Multi-configurable, scalable, redundant battery module with multiple fault tolerance

• US 7,990,101 B2
• Filed: 05/15/2007
• Issued: 08/02/2011
• Est. Priority Date: 05/15/2006
• Status: Active Grant

• Current Assignee: A123 Systems Incorporated
• Original Assignee: A123 Systems Incorporated
• Inventors: Tremelling, Greg, Fulop, Ricardo, Shaffer, Benjamin Craig, Hoff, C. Michael, Myerberg, Jonah S., Chu, Andrew C.
• Primary Examiner(s): Tso; Edward
• Assistant Examiner(s): PIGGUSH, AARON C
• Application Number:
  US11/803,424
• Publication Number:
  US 20070279953A1
• Time in Patent Office: 1,540 Days
• Field of Search: 320/122, 320/134, 320/107, 324/434, 429/61
• US Class Current: 320/107
• CPC Class Codes: G01R 31/396 Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery
• CPC Class Codes: H01M 10/04 Construction or manufacture in general H01M10/058, H01M10/12, H01M10/28, H01M10/38 take 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 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/509 characterised by the type of connection, e.g. mixed connections
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/512 Connection only in parallel
• CPC Class Codes: H01M 50/519 comprising printed circuit boards [PCB]
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0014 Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: H02J 7/005 Detection of state of health [SOH]
• 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

An energy delivery system includes at least one string of two or more energy delivery modules electrically coupled in series. Each energy delivery module includes one or more energy delivery devices for storing and delivering electrical current, and a module monitor for monitoring and controlling each of the energy delivery devices. Each string of energy delivery modules includes a string communication path accessible to each of the energy delivery modules, wherein the module monitor of each energy delivery module is operable to communicate information associated with its energy delivery module through the string communication path. Each string also includes a string manager device for communicating with each module monitor in the string, through the string communication path. The energy delivery system also includes a system controller for communicating with each string manager device through a system communication path.

Claims

1. An energy delivery system, comprising:

a plurality of strings, each string in the plurality comprising,

(i) two or more energy delivery modules electrically coupled in series, wherein each energy delivery module includes one or more energy delivery devices for storing and delivering electric current, and a module monitor for monitoring and controlling each of the energy delivery devices in the energy delivery module, and

(ii) a string communication path accessible to each of the energy delivery modules, wherein the module monitor of each energy delivery module is operable to communicate information associated with its energy delivery module through the string communication path;

a plurality of string manager devices for communicating with the module monitors in the strings through the string communication paths, each string manager device being respectively associated with a different string of the plurality of strings, wherein each string manager device is configured to independently communicate with the module monitors by sending an address specific message to the module monitors along its string communication path, such that a response is given by the module monitor that corresponds to the address specific message sent by the string manager device; and

a system controller for communicating with each string manager device through a system communication path.

2. The energy delivery system of claim 1, further including a device monitor for monitoring and controlling each energy delivery device, wherein each device monitor communicates with the module monitor such that the module monitor functions as a proxy for the device monitors and the energy delivery devices.

3. The energy delivery system of claim 1, wherein the information associated with the energy delivery module includes electrical characteristics of the energy delivery module.

4. The energy delivery system of claim 1, wherein the information associated with the energy delivery module includes commands for controlling the energy delivery module.

5. The energy delivery system of claim 1, wherein the information associated with the energy delivery module includes instructions for configuring a predetermined arrangement of the modules within the system.

6. The energy delivery system of claim 1, wherein the information associated with the energy delivery module includes environmental information associated with the module.

7. The energy delivery system of claim 1, further including one or more isolating switches for isolating an abnormal module from the communication path.

8. The energy delivery system of claim 1, wherein the communication path is a wire communication bus that supports an addressed communication protocol.

9. The energy delivery system of claim 1, wherein the system controller subsumes at least one of the string managers, so that the system controller provides functionality associated with the at least one of the string managers.

10. The energy delivery system of claim 1, wherein each string manager accommodates more or fewer modules in the string, and the system manager accommodates more or fewer string managers in the system.

