Battery module

A battery module includes a set of power contacts, a set of signal contacts and a battery pack operable to deliver electrical power to the set of power contacts. An electronic isolation system is operable to electrically disconnect and connect the battery pack and the set of power contacts. An electronic control system is electrically connected to the electronic isolation system and to one of the set of signal contacts or the set of power contacts. The electronic control system is operable to measure a parameter associated with one of the battery module and an electrical device and to compare the parameter to a predefined value. The electronic isolation system connects the battery pack to the set of power contacts based on a positive result of the comparison, and disconnects the battery pack and the set of power contacts based on a negative result of the comparison.

TECHNICAL FIELD

The present disclosure relates to battery modules. More specifically, the disclosure relates to battery modules having electronic isolation and power flow control systems.

BACKGROUND

A battery module system is a set of any number of battery modules, wherein each battery module includes a battery pack. Each battery pack includes one or more battery cells. The battery modules of the battery module system may be electrically configured in series, parallel or a mixture of both to deliver the desired voltage, capacity, or power density required for any number of applications. Battery module systems are used in energy dense battery applications such as charging an electric vehicle (“EV”), powering heavy duty power tools, or the like.

The risk of assembling the battery modules of a battery module system may be low as long as the battery packs are equally matched. Battery packs may be precisely measured, calibrated and matched at the initial manufacturer for such parameters as internal resistance, initial voltage and state of charge (SOC). The battery modules may then be discharged at the factory down to a SOC that is legal for shipping (for example, between 30% to 60% of full charge) and shipped to their final destination, where the battery modules can be assembled into the desired battery module systems.

Problematically however, battery modules may have their SOC, internal resistance and other internal parameters inadvertently changed during shipment. For example, conductive materials may come into contact with the power contacts of the battery modules during shipment. Additionally, the battery modules may have their internal parameters altered at different rates or to different degrees during use. If the difference in internal parameters between two battery modules are unacceptably high, the risk of arcing, fire or other hazards grow significantly.

Further, if two battery modules are at a significantly different SOC, the battery module with the greater SOC will discharge into the battery module with the lesser SOC, and the total power output will drop significantly. Moreover, significantly different SOCs between battery modules may cause back flow currents, which can damage a battery module.

Accordingly, there is a need for a battery module that can prevent or inhibit making electrical contact with other battery modules (or other similar electrical devices) if their internal parameters are significantly different. Further, there is a need for a battery module that can prevent or inhibit back flow. Additionally, there is a need for a battery module system wherein the individual battery modules of the battery module system may selectively connect with each other depending on the differences in internal parameters of each battery module.

BRIEF DESCRIPTION

The present disclosure offers advantages and alternatives over the prior art by providing a battery module with an electronic isolation system and a power flow control system electrically connected between the battery pack and the power contacts of the battery module. The electronic isolation system prevents the battery pack from connecting to the power contacts if one or more parameters from either the battery module or a second electrical device that is to be connected to the battery module are at an unacceptable value. For example, the electronic isolation system may prevent electrical contact between the battery pack and power connectors of a first battery module that is to be connected to a second battery module, if the SOCs of the first and second battery modules are outside of an acceptable range of value. Further, the battery modules may be assembled into a battery module system wherein each of the battery modules may selectively connect to the other battery modules depending on differences in their internal parameters.

Additionally, the power flow control system prevents or inhibits current back flow from the power connectors to the battery pack of a battery module no matter what the battery module is connected to. For example, the power flow control module may include one or more diodes or other unidirectional current devices and systems to prevent or inhibit such back flow.

A battery module in accordance with one or more aspects of the present disclosure includes a first set of power contacts, a first set of signal contacts and a battery pack operable to deliver electrical power to the set of power contacts. An electronic isolation system is operable to electrically disconnect and electrically connect the battery pack and the first set of power contacts. An electronic control system is electrically connected to the electronic isolation system and to the first set of signal contacts and/or the first set of power contacts. The electronic control system is operable to measure a parameter associated with the battery module and/or an electrical device and to compare the parameter to a predefined value to determine if it is desirable to connect the battery module to the electrical device. The electronic isolation system connects the battery pack to the first set of power contacts based on a positive result of the comparison. The electronic isolation system disconnects the battery pack and the first set of power contacts based on a negative result of the comparison.

