Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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TITLE: Electrical Energy Storage system, device and method
FIELD OF THE INVENTION
[0001] This invention relates to an electrical energy storage device, system
and method, and
particularly relates to an Nickel, Manganese, and Cobalt (sometimes known as
Lithium
Manganese Cobalt Oxide) battery with modules containing energy storage cells
wherein said
modules have modular heating for maintaining the modules internal energy cell
temperature in a
selected temperature range in sub-zero applications.
BACKGROUND OF THE INVENTION
[0002] Individual energy cells are frequently combined together to form packs
or modules, either
to increase the voltage output of the pack by combining cells in series or to
increase current by
combining cells in parallel. Over time and many charging and discharging
cycles the energy
capacity of any single energy cell diminishes, and at different rates for the
cells in the module.
[0003] Generally speaking, the performance of a module becomes limited to the
performance of
the weakest cell. There may also be safety issues with over charging or over
discharging any
individual cell which means that once a single battery cell has been
exhausted, the whole module
is unusable, even though some energy cells may still have some useable
capacity. Similarly,
when a single energy cell has reached full charge, the supply of charge
current should be stopped
to the whole module to avoid over-charging, even though some cells may not yet
be fully
charged. Prior art devices have attempted to address this issue.
[0004] For example US 10,291,037 relates to an electrical energy storage
device comprising: a
plurality of energy cell slots for receiving energy cells; and an individual
controller for each
energy cell slot of the plurality of energy cell slots; wherein each
controller is arranged to
estimate a characteristic of a cell in its respective energy cell slot; and
wherein each controller is
arranged to apply charge and discharge currents to its respective energy cell
slot dependent upon
at least one estimated characteristic currently associated with that slot.
[0005] However US 10,291,037 relates to cell 'slots' that decide whether to
allow current to
charge/discharge to particular cells. In the invention to be described herein
the modules do not
themselves make decisions on whether to allow current to flow. The modules to
be described
herein simply relay the information to a master controller that then decides
whether to activate
the module or not, by closing the module relay.
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[0006] Furthermore US 10,290,909 relates to a battery module including two or
more battery
cells, which can be charged and discharged, arranged in a stacked state and
cartridges for fixing
the battery cells to constitute a battery cell stack, wherein each of the
cartridges includes a pair of
assembly type frames, which are coupled to each other in a state in which a
corresponding one of
the battery cells is mounted in the frames, at least one of the cartridges
includes a temperature
sensor mounting unit, and a temperature sensor, mounted in the temperature
sensor mounting
unit, is configured to have a structure in which ends of a surface of the
temperature sensor
contacting a corresponding one of the battery cells are round.
[0007] However module design of 10.290,909 highlights the serviceability of
the contained cells.
The designs centres around 'pouch' cells, whereas the invention to be
described herein relates to
'aluminum hard-cased' cells.
[0008] Moreover the capacity of energy cells generally diminish when the
battery pack is
operated in cold or sub-zero environments such as battery operated lift trucks
in a large freezer
structure. There is a need for an improved energy storage device, system and
method.
SUMMARY OF THE INVENTION
[0009] It is an aspect of this invention to provide an electrical energy
storage device comprising:
a plurality of spaced energy cells; spaced holders for holding said plurality
of spaced energy cell
there between; at least one heater associated with at least one of said
holders for heating said
spaced energy cells at a selected temperature range; sensors for sensing one
of the temperature or
power capacity of said spaced energy cells; and a controller for controlling
said heater to heat
said spaced energy cells to said selected temperature range.
[0010] In one embodiment the controller deactivates any energy module that
falls below a
selected power capacity.
[0011] In another embodiment, the heater is comprised of silicone rubber
encasing a resistive
wire. The spaced holders can comprise extruded aluminum.
[0012] In yet another embodiment the spaced holders comprise a top holder and
bottom holder
for holding said spaced plurality of energy cells there between in a module.
[0013] Furthermore the heater is disposed between one of said top and bottom
holders, and said
plurality of energy cells. The energy cells comprise an NMC battery.
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[0014] Furthermore in another embodiment the plurality of energy cells are
disposed in pairs,
where each said pairs of energy cells include a voltage sensor, and where each
said module
includes a plurality of temperature sensors.
[0015] In yet another embodiment the electrical energy storage device has a
module comprises
one of;
(a) a 36 volt module and has 3 temperature sensors; or
(b) a 48 volt module and has 4 temperature sensors.
