Reconfigurable battery system for efficient charging and discharging

Abstract

Reconfigurable battery system for efficient charging and discharging, a reconfigurable battery system is disclosed. The reconfigurable battery system includes a reconfigurable battery cell array, a controller, and a bus switch. The battery cell array is configured to operate in a first discharge mode, a second discharge mode, or a charge mode. The battery cell array includes a plurality of battery cells arranged in at least a first column of battery cells between a second battery terminal and a first battery terminal, and a switch between each battery cell within the first column of battery cells. The bus switch is in signal communication with the battery cell array at the first battery terminal and is configured to select between electrically connecting the first battery terminal to a normal voltage bus or a high voltage bus.

Description

Technical Field

[0001] The field of this disclosure generally relates to battery systems, and more specifically to high-efficiency battery systems. Background Technology

[0002] Electric vehicles, such as electric cars, trucks, marine vehicles, and airplanes, are becoming increasingly common in today's society. All of these vehicles include batteries that require rapid charging times, comparable to the refueling process for petroleum-based vehicles. Unfortunately, the charging rate of a battery is primarily limited by the charge transport processes and chemical reaction processes (i.e., oxidation-reduction) within the battery. Exceeding these limits through rapid charging results in reduced charging capacity and may generate excessive heat that can lead to battery thermal degradation.

[0003] Furthermore, as batteries discharge, their voltage decreases. Near the end of the discharge cycle, the battery voltage can drop to as low as 40% of its full state-of-charge voltage. At this lower voltage, the battery current increases under constant power load. This increased current generates significantly more heat in the battery and any devices electrically connected to it compared to the heat generated when the battery voltage is higher and closer to full state of charge. The adverse effects of this increased heat include, for example, energy loss (reduced efficiency), increased system cooling load (more power consumption), increased device rated current (heavier), and accelerated device degradation (shorter cycle life). Therefore, systems and methods are needed to address these problems. Summary of the Invention

[0004] A reconfigurable battery system is disclosed. The reconfigurable battery system includes a battery cell array and a bus switch. The battery cell array is configured to operate in a first discharge mode, a second discharge mode, and a charging mode. The battery cell array includes a plurality of battery cells arranged between a second battery terminal and a first battery terminal, comprising at least a first row of battery cells, and a switch between each battery cell within the first row of battery cells. The bus switch communicates signalingly with the battery cell array at the first battery terminal and is configured to select between electrically connecting the first battery terminal to a normal voltage bus or a high voltage bus. The battery cell array may also include a plurality of battery cells arranged between multiple rows of battery cells, and the switch may be available between each battery cell within each row of battery cells in a multi-row battery power supply.

[0005] In an operational example, the reconfigurable battery system can perform a method comprising: when the battery cell array is configured to operate in a first discharge mode, electrically connecting a first battery terminal to a normal voltage bus and electrically connecting each battery cell in a first column of battery cells to form an electrically parallel connection between the first battery terminal and a second battery terminal, wherein each battery cell in the first column of battery cells is connected in parallel between the first battery terminal and the second battery terminal. The method also includes, when the battery cell array is configured to operate in a second discharge mode, electrically connecting the first battery terminal to a high voltage bus and electrically connecting each battery cell in the first column of battery cells to form an electrically series connection between the first battery terminal and the second battery terminal, wherein the electrically series connection includes all battery cells in the first column of battery cells. Furthermore, the method also includes, when the battery cell array is configured to operate in a charging mode, electrically connecting the first battery terminal to a high voltage bus and electrically connecting each battery cell in the first column of battery cells to form an electrically series connection between the first battery terminal and the second battery terminal, wherein the electrically series connection includes all battery cells in the first column of battery cells.