Another battery module in accordance with one or more aspects of the present disclosure includes a first set of power contacts, a first set of signal contacts and a battery pack operable to deliver electrical power to the set of power contacts. A power flow control system is connected between the battery pack and the first set of power contacts. The power flow control system is operable to inhibit reverse flow of current from the first set of power contacts to the battery pack.

A battery module system in accordance with one or more aspects of the present disclosure includes a battery module system power bus and a plurality of battery modules. A first battery module of the plurality of battery modules includes a first set of power contacts electrically connected to the power bus, a first set of signal contacts and a first battery pack operable to deliver electrical power to the first set of power contacts. A first electronic isolation system is operable to electrically disconnect and connect the first battery pack and the first set of power contacts. A first electronic control system is electrically connected to the first electronic isolation system and to one of the first set of signal contacts and the first set of power contacts. The electronic control system is operable to measure a parameter associated with one of the first battery module and a second battery module of the plurality of battery modules and to compare the parameter to a predefined value to determine if it is desirable to connect the first battery module to the second battery module. The electronic isolation system connects the battery pack to the first set of power contacts based on a positive result of the comparison. The electronic isolation system disconnects the battery pack and the first set of power contacts based on a negative result of the comparison.

DETAILED DESCRIPTION

Certain examples will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the methods, systems, and devices disclosed herein. One or more examples are illustrated in the accompanying drawings. Those skilled in the art will understand that the methods, systems, and devices specifically described herein and illustrated in the accompanying drawings are non-limiting examples and that the scope of the present disclosure is defined solely by the claims. The features illustrated or described in connection with one example maybe combined with the features of other examples. Such modifications and variations are intended to be included within the scope of the present disclosure.

The terms “significantly”, “substantially”, “approximately”, “about”, “relatively,” or other such similar terms that may be used throughout this disclosure, including the claims, are used to describe and account for small fluctuations, such as due to variations in processing from a reference or parameter. Such small fluctuations include a zero fluctuation from the reference or parameter as well. For example, they can refer to less than or equal to ±10%, such as less than or equal to ±5%, such as less than or equal to ±2%, such as less than or equal to ±1%, such as less than or equal to ±0.5%, such as less than or equal to ±0.2%, such as less than or equal to ±0.1%, such as less than or equal to ±0.05%.

Referring toFIG.1, an example is depicted of a schematic of a first battery module100and its outside interfaces, according to aspects described herein. The outside interfaces include one or more sets of power contacts102and one or more sets of signal contacts104. Each set of power contacts102may have one or more contacts that are operable to conduct power generated from a battery pack106(seeFIG.2) to the battery module100. Each set of signal contacts104may have one or more contacts that are operable to communicate with, send and/or receive signals.

As an overview, battery modules, such as battery module100, may be electrically isolated from the outside world during transportation and storage to prevent the risk of electric shock and other safety hazards, such as arcing. As will be described in greater detail herein, the battery module100uses hardware and software redundancies before allowing for the energization of the power contacts102.

This ensures that the power contacts102only become energized after being connected to a second electrical device120(seeFIG.3) when certain measured parameters of either the battery module100or the second electrical device120have an acceptable value. The second electrical device may be, for example, an energy transfer module, a specific battery module charger, a specific predetermined load, and/or additional battery modules. The battery module100may be used in energy dense battery module systems200(seeFIG.5) used, by way of example, for a portable electric vehicle206(seeFIG.5) charging. In addition, the battery module100contains electrical hardware that ensures multiple battery modules connected do not discharge into each other. The power flow control system108of battery module100ensures substantially insignificant reverse currents no matter what voltage the battery module100and a second electrical device120are at. This improves the efficiency and reliability of the battery module100.

Referring toFIG.2, an example is depicted of a schematic of power and communication systems of the battery module100, according to aspects described herein. As mentioned earlier, the battery module100includes, one or more sets of power contacts102and signal contacts104as outside interfaces. Additionally, inside the battery module100is battery pack106, power flow control system108, an electronic isolation system110, and an electronic control system112for both the battery module100and the other electrical devices, such as the second electrical device120depicted inFIG.3.