In another embodiment, a relay is disposed in an end cap of said module.
Furthermore, each said
energy storage device could include a top and bottom cell holder.
100161 Another aspect of this invention relates to a modular heating system
for energy storage
devices comprising: a plurality of energy cells in spaced adjacent
configuration; spaced
aluminum holders for holding said plurality of spaced energy cells between
said opposite
aluminum holders to define a module; a heater disposed between at least one of
said aluminum
holders and said plurality of energy cells; a sensor adjacent each pair of
said plurality of energy
cells to sense the temperature and/or power capacity of said pair of said
plurality of said energy
cells; a controller connected to each sensor adjacent each pair of said
plurality of energy cells for
receiving signals from said sensors to control the temperature and/or energy
capacity of each pair
of said plurality of said energy cells.
[0017] In yet another embodiment the heater comprises: a single top heater is
disposed along the
entire length of a top extrusion between said top aluminum holder and said
plurality of energy
cells; and; a single bottom heater disposed along the entire length of a
bottom aluminum holder
and said plurality of energy cells.
[0018] A further aspect of this invention relates to a method for energy
storage for sub-zero
applications comprising: placing a plurality of energy cells in spaced
adjacent configuration;
holding said plurality of spaced energy cells between opposite aluminum casing
to define a
module; placing a heater between at least one of said aluminum casing and said
plurality of
energy cells; placing a sensor adjacent each pair of said plurality of energy
cells to sense the
temperature and/or power capacity of said pair of said plurality of said
energy cells; and
connecting a controller to each sensor adjacent each pair of said plurality of
energy cells for
receiving signals from said sensors to control the temperature and/or energy
capacity of each pair
of said plurality of said energy cells.
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[0019] In one embodiment the method comprises placing a plurality of modules
in rows and
columns. In another embodiment the controller is external to said module and
activates the
silicon heater when the sensor senses that the temperature of said pair of
said energy cells falls
outside a selected temperature range to heat the all said energy cells in a
module.
[0020] In another embodiment of the method the controller deactivates the pair
of said energy
cells when the voltage of said pair of said energy cells falls outside a
selected voltage level.
[0021] Moreover in yet another embodiment of the method the opposite aluminum
holders
comprise: a top aluminum extrusion and a bottom aluminum extrusion; and said
silicon heater
comprises:
(a) a top silicon heater disposed along the entire length of said top aluminum
extrusion
between said top aluminum extrusion and said plurality of energy cells; and;
(b) a bottom silicon heater disposed along the entire length of said bottom
aluminum
extrusion between said bottom aluminum extrusion and said plurality of energy
cells;
and;
wherein said controller is external to said module; and wherein said method
further includes
powering said top silicon heater and said bottom silicon heater together to
heat all said energy
storage cells in a module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Fig. 1 is a schematic view that illustrates the heater elements of a
battery module
designed to be utilized in battery packs and maintain an ideal temperature in
sub-zero
applications, according to certain embodiments of the invention; where a
battery pack
incorporates a plurality of battery modules connected in either series or
parallel.
[0023] Fig. 2A-2B are perspective views of the invention integrated into
different 36V battery
module and 48V battery modules, according to certain embodiments of the
invention.
[0024] Fig. 3A-3C are perspective views of other embodiments of module cells &
cell holders
that are utilized in plurality to assemble different variants of a battery
module core, according to
certain embodiments of the invention.
[0025] Fig. 4A-4B are perspective views of a 36V and 48V battery module cores
found in Fig
2A-2B respectively.
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[0026] Fig. 5 illustrates a view of a 36V battery module core integrated with
the 36V
embodiment of the battery module end cap and the temperature sensors,
according to certain
embodiments of the invention.
[0027] Fig. 6 illustrates a view of a 48V battery module core integrated with
the 48V
embodiment of the battery module end cap and the temperature sensors,
according to certain
embodiments of the invention.
[0028] Fig. 7A-7B illustrates a perspective view of the top and bottom module
casing plus heater
sub assembly in 36V configuration, according to certain embodiments of the
invention.
[0029] Fig. 8A-8B illustrates a perspective view of the top and bottom module
casing plus
heater sub assembly in 48V configuration, according to certain embodiments of
the invention.
[0030] Fig. 9 illustrates an exploded view of the 36V battery module according
to certain
embodiments of the invention.
[0031] Fig. 10 illustrates an exploded view of the 48V battery module
according to certain
embodiments of the invention.