11. An energy delivery system, comprising:

a plurality of energy delivery devices, wherein each energy delivery device is operable to store energy provided to it and deliver stored energy as electrical current;

a plurality of first electrical devices for providing functionality related to at least one of monitoring, controlling and managing the plurality of energy delivery devices;

a plurality of string communication paths associated with the plurality of first electrical devices;

a plurality of second electrical devices for communicating with the plurality of first electrical devices through the plurality of string communication paths, each of the second electrical devices being separately associated with a corresponding one of the string communication paths, wherein the plurality of second electrical devices are configured to independently communicate with the first electrical devices by sending address specific messages to the first electrical devices, such that responses are given by the first electrical devices that correspond to the address specific messages sent by the second electrical devices; and

a printed circuit board including;

(i) electrical contacts for electrically coupling the energy delivery devices to the printed circuit board, and,

(ii) electrical conductors for electrically coupling the energy delivery devices to one another in a predetermined arrangement, and for coupling the energy delivery devices to the plurality of first electrical devices;

wherein the plurality of energy delivery devices and the plurality of first electrical devices are mounted directly to the printed circuit board.

12. A method of assembling an energy delivery system, comprising:

providing a pair of endcaps, wherein the endcaps include (i) posts for constraining an array of energy delivery devices in a predetermined arrangement, (ii) electrically conductive plates for providing an electrical connection to the energy delivery devices, and (iii) access ports for accessing the electrically conductive plates through the endcaps at locations corresponding to electrical ports of the energy delivery devices, the access ports are formed in an exterior surface of the electrically conductive plates;

disposing the energy delivery devices between the endcaps, such that the posts constrain the energy delivery devices in the predetermined arrangement, and the electrical ports of the energy delivery devices are in contact with the electrically conductive plates;

securing the endcaps together, so as to clamp the batteries between the endcaps in the predetermined arrangement;

applying heat through the access ports to the electrically conductive plates, which forms an electrically conductive bond between the electrical ports of the energy delivery devices and predetermined locations on the electrically conductive plates.

13. The method according to claim 12, further wherein the posts are configured to protrude from an interior surface of the electrically conductive plates, such that the posts constrain the energy delivery devices to reduce stress on the bonds.

14. The method according to claim 12, wherein applying heat through the access ports further includes resistance welding the conductive plate.

15. The method according to claim 12, further including disposing a printed circuit board at a top portion of the endcaps, wherein one or more conductive tabs extending from the conductive plates provide an electrical coupling between the cells and the printed circuit board.

16. The method according to claim 12, further including providing a frame for arranging two or more modules in a predetermined configuration.

17. An energy delivery system, comprising:

a pair of endcaps, wherein the endcaps include (i) posts for constraining an array of energy delivery devices in a predetermined arrangement, (ii) electrically conductive plates for providing an electrical connection to the energy delivery devices, and (iii) access ports for accessing the electrically conductive plates through the endcaps at locations corresponding to electrical ports of the energy delivery devices, the access ports are formed in an exterior surface of the electrically conductive plates;

wherein the energy delivery devices are disposed between the endcaps, such that the posts constrain the energy delivery devices in the predetermined arrangement, and the electrical ports of the energy delivery devices are in contact with the electrically conductive plates;

wherein the endcaps are secured together, so as to clamp the batteries between the endcaps in the predetermined arrangement; and

,

wherein an electrically conductive bond is formed between the electrical ports of the energy delivery devices and predetermined locations on the electrically conductive plates by applying heat through the access ports to the electrically conductive plates.

18. The energy delivery system of claim 17, further including a printed circuit board disposed at a top portion of the endcaps, wherein the printed circuit board is electrically coupled to one or more tabs extending from the electrically conductive plates.

19. The energy delivery system of claim 18, furthering including an electrical connector for coupling to a communication path, wherein the electrical connector is electrically coupled to one or more electrical devices mounted on the printed circuit board.

20. The energy delivery system of claim 17, wherein the energy delivery devices are arranged in groups of alternating polarity, such that the groups of energy delivery devices are electrically connected in series.

21. The energy delivery system of claim 17, wherein the energy delivery devices are arranged in groups that are electrically connected in parallel.

22. The energy delivery system according to claim 17, wherein the posts are configured to protrude from an interior surface of the electrically conductive plates, such that the posts constrain the energy delivery devices to reduce stress on the bonds.