The power contacts102provide the ability to charge or discharge the battery module100. The signal contacts104transfer auxiliary voltages, control signals, and serial communication lines between battery modules100and other electrical devices120. As depicted inFIG.2, the power flow control system108prevents or inhibits a battery module100with a lower state of charge (SOC) from being charged by a battery module100with a higher SOC. The electronic isolation system110is a system that may include active switching elements (seeFIG.4) that ensure that the power connectors102are not energized in the absence of a control voltage (not shown) on the electronic isolation system110. The electronic control system112in the battery module100handles a multitude of functions. By way of example, the electronic control system112may provide auxiliary voltages to devices external to the battery module100, determine the number of connected battery modules100in a battery module system200(seeFIG.5), provide serial communication between the battery module100and external devices (such as electrical device120ofFIG.3), and determine when to safely turn on and off the electronic isolation system110.

The electronic control system112contains several electrical signals and sensors (seeFIG.4) that may be used to control the electronic isolation system110and the power flow control system108. Those signals and sensors include, but are not limited to battery count, top detect, bottom detect, CAN bus, battery enable, and control voltages. The combination of these signals and sensors allow for the battery module100and battery module system200to ensure that they only energize the power terminals102when an appropriate device (such as second electrical device120ofFIG.3) is connected and ready to use the energy stored in the battery modules100and/or batter module systems200.

Referring again toFIGS.1and2, the first battery module includes a first set of power contacts102and a first set of signal contacts104as outside interfaces. A battery pack106is operable to deliver electrical power to the set of power contacts102. The battery pack106may be comprised of a system of battery cells (not shown). Each battery cell may include one or more anodes and cathodes separated by an electrolyte.

An electronic isolation system110is operable to electrically disconnect and electrically connect the battery pack106and the first set of power contacts102. An electronic control system112is electrically connected to the electronic isolation system110and to at least one of the first set of signal contacts104or the first set of power contacts102. The electronic control system112is operable to measure a parameter associated with the first battery module100and/or a second electrical device120(seeFIG.3) and to compare the parameter to a predefined value to determine if it is desirable to connect the first battery module100to the second electrical device120. The electronic isolation system110may connect the battery pack106to the first set of power contacts102based on a positive result of the comparison of the parameter to the predetermined value. The electronic isolation system may disconnect the battery pack106and the first set of power contacts102based on a negative result of the comparison.

The second electrical device120can be several different types of devices. For example, it could be another battery module100. Also, it could be a charging device, or an energy transfer module or a specific predetermined load.

The measured parameter described above may be one of several parameters and/or characteristics of either the first battery module100or the second electrical device120that are important for functioning. For example, the measured parameter could indicate the presence or absence of a certain characteristic in the first battery module100and/or second electrical device120. Also, by way of example, the parameter could be a resistance, a current, a voltage, State of Charge (SOC) or a state of health (SOH) of either the first battery module100or the second electrical device120.

The parameter associated with the first battery module100and/or the second electrical device120may also include a first parameter associated with the first battery module100, and a second parameter associated with the second electrical device120. Additionally, the comparison of the parameter to a predefined value may further include a comparison of a difference between the first parameter and the second parameter to a predefined acceptable range of the difference. If the difference is within the acceptable range, the electronic isolation system110may connect the battery pack106to the first set of power contacts102. If the difference is not within the acceptable range, the electronic isolation system110may disconnect the battery pack106and the first set of power contacts102.

In other words, the parameter may also be a differential of two parameters measured in both the first battery module100and the second electrical device120. For example, the parameter may be a difference between a state of health (SOH) or a state of charge (SOC) between the first battery module100and the second electrical device120.

The predetermined value that the parameter is compared to may be a value that is significant for functioning of the first battery module100and/or the second electrical device120. For example, the predetermined value may be an acceptable range for a difference in the SOC between the first battery module100and the second electrical device120(e.g., the second electrical device120may be a second battery module100). For example, an acceptable range may be that the SOC of the first battery module100be within plus or minus 50 percent, plus or minus 30 percent, plus or minus 25 percent, plus or minus 15 percent, plus or minus 10 percent, or plus or minus 5 percent of the SOC of the second electrical device.