[0032] Fig. 11A-11B illustrate a cross-sectional view of the assembled battery
module and the
heating system according to certain embodiments of the invention.
[0033] Fig. 12 is a schematic view that illustrates a master controller and
thermal management
system interconnections with a plurality of battery modules within a battery
back according to
certain embodiments of the invention.
[0034] Fig. 13 illustrates the primary components of a battery pack including
a plurality of
battery modules within a battery pack enclosure and power shelf housing a
master controller
according to certain embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] In the following description of the invention, embodiments of an energy
storage system,
in particular any embodiments utilized in thermal management system will be
referenced in the
accompanying drawings. These illustrations are intended to showcase the
invention in practice.
Wherever possible, corresponding or similar reference numbers will be used
throughout the
drawings to refer to the corresponding part.
[0036] The present invention and its embodiments serve the purpose to
establish a thermal
management system that is utilized to enable battery pack systems to operate
in low temperature
environments. By maintaining the temperature in a determined ideal range or
selected range
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during operation, the overall battery pack performance is maximized or
improved including the
system power delivery and available capacity. In addition, this method of
operating the battery
pack, maintaining an ideal temperature will maximize or improve longevity by
minimizing or
lessening degradation due to cold or heat.
[0037] In FIG.1, an illustration of the main compromising component sub-
assemblies of an
energy storage module or energy storage device with a thermal management
system. The energy
storage battery module 100 is generally comprised of battery module end cap
101, battery
module core 102, and battery module housing 103. The battery module housing
103 is designed
to interlock with other modules to form battery packs. In addition, it is
designed for passive
module cooling creating a larger thermal mass absorb thermal energy, to be
more fully described
herein. It can also be fitted with an active heating system that is featured
in the battery module
casing or housing 103 as will be described. The battery module end cap 101
monitors & reports
temperatures via sensors integrated with the battery module core 102, as
described herein and
provides a means to control the integrated heating system via an external
master controller 110
having a 24 VDC power supply more fully particularized below.
[0038] The proposed invention can be integrated in to different battery module
configurations
with varying voltages and capacity. FIG.2A shows a perspective view of one
example of a 36V
battery module 200 while FIG.2B shows a perspective view of one example of a
48V battery
module 300. As shown in the illustration, the module housing 103 can be
configured for different
battery module cores 102 as illustrated for the 36V module housing 202 or the
48V module
housing 302. Each battery module 200, 300 is capable of being controlled
independently by a
master controller 110. Each variation of a battery module 200, 300 can be
connected electrically
in series & or parallel configurations. This is achieved first by mechanically
stacking the battery
modules 200, 300 and placing stacks alongside each other in various grid like
configurations.
The desired electrical configuration is achieved battery module 200, 300
electrical interconnects
at the positive module terminal 206 and negative module terminal 207 as shown
on the battery
module 200, 300 in FIG. 2A-2B. It should be noted these series or parallel
connections can be
made with bus bars or a comparable alternative such as cable & lug
connections. This will be
explained further in the invention's description. The module housing 103 is
made up of a top and
bottom 103t and 103b which integrate or connect with spaced energy cell
holders and is
designed for optimal mechanical stacking in addition to enabling passive
cooling and active
heating. Passive cooling is achieved by conduction through the aluminum and
steel thermal mass
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making up the module housing 103. The activing heating portion of the thermal
management is
achieved via integrated heaters 701 within the module housing 103 which
provides a controlled
heat flow back into the battery module 100. The thermal management details
will be further
explained into the invention's description. It should be noted the master
controller 110 can
.. control energy flow to each battery module and activate heaters to maintain
an optimal or
selected cell temperature range with a distribution of for example 5 C.
[0039] FIG.3A through to FIG.3B illustrate various cell blocks or energy cells
400, 410, 420
from which a plurality can be assembled together to form a battery module core
102. As shown
in FIG.3A, a rechargeable battery cell or energy cell 401 is fitted with a
bottom energy cell
holder 402 and top energy cell holder 403 to assemble a standard cell block
400 The battery cell
or energy cell 401 form factor is a prismatic can compromising in one
embodiment an outer
aluminum casing, positive cell terminal 407 and negative cell terminal 408.
The thermal
management system was designed according to the thermal/mechanical properties
of the energy
cell 401 to enable effective passive cooling and active heating through the
module housing 103.