[0006] Other apparatuses, devices, systems, methods, features, and advantages of the present invention will be or will become apparent to those skilled in the art upon examination of the following drawings and detailed description. It is intended that all such additional apparatuses, devices, systems, methods, features, and advantages fall within the scope of this invention and are protected by the appended claims. Attached Figure Description

[0007] The invention can be better understood by referring to the following accompanying drawings. The components in the drawings are not necessarily drawn to scale, but rather to emphasize the principles of the invention. In the drawings, the same reference numerals denote corresponding parts in different views.

[0008] Figure 1 This is a system block diagram illustrating an example implementation of a reconfigurable battery system according to the present disclosure.

[0009] Figure 2 This is a system block diagram illustrating an example implementation of a battery cell array of a reconfigurable battery system according to the present disclosure.

[0010] Figure 3A This is a system block diagram illustrating an example implementation of a reconfigurable battery cell array in a first discharge mode according to the present disclosure.

[0011] Figure 3B This is a system block diagram illustrating an example implementation of a reconfigurable battery cell array in charging mode according to the present disclosure.

[0012] Figure 3CThis is a system block diagram illustrating an example implementation of a reconfigurable battery cell array in a second discharge mode according to the present disclosure.

[0013] Figure 4 This is a flowchart illustrating an example of an implementation of a method for operating a reconfigurable battery system according to the present disclosure.

[0014] Figure 5 This is a flowchart illustrating an example of an implementation of another method of operation of the reconfigurable battery system according to this disclosure. Detailed Implementation

[0015] A reconfigurable battery system is disclosed. The reconfigurable battery system includes a battery cell array and a bus switch. The battery cell array is configured to operate in a first discharge mode, a second discharge mode, and a charging mode. The battery cell array includes a plurality of battery cells arranged (1) between a second battery terminal and a first battery terminal in at least a first column of battery cells and (2) a switch between each battery cell in the first column of battery cells. The bus switch communicates signalally with the battery cell array at the first battery terminal and is configured to select between electrically connecting the first battery terminal to a normal voltage bus or a high voltage bus. The battery cell array may also include a plurality of battery cells arranged in multiple columns of battery cells between the second battery terminal and the first battery terminal, and the switch may be between each battery cell in each column of the multiple columns of battery cells.

[0016] In an operational example, the reconfigurable battery system can perform a method comprising: when the battery cell array is configured to operate in a first discharge mode, electrically connecting a first battery terminal to a normal voltage bus and electrically connecting each battery cell in a first column of battery cells to form an electrically parallel connection between the first battery terminal and a second battery terminal, wherein each battery cell in the first column of battery cells is connected in parallel between the first battery terminal and the second battery terminal. The method also includes, when the battery cell array is configured to operate in a second discharge mode, electrically connecting the first battery terminal to a high voltage bus and electrically connecting each battery cell in the first column of battery cells to form an electrically series connection between the first battery terminal and the second battery terminal, wherein the electrically series connection includes all battery cells in the first column of battery cells. Furthermore, the method also includes, when the battery cell array is configured to operate in a charging mode, electrically connecting the first battery terminal to a high voltage bus and electrically connecting each battery cell in the first column of battery cells to form an electrically series connection between the first battery terminal and the second battery terminal, wherein the electrically series connection includes all battery cells in the first column of battery cells.

[0017] exist Figure 1The present disclosure illustrates an example system block diagram of an embodiment of a reconfigurable battery system 100. The reconfigurable battery system 100 may be, for example, part of an electric vehicle 101. The reconfigurable battery system 100 is configured to signal-communicate with an electric vehicle load (generally referred to simply as a "load") 102 and a charging station 104 via a plurality of electrical connections including a normal voltage bus 106, a load bus 108, a high voltage bus 110, and a negative bus 111. The reconfigurable battery system 100 may include a battery cell array 112, a controller 114, and a bus switch 116. The controller 114 signal-communicates with the battery cell array 112 and the bus switch 116. The bus switch 116 also signal-communicates with the battery cell array 112, the load 102, and the charging station 104 via a first battery terminal 118, a second battery terminal 119, the normal voltage bus 106, the load bus 108, the high voltage bus 110, and the negative bus 111, respectively. In this example, the first battery terminal 118 can be a positive terminal and the second battery terminal 119 can be a negative terminal.