The first battery module100also includes a power flow control system108that is connected between the battery pack106and the first set of power contacts102. In the example illustrated inFIG.2, the power flow control system108is connected between the electronic isolation system110and the first set of power contacts102. The power flow control system108is operable to prevent or inhibit reverse flow of current from the first set of power contacts102to the battery pack106. The power flow control system108may include at least one diode140(seeFIG.4) connected between the battery pack106and the first set of power contacts102.

Referring toFIG.3, an example is depicted of a schematic of a control interface128between the first battery module100and a second electrical device120, according to aspects described herein. The first battery module100includes a first set of power contacts102that are operable to electrically connect at control interface128to a second set of power contacts122of the second electrical device120. Additionally, the first set of signal contacts104of the battery module100are operable to electrically connect to a second set of signal contacts124of the second electrical device120.

As illustrated inFIG.3, the electronic control system112of the battery module100and the electronic control system126of the second electrical device120are both operable to measure a difference between a first parameter associated with the battery module100and a second parameter associated with the second electrical device120when the first and second sets of signal contacts104,124are connected together and/or when the first and second sets of power contacts102,122are connected together. The electronic control system112of the battery module100may measure the parameter through the first set of power contacts102and/or through the first set of signal contacts104. The electronic control system126of the second electrical device120may measure the parameter through the second set of power contacts122and/or through the second set of signal contacts124.

Referring toFIG.4, an example is depicted of a schematic of circuitry of the electronic control system112, the electronic isolation system110and the power flow control system208of the battery module100, according to aspects described herein. The electronic control system112may include a microprocessor130having a memory and an executable program in the memory. The microprocessor130may be in communication with, receive and/or process signals from the signal contacts104and/or the power contacts102.

The electronic control system112may include various voltage sensors132,134, in electrical communication with the microprocessor130, to measure various voltages between the first set of power contacts102and the battery pack106. Further, the electronic control system112may include a current sensor136, in electrical communication with the microprocessor130, to measure the current being conducted between the battery pack106and the first set of power contacts102.

The electronic isolation system110may include at least one switching device138electrically connected between the battery pack106and the first set of power contacts102. When the at least one switching device138is in an open position, the first set of power contacts102are isolated from the battery pack106. When the at least one switching device138is in a closed position, the first set of power contacts102are electrically connected to the battery pack106. The at least one switching device138may include one or more relays, MOSFET and/or other types of transistor switches or the like.

The power control system108may include one or more diodes140. Additionally, other unidirectional current elements and/or circuits may be utilized.

Referring toFIG.5, an example is depicted of a schematic of a battery module system200having a plurality of battery modules100, according to aspects described herein. The battery module system200includes a battery module system power bus202that directs the power output from the electrically parallel connected battery modules100to an external electric load, such as the battery of electric vehicle206. By way of example, the power output of the battery module system200may be connected to the external electric load through a load connector208.

In the example illustrated inFIG.5, an external electric load is a battery for an electric vehicle206that the battery module system200is charging. However, the external electric load may include any number of electric devices, systems and applications. For example, the external electric load may include power tools, aircraft systems or the like.

The battery module system200includes the plurality of battery modules100a-100e,which are connected together in parallel at the power bus202. However, any number of battery modules100may be used in the battery module system200.

The like reference numbers for like components are used inFIG.5when referring to any, or all, of the battery modules, and/or the components and systems of the battery modules, in the battery module system200. However, for purposes of clarity, when referring to a specific battery module, component or system inFIG.5, the letters “a-e” are appended to the end of the reference number.

A first battery module100aof the plurality of battery modules100a-100eincludes a first set of power contacts102a,which are electrically connected to the power bus202. First battery module100aalso includes a first set of signal contacts104a,which are electrically connected together through a signal bus204. Alternatively, the signal contacts may be independently connected to sources of signals such as various sensors. Such independent signals could be passed through a larger cable harness with independent conductors carrying such signals but without a common signal bus.

A first battery pack106aof the first battery module100ais operable to deliver electrical power to the first set of power contacts102a.A first electronic isolation system110aof the first battery module100ais operable to electrically disconnect and connect the first battery pack102aand the first set of power contacts102a.A first electronic control system112ais electrically connected to the first electronic isolation system110aand to one, or both, of the first set of signal contacts104aand the first set of power contacts102a.