The electrochemistry of the battery cell or energy cell 401 is NMC with for
example a nominal
voltage of 3.7 VDC & 50 AH capacity. However the invention can be utilized
with other
chemistries, form factors, and capacity. In another embodiment, shown in
FIG.3B, an extremity
cell block 410 is assembled with an extremity cell holder 404 instead of a top
cell holder 403.
An extremity cell block 410 is specialized to terminate each end of a battery
module core 102. In
yet another embodiment, shown in FIG.3C a horizontal cell block 420
specialized for the use in
multi row battery module core 600 as shown in FIG.4B and FIG.6. It is
assembled using a
horizontal cell holder 405 instead of the top cell holder 403 which enables
the horizontal cell
block 420 to interconnect with adjacent units 90 degrees relative to the
standard cell block 400
orientation. It should be noted that the bottom cell holder 402, top cell
holder 403, extremity cell
holder 404, and horizontal cell holder 405 are comprised of suitable
insulating material such as
ABS but can alternatively be composed of any equivalent material with similar
dielectric,
thermal, and flame retardant properties. In addition to serve as an insulator
between cells 401, the
top cell holder 403 and extremity cell holder 404 feature holes that are
fitted with inserts 406
which serve as mounting points for module housing 103 that contains the energy
cells therein.
[0040] FIG.4A-4B illustrate two embodiments of a battery module core 102 which
compromises
of a plurality of different cell blocks 400, 410, 420 that are mechanically
interlocked together
under compression, strapped together, and electrically interconnected via bus
bars (not shown) in
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series and parallel to form a battery module core 102, which is the energy
storage component of
the battery module 100. In one embodiment, a 36V battery module core 102, 500
shown in
FIG.4A where a plurality of cell blocks 400, 410 are configured in a 10 series
/ 2 parallel
configuration. By 10 series we mean 10 cell pairs from 430a to 430j pairs; and
by 2 parallel we
mean 2 cells in a block 430. The parallel cell pair A 430a are made by
connecting the negative
cell terminals 408 and positive cell terminal 407 of adjacent. The next series
connection of a pair
of cell blocks 400, 410 shown as 430b in FIG.4A have their respective positive
cell terminals
407 and negative cell terminal 408 connected in parallel. The interconnection
between two cell
block pairs 430a and 430b are connected from the first cell block pair A 430a
positive cell
terminals 407 to the adjacent cell block pair B 430b negative cell terminals
408. This is repeated
to obtain the desired electrical connection which are then connected in series
to get a nominal
voltage of 36VDC and 100AH capacity. This embodiment utilizes standard cell
blocks 400 with
an extremity cell block 410 on either end which are compressed together from
both ends before
being strapped using core straps 501. It should be noted that each type of
cell block 400, 410,
420 when interlocked with the adjacent unit has a minimum distance of 3 mm
between each cell
401 face. This distance is to ensure the longevity of the overall battery
module 100 as cells can
expand overtime. This distance can vary depending on the utilized lithium cell
in various
embodiments. The energy cells 401 are thermally insulated from each other via
the plastic cell
holders (402, 403, 404, 405) and electrically isolated since in one embodiment
the cell holders
(402, 403, 404, 405) are comprised of ABS. In another embodiment, a 48V
battery module core
600 is shown in FIG.4B which compromises primarily of standard cell blocks 400
to form the
bulk of the module core 102, 600, extremity cell block 410 for the two
opposite ends along with
horizontal cell blocks 420 to maintain a compatible form factor for the module
housing and
thermal management system. In the case of the 48V battery module core there
are 13 pairs of cell
blocks 430a to 430m rather than the 10 pairs in 36V embodiment. In addition to
active cell
blocks 400, 410, 420 that provide the energy storage capabilities of the
system, certain
embodiments feature a core spacer 602 and or a block spacer 603 to maintain
battery core shape
when being compressed during the 48V core strap 601 installations. It should
be noted that the
36V core strap 501 or 48V core strap 601 material is a flexible polypropylene
plastic or
equivalent material with enough strength to hold the cell blocks together
while being electrically
and thermally insulating. The core spacer 602 and block spacer 603 are
comprised of suitable
flexible material to accommodate any expansion or contraction due to thermal
variation.
