Battery array safety covers for energy storage system

• US 9,321,340 B2
• Filed: 06/06/2012
• Issued: 04/26/2016
• Est. Priority Date: 12/07/2010
• Status: Active Grant

• Current Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Original Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Inventors: Maskew, Brian J., Delrymple, Derek A., Morrow, Brian C.
• Primary Examiner(s): Gilliam, Barbara
• Assistant Examiner(s): MARTIN, ANGELA J
• Application Number:
  US13/490,080
• Publication Number:
  US 20120244403A1
• Time in Patent Office: 1,420 Days
• US Class Current: 1/1
• CPC Class Codes: B60K 2006/4825 Electric machine connected or connectable to gearbox input shaft
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/26 Vehicle weight
• CPC Class Codes: B60L 2240/421 Speed
• 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 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0084 relating to control modules
• CPC Class Codes: B60L 3/108 whilst braking, i.e. ABS
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 : using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 50/64 : Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 : Arrangements of batteries
• CPC Class Codes: B60L 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 58/20 : having different nominal voltages
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: F28F 9/00 : Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
• CPC Class Codes: G01K 1/146 : arrangements for moving thermometers to or from a measuring position
• 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 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• 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 10/637 : characterised by the use of reversible temperature-sensitive devices, e.g. NTC, PTC or bimetal devices; characterised by control of the internal current flowing through the cells, e.g. by switching means for preventing undesired use or discharge H01M50/572
• CPC Class Codes: H01M 10/6551 : Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6554 : Rods or plates
• CPC Class Codes: H01M 10/6563 : with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/658 : by thermal insulation or shielding
• CPC Class Codes: H01M 2010/4278 : Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2200/00 : Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/204 : Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/244 : Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: H01M 50/264 : for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 : Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/289 : characterised by spacing elements or positioning means within frames, racks or packs spacing elements inside cells other than separators, membranes or diaphragms H01M50/471
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/317 : Re-sealable arrangements
• CPC Class Codes: H01M 50/569 : Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H01M 50/574 : Devices or arrangements for the interruption of current
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor

Abstract

An energy storage system comprising at least one energy storage module adapted to supply electrical energy to a hybrid vehicle. The energy storage module comprises an enclosure and at least one battery array located within the enclosure. The battery array also includes a voltage sense board having a plurality of bus bars disposed therein. The bus bars connect a positive terminal of a first battery cell to a negative terminal of a second battery cell. The voltage sense board has missing final bus bars in designated locations of the voltage sense board to limit the exposed voltage to 50 volts during initial assembly. The final bus bars are installed last in conjunction with safety covers which have overlap portions to cover the installed final bus bars.

Claims

1. An energy storage system, comprising:

at least one energy storage module adapted to supply electrical energy to a hybrid vehicle, the energy storage module comprising;

a primary enclosure; and

at least one battery array located within the primary enclosure;

wherein the at least one battery array comprises;

a voltage sense board;

a first subgroup of battery cells, the first subgroup including a first battery cell adjacent to a second battery cell;

a second subgroup of battery cells, the second subgroup including a third battery cell;

a plurality of bus bars disposed within the voltage sense board, a first bus bar of the plurality of bus bars connecting a positive terminal of the first battery cell to a negative terminal of the second battery cell;

at least one final bus bar coupled to and extending away from a first insulative cover, the final bus bar connecting the negative terminal of the second battery cell to a positive terminal of the third battery cell;

wherein the voltage of the first subgroup of battery cells and the voltage of the second subgroup of battery cells is not greater than 50 volts.

2. The energy storage system of claim 1, wherein the first subgroup of battery cells is adjacent the second subgroup of battery cells, and wherein the first and second subgroups are connected in series.

6. The energy storage system of claim 1, wherein the first subgroup of battery cells are connected together in series by a first plurality of the plurality of bus bars in the voltage sense board, and the second subgroup of battery cells are connected together in series by a second plurality of the plurality of bus bars within the voltage sense board.

7. The energy storage module of claim 1, comprising:

a second cover with at least one insulated portion extending outwardly away from the second cover, wherein the at least one final bus bar extends outwardly away from the first cover positioned between the second battery cell and the insulated portion of the second cover.

3. An energy storage system, comprising:

at least one energy storage module adapted to supply electrical energy to a hybrid vehicle, the energy storage module comprising;

a primary enclosure; and

at least one battery array located within the primary enclosure;

wherein the at least one battery array comprises;

a voltage sense board including a plurality of bus bars extending outwardly away from the voltage sense board, the plurality of bus bars divided into a first and second voltage section of adjacent bus bars;

wherein the bus bars in the first voltage section connect together in series a first plurality of battery cells in the array, and the bus bars in the second voltage section connect together in series a second plurality of battery cells in the array; and

a final bus bar separate from the plurality of bus bars, the final bus bar mounted to and extending away from a first insulative cover, the final bus bar connecting together in series a battery cell from the first plurality of battery cells and a battery cell from the second plurality of battery cells;

wherein the voltage of the first plurality of battery cells and the voltage of the second plurality of battery cells is not greater than 50 volts.

4. The energy storage module of claim 3, wherein the battery array further comprises:

multiple additional insulating covers forming a plurality of insulating covers, at least one of the covers having an overlap portion which covers a portion of an adjacent cover when installed.

5. The energy storage system of claim 4, wherein the final bus bar extends from within the first cover, and wherein the final bus bar is positioned between battery cells from the first and second plurality of cells and an overlap portion of another cover of the plurality of covers that is adjacent to the first cover.

8. An energy storage module, comprising:

a primary enclosure;

a battery array located within the primary enclosure;

a voltage sense board including multiple bus bars extending from the voltage sense board, the bus bars configured to electrically connect in series separate groups of the multiple battery cells in the battery array;

wherein the voltage sense board and the multiple bus bars are configured to electrically connect together the multiple battery cells within the multiple groups;

wherein the voltage sense board is configured to insulate the separate groups of battery cells connected in series from one another; and

multiple overlapping insulative covers including final bus bars, wherein the final bus bars are configured to electrically connect together the separate groups of battery cells.

9. The energy storage module of claim 8, wherein the separate groups of the multiple battery cells includes a first group including a first plurality of battery cells, and a second group including a second group of battery cells, wherein the battery cells in the first plurality of battery cells are adjacent one another, and the battery cells in the second plurality of battery cells are adjacent one another.

10. The energy storage module of claim 9, wherein the first and second groups are adjacent one another.

11. The energy storage module of claim 8, wherein the multiple overlapping insulative covers include a first insulative cover with a final bus bar extending outwardly from the first cover, and a second insulative cover having an insulated portion extending outwardly away from the second cover, and wherein the final bus bar is positioned between a battery cell and the insulated portion of the second insulative cover.

12. The energy storage module of claim 8, wherein the combined voltage of the separate groups of battery cells in the battery array connected together in series is not greater than 50 volts.

13. The energy storage module of claim 8, wherein the battery array is mounted inside the primary enclosure, and the primary enclosure is hermetically sealed.