The electronic control system112aof first battery module100amay be operable to measure a parameter associated with the first battery module100aand/or a second battery module100bof the plurality of battery modules100a-100e.The electronic control system112amay also be operable to compare the parameter to a predefined value to determine if it is desirable to connect the first battery module100ato the second battery module100b.The electronic isolation system110aof battery module100amay then connect the battery pack106aof battery module100ato the first set of power contacts102aof battery module100abased on a positive (e.g., compatible state of charge or compatible voltages before charging) result of the comparison. The electronic isolation system110amay disconnect the battery pack106aand the first set of power contacts102abased on a negative (e.g., non-compatible state of charge) result of the comparison.

Though the first and second battery modules of the battery module system200were specifically referenced as battery module100aand battery module100brespectively, the first and second battery modules may each be any battery module100of the battery module system200. In other words, the first battery module100may include any battery module100a-100eof the plurality of battery modules of battery module system200. Additionally, the second battery module100may include any other battery module100a-100eof the plurality of batter modules of battery module system200.

The parameter measured by electronic control system112aand associated with one, or both, of the first battery module100aand the second battery module100b,may further include: a first state of charge associated with the first battery module100a,and a second state of charge associated with the battery module100b.Additionally, the comparison of the parameter to a predefined value may further include: a comparison of a difference between the first state of charge and the second state of charge to a predefined acceptable range of the difference.

If the difference between the first state of charge (first SOC) and the second state of charge (second SOC) is within the acceptable range, the electronic isolation system110amay connect the battery pack106to the first set of power contacts102a.If the difference is not within the acceptable range, the electronic isolation system110amay disconnect the battery pack106aand the first set of power contacts102a.An acceptable range may be that the SOC of the first battery module100abe within plus or minus 50 percent, plus or minus 30 percent, plus or minus 25 percent, plus or minus 15 percent, plus or minus 10 percent, or plus or minus 5 percent of the SOC of the second battery module100b.

The first battery module100aof the battery module system200also may include a first power flow control system108aconnected between the first battery pack106aand the first set of power contacts102a.The first power flow control system108ais operable to prevent, or inhibit to a substantially insignificant level, reverse flow of current from the first set of power contacts102ato the first battery pack106a.This may be done with one or more diodes140(seeFIG.4) of with the use of other unidirectional current elements or circuits.

The second battery module100bmay also include a second power flow control system108bconnected between the second battery pack106band the second set of power contacts102b.The second power flow control system108bis operable to prevent or inhibit reverse flow of current from the second set of power contacts102bto the second battery pack106b.

The various battery modules100a-100eof the battery module system200may also include a top detection device and a bottom detection device. For example, the first battery module100amay include a top detection device that is operable to detect another battery module100of the plurality of battery modules100a-100epositioned on a top of the first battery module100a.Additionally, the first battery module100amay include a bottom detection device that is operable to detect another battery module100of the plurality of battery modules100a-100epositioned on a bottom of the first battery module100a.

The top and bottom detection devices may include any number of circuit elements and systems designed to determine if a battery module100is in the middle portion of the stack of battery modules100. The top and bottom detection devices may also aid in determining how many battery modules100are above or below any given battery module100. In an example, a CAN bus contact may be enabled on a bottom side of a bottommost battery module (e.g., battery module100a) in a stack of battery modules to allow the contact to connect to such a CAN bus. In the remainder, i.e., non-bottommost battery modules, such a CAN bus contact would not be enabled since the CAN bus would only be connected to the bottommost module and a CAN bus contact on a middle or top module in a stack would not be useful. Thus, a location detection device (e.g., a top or bottom detection device) may be useful when only one or more of a stack of battery modules connect to another device, or otherwise function differently that a rest of the stack of battery modules. Another example of a use for the top and bottom detectors is that they may be able to determine if the power bus may be safely isolated from a user/operator. On the bottommost batter a base or cover may be included to ensure the power bus remains fully isolated.

It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail herein (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.

Although the invention has been described by reference to specific examples, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the disclosure not be limited to the described examples, but that it have the full scope defined by the language of the following claims.