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[0041] As of the invention is to monitor the energy cell 401 temperatures must
be monitored in
order to regulate the heating system in each battery module 100 within a
battery pack 1100
shown illustrated in FIG.12 which operates in less than for example 0 C or
other selected
ambient condition. FIG.5 illustrates a 36V battery module 200 view without the
outer 36V
module housing 202 specifically looking at the cell tab side where you can see
the energy cell's
401 positive cell terminal 407 and negative cell terminal 408 of the cell
blocks. The 36V end cap
201 shows a battery monitoring module inside its encasement responsible for
collecting voltage
and temperature data on each module and reporting it to a master controller
110 located on the
power shelf 1102 inside the battery pack 1100b as shown in FIG.13 for example.
Voltage
sensors 209 are placed at every series connection while the temperature
sensors 205 are placed in
a way to map out the temperature distribution within a battery module core 102
from the
extremities to the center. The 36V end cap 201 is integrated with a 36V
battery module core 500
via a sensor probe harness (not shown) with three temperature sensing
thermistors 205 (see
FIG.6) that are applied to the first, middle and end cell 401 in the 36V
battery module core 500.
.. However any number of thermistors 205 can be used. The voltage sensors 209
are placed on
each serial connection for a total of 10 in the 36V module core 500. In
another embodiment
shown in FIG.6, the 48V battery module 300 is shown without the outer 48V
module housing
302. The 48V end cap 301 with a battery monitoring module with a 48V version
of the sensor
probe harness (not shown) that is integrated or connected with the 48V module
core 600. In this
embodiment, four temperature sensing thermistors 205 are applied to the first,
middle, end cell,
and horizontal cell with sensor positions pointed out in FIG.6. Similarly
there are voltage sensors
209 placed at every series connection for a total of 13 also shown in FIG.6.
However in alternate
embodiments different battery modules can be configured with varying number of
sensors for
different battery module cores 102.
[0042] The thermal management system of the present invention manages the heat
flow in and
out of the battery module core 102 through the battery module housing 103. It
compromises of a
top and bottom casing or housing 103t and 103b in addition to side plates 203
and 303 shown in
the explosion views in FIG.9-10. FIG.7A-7B illustrate 36V top casing 800 (or
top housing 103t)
and 36V bottom casing 700 (or bottom housing 103b) that make up the top and
bottom portions
of the 36V module housing 202. Both casings or housings are made of an
aluminum case
extrusion 702 integrated with a silicone rubber resistive heater pad 701 via a
pressure adhesive.
Other materials can also be used that perform the same function. The heater
pads 701 feature
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leads that are connected to the 36V end cap 201 during the installation. The
heater pad 701
features for example up to 40W of power, thermally conductive silicone rubber
and electrically
isolating between the cell and the outer aluminum casing. The power density
can be adjusted for
different embodiments of the outer module housing 103 and different types of
battery cells 401.
In another embodiment the thermal system can be fitted with thermoelectric
peltier devices as a
substitute for the heater pads 701. It should also be noted that the silicone
rubber material
encasing the resistive heater can be composed of a comparable material with
similar thermal
conductivity and electrical isolation.
100431 In another embodiment of the invention, in order for the casing or
housing to be mounted
the battery core the case extrusion 702 has a plurality of mount holes 704
purposed for different
battery module assemblies. Particular mount holes 704 are fitted with pem nuts
703 in FIG.7A
and FIG. 7B to enable 36V side plates 203 installation better shown in the
explosion view of the
36V battery module 200 in FIG.9. In another embodiment, as shown in FIG. 8A to
FIG. 8B, 48V
bottom casing 900 or 103b and the 48V top casing 1000 or 103t are configured
via a different set
of pem nut 703 installation points. These set of casings are utilized with a
48V battery module
core 600. It should be noted that the-extrusions 702 are designed to be
asymmetrical to allow
module stacking regardless of the battery module core 102 construction for
better stability. The
opposite side of the pem nut 703 installation on each aluminum (although other
materials other
than aluminum can be used) case extrusion 702 feature additional mount holes
704 to enable
mounting to the inserts 406 on the top cell holder 403 and extremity cell
holder 404.
100441 The assembly of the embodiments making up the thermal management
applied in a 36V
battery module 200 are shown in an FIG.9 explosion view. The 36V end cap 201
integrated with
the 36V battery module core 500 form the main sensory intake portion of the
system, collecting
temperature data on the energy cells 401 and reporting it to the master
controller 110. FIG.12
illustrates an example of a communication and thermal management backbone
within a battery
pack 1100. The master controller 110 is electrically interconnected with a
plurality of battery
modules 100 via a single or plurality of intermodule harnesses 111 through
which
communication data and heater power is sent through between the master
controller 110 and
battery modules 200, 300. Each harness 111 is connected to the battery module
com port 208
better shown in FIG.2A-2B at the front of each battery module 200, 300. Each
com port 208
provides power, communication, heater power to the battery module end caps
201, 301. The
method by which the thermal management system provides passive cooling and
active heating is
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achieved via the 36V module housing 202 and master controller providing 24V
power source to
the heaters 701 via the 36V end cap 201. The 36V bottom casing 700 and 36V top
casing 800 are
both installed onto the sides of the 36V battery module core 500 where the
silicone rubber pad
with an isolated resistive heater interfaces with the plurality of cells 401.
The passive cooling is
achieved via the case extrusion 702 by conduction. The top and bottom casings
or housings 103t,
800 and 103b, 700 are joined together via the 36V side plate 203 to both add
additional thermal
mass and structural rigidity. The side plates 203 are installed via the
inserts 406 on the front right
side of the 36V module core 500 and pem nuts 703 on the top and bottom casing.
In addition to
insulating the module further and providing structural support, the 36V module
end plate 204
closes off the back end of the 36V battery module 200.
[0045] In another embodiment of the invention, the breakdown of components
making up
thermal management system applied in a 48V battery module 300 configuration
are shown in
FIG.10 explosion view. The 48V end cap 301 integrated with the 48V battery
module core 600
provides the sensory input just as the 36V embodiment with additional
thermistor 205
temperature sensor given the larger form factor and additional cells 401 to
manage within the
48V module core 600. The master controller 110 provides power to the heaters
in a similar
manner to the 36V embodiment described above but may utilize different control
algorithms
within the master controller 110 to achieve the appropriate selected
temperature or temperature
range. The 48V bottom casing 900 and 48V top casing 1000 form that main
thermal conductive
pathway to the plurality of cells within the 48V module core 600. The heat is
generated from the
two heating pads 701, and alternatively allows excessive heat to pass through
into the aluminum
case extrusions 702 as a heat sink. The 48V side plates 303 provide an
additional structural
rigidity and thermal mass increasing ability to spread the generated heat
throughout the module
for an evenly distributed heat transfer. Each 48V side plate 303 are mounted
via the inserts 406
and pem nuts 703 that have been configured for the 48V battery module core
600.
[0046] As shown in FIG.11A, a cross sectional view of the 36V battery module
200 showcasing
36V module housing 202 encasing the 36V module core 500. As shown in the cross
section the
standard cell blocks 400c is encased between the 36V top casing 800, 103t &
36V bottom casing
900, 103b. As shown in FIG.11A the module is fitted with two heater pads 701
(although a
number of pads could be used) for a total of 80W of available power compressed
onto a plurality
of the cell 401 faces. Heat flow can go in either direction at this interface.
The aluminum case
extrusions 702 act as heat sinks during normal operation wicking excessive
heat through the
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inactive silicone rubber heater 701. Similarly, in another embodiment as shown
in FIG.11B, a
cross-section view of the 48V battery module 300, illustrates the 48V battery
module core 600
encased in the 48V module housing 302. FIG.11B showcases the cross sectional
view of the
standard cell blocks 400c and cross sectional horizontal cell blocks 420c in
different orientations
making contact with the two 40W heater pads 701 for a total of 80W. The cross
sectional view
illustrates the interlocking features of the case extrusion 702 which allow
different battery
modules to be interlocked and stacked with each other physically to create
dense battery pack
systems. These battery packs can have a plurality of 36V battery modules 200
and 48V battery
module 300 interconnected in series or parallel. In addition to providing
localized heating to
specific battery modules 100, different methodologies can be employed on the
pack level such
that the master controller 110 activates adjacent module heaters 702 more
frequently to heating
towards more critical modules. The invention as presented can dynamically
adjust in order to
maintain optimal cell 401 temperatures reported through the thermistors 205.
This control is
conducted via power pulse of 24V at different frequencies to establish an
adjustable RMS power
through the master controller 110. In addition to the dynamic control in
expanded systems, the
thermal mass and interlocking features in the battery modules 100 allow a
greater ability to
passively cool the system in heavier load applications. The battery pack 1100
can be fitted with a
larger outer enclosure 1101 for an additional thermal mass and insulation from
outer ambient
conditions. FIG.13 conceptually illustrates a possible embodiment of a battery
pack 1100b
featuring 10 battery modules 100b (shown in from the front face perspective)
configured
mechanically in a 2 by 5 battery pack core 1103, a power shelf 1102 with a
master controller
110b (shown as a mechanical sub assembly inside), and a battery pack enclosure
1101. FIG.13
can also better illustrate a possible embodiment of a plurality of battery
modules 100b stacked on
top of each other and joined side to side to form multiple thermal conduction
pathways in
addition to the outer battery pack enclosure 1101.
[0047] As previously mentioned, the battery modules 100 also feature voltage
sensors 209,
which is reported to the master controller 110. If a voltage is detected
outside a preset boundary
conditions, that said battery module can be electrically isolated from the
battery pack 1100
common power bus through the battery module end cap 101 at the command of the
master
controller 110. In addition to protecting battery modules from loads or charge
sources during
these specified voltage points, it can terminate its heating power supply if
any one cell 401 is
outside its acceptable voltage range. This is to prevent events such as over
discharging or
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isolating the heating system in some other event where one of the battery
modules 100 are
compromised in any way.
[0048] The invention described herein describes a modular heating system for
energy storage
devices comprising: a plurality of energy cells in spaced adjacent
configuration; spaced
aluminum holders for holding said plurality of spaced energy cells between
said opposite
aluminum holders to define a module; a heater disposed between at least one of
said aluminum
holders and said plurality of energy cells; a sensor adjacent each pair of
said plurality of energy
cells to sense the temperature and/or power capacity of said pair of said
plurality of said energy
cells; and a local controller connected to each sensor adjacent each pair of
said plurality of
energy cells for receiving signals from said sensors to control the
temperature and/or energy
capacity of each pair of said plurality of said energy cells.
[0049] Furthermore the invention describes a method for energy storage for sub-
zero
applications comprising: placing a plurality of energy cells in spaced
adjacent configuration;
holding said plurality of spaced energy cells between opposite aluminum
holders to define a
module; placing a silicon heater between at least one of said aluminum holders
and said plurality
of energy cells; placing a sensor adjacent a pair of said plurality of energy
cells to sense the
temperature and/or power capacity of said pair of said plurality of said
energy cells; connecting a
controller to each sensor adjacent each pair of said plurality of energy cells
for receiving signals
from said sensors to control the temperature and/or energy capacity of each
pair of said plurality
of said energy cells.
100501 It is to be understood that the terminology which has been used is
intended to be describe
the invention rather than be a limitation. Many modifications and variations
of the present
invention are possible. It should also be noted that the presented embodiments
are specialized
towards cold applications and can be adjusted for different varying
conditions. Therefore, within
the scope of the appended claims, the present invention may be practiced
otherwise than as
specifically described.
LIST OF ELEMENTS
100 Battery Module
100b Battery Module - box view
101 Battery Module End Cap
102 Battery Module Core
103 Battery Module Housing
103t Top Module Housing / Casing
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103b Bottom Module Housing / Casing
110 Master Controller
110b Master Controller ¨ box view
111 Intermodule Harness
200 36V Battery Module
201 36V End Cap
202 36V Module Housing
203 36V Side Plate
204 36V Module End Plate
205 Thermistor
206 Positive Module Terminal
207 Negative Module Terminal
208 COM Port
209 Voltage sensor
300 48V Battery Module
301 48V End Cap
302 48V Module Housing
303 48V Side Plate
304 48V Module End Plate
400 Standard Cell Block
400c Cross-section standard cell block
401 Battery Cell /
402 Bottom Energy Cell Holder
403 Top Energy Cell Holder
404 Extremity Energy Cell Holder
405 Horizontal Energy Cell Holder
406 Insert
407 Cell Positive Terminal
408 Cell Negative Terminal
410 Extremity Cell Block
420 Horizontal Cell Block
Horizontal Cell Block-Cross-
420c section view
430a Cell Block Pair A
430b Cell Block Pair B
500 36V Battery Module Core
501 36V Core Strap
600 48V Battery Module Core
601 48V Core Strap
602 Core Spacer
603 Block Spacer
700 36V Bottom Casing
701 Heater Pad
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702 Case Extrusion
703 Pem Nut
704 Mount Hole
800 36V Top Casing
900 48V Bottom Casing
1000 48V Top Casing
1100 Battery Pack
1100b Battery Pack - box view
1101 Battery Pack Enclosure
1102 Power Shelf
1103 Battery Pack Core.
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