a first condition;

an enabling circuit having an interface capable of connecting the enabling circuit to all module disabling circuits, the enabling circuit releasing cell energy from each module during a second condition defined as when all modules are connected to the enabling circuit and the enabling circuit is receiving energy only from the modules; and

a control circuit coupled to the enabling circuit and delivering cell energy to a host device interface during the second condition.

2. A portable power supply according to claim 1, further comprising:

a power supply frame, the frame having a plurality of receptacles for receiving modules;

the enabling circuit and control circuit disposed at least partially on the frame; and

each module further comprising a rigid housing, the module disabling circuit and cell disposed within the housing.

3. A portable power supply according to claim 2, wherein:

the frame is a separable thin planar tray having a tray aspect ratio and wherein the receptacles are aligned in a single plane; and

the modules each have an aspect ratio which is less than the tray aspect ratio.

4. A portable power supply according to claim 3, wherein:

each module aspect ratio is less than 50;

1.

5. A portable power supply according to claim 4, wherein:

each module aspect ratio is greater than 15;

1.

6. A portable power supply according to claim 1, wherein:

the enabling circuit comprises a predetermined number of unlocking circuits, each unlocking circuit connected to a single module in the second condition.

7. A portable power supply according to claim 1, wherein:

each cell is rechargeable.

8. A portable power supply according to claim 7, wherein:

each cell comprises a lithium ion polymer cell.

9. A portable power supply according to claim 7, wherein:

each cell comprises a lithium-sulfur cell.

10. A portable power supply according to claim 2, wherein:

the frame is configured to be integrated into a host device.

11. A portable power supply according to claim 1, wherein:

each cell is isolated from charging current by the disabling circuit during the first condition.

12. A portable power supply according to claim 1, wherein:

each cell has at least two terminals;

each disabling circuit comprises a switch, the switch isolating one respective cell terminal in the first condition; and

the enabling circuit causing the switch to close in the second condition.

13. A portable power supply according to claim 12, wherein:

the switch comprises at least one metal oxide field effect transistor device.

14. A portable power supply according to claim 1, wherein:

each cell module is without internal elements for protecting the cell against internal electrical shorting in the first condition.

15. A portable power supply comprising:

a predetermined number of electrochemical cell modules;

each module comprising;

at least one electrochemical cell, each cell having terminals, means of electrically isolating at least one cell terminal in a first condition;

a frame having a transmission means for transmitting cell energy to a host device, the transmission means having means of releasably connecting the cell modules and having means of enabling release of stored energy from the cells using the power within the cells during a second condition defined when all the cell modules are connected.

16. A portable power supply according to claim 15, wherein:

the cell is rechargeable.

17. A portable power supply comprising:

at least two cell modules, each module comprising;

rigid module housing,

at least one thin flat electrochemical cell disposed within the housing;

a thin tray having the same number of receptacles as the number of modules, each receptacle configured for receiving a module, the tray having a tray aspect ratio greater than 50 to 1, and having an enabling circuit for accessing cell energy and transmitting cell energy to a host device.

18. A portable power supply according to claim 17, wherein:

each module has an aspect ratio less than 50 to 1.

19. A portable power supply according to claim 17, wherein:

each cell module is without internal elements for protecting the cell against internal electrical shorting in the first condition.

20. A portable power supply according to claim 17, wherein:

the cell is rechargeable.

21. A portable power supply according to claim 20, wherein:

each cell comprises a lithium ion polymer cell.

22. A portable power supply according to claim 21, wherein:

each cell comprises a lithium-sulfur cell.