[0018] In this example, load 102 is a device that acts as an electrical load for the reconfigurable battery system 100. Examples of electric vehicles 101 may include electric or hybrid vehicles, trucks, motorcycles, aircraft, ships, etc. Therefore, examples of load 102 may include, for example, one or more electric motor drives or other electrical loads. Furthermore, in addition to vehicles, load 102 may also be replaced by non-vehicle devices that utilize electricity and desire rapid charging and efficient discharging of battery systems. Examples of this type of non-vehicle device may include stationary loads, such as solar systems on buildings and / or homes, or portable electrical and / or electronic loads. Charging station 104 may be a power source, a charging station for electric vehicles, such as a fast charger for an electric car, a solar system on a building and / or home, or other similar power supply devices. Furthermore, charging station 104 may also be, for example, an onboard station or a DC bus on an aircraft system.

[0019] The battery cell array 112 includes a plurality of battery cells and at least one switch between at least two battery cells of the plurality of battery cells, wherein the plurality of battery cells are arranged in at least a first column of battery cells. Typically, a battery cell array includes two (2) × N × M battery cells arranged in one or more columns of battery cells, where N is the number of battery cells in each column of the multiple columns of battery cells, and M is the number of columns of battery cells. In this example, both N and M are at least equal to one, such that the smallest battery cell array 112 is a 2 × 1 battery cell array.

[0020] Therefore, the battery cell array 122 includes multiple battery cells, with at least one switch between each battery cell or between a group of battery cells. As an example, with a switch between each battery cell, if the battery cell array 112 is configured as a 2×1 battery cell array, then the battery cell array 112 includes a single switch between two battery cells arranged in a single row. Conversely, if the battery cell array 112 is configured as a 4×1 battery cell array, then the battery cell array 112 is arranged in a single row of battery cells, with three switches between the four battery cells in that single row. Furthermore, if the battery cell array 112 is configured as a 2×3 battery cell array, then the battery cell array 112 is arranged in three rows of battery cells, where each row of battery cells has two battery cells within a row. In this example, each row of battery cells will have a single switch between the two battery cells in each row, resulting in the battery cell array 112 having a total of three switches (i.e., one per row of battery cells). Conversely, if the battery cell array 112 is configured as a 4×5 battery cell array, then the battery cell array 112 is arranged in five columns of battery cells, with each column having four battery cells in that column. In this example, each column of battery cells will have three switches between the four battery cells in each column, resulting in the battery cell array 112 having a total of fifteen (15) switches (i.e., three per column of battery cells).

[0021] In an alternative example, if at least one switch is among a group of battery cells, the same previous description applies, but these descriptions instead pertain to an array of individual battery cells. Battery cell array 122 may comprise an array of individual groups of battery cells, where each group of battery cells acts as a single combination of battery cell modules that can have a voltage greater than that of an individual battery cell. For ease of illustration and description in this application, the term "battery cell" is used to refer to an individual battery cell (i.e., a single battery) or a single battery cell module (i.e., a battery cell module comprising a single combination of multiple individual batteries within a battery cell module).

[0022] In this example, at least one switch of the battery cell array 112 and the bus switch 116 can be, for example, an electronic switch, an electromechanical switch, or a mechanical switch. As an example, the bus switch can be a single-pole double-throw (SPDT) switch configured to connect the battery cell array 112 to a normal voltage bus 106 or a high-voltage bus 110. Alternatively, each switch of the battery cell array 112 (between each battery cell in the battery cell array 112) can be, for example, a double-pole double-throw (DPDT) switch.

[0023] Bus switch 116 is configured to electrically connect battery cell array 112 to normal voltage bus 106 when battery cell array 112 is configured to a first discharge mode or a second discharge mode. In this example, the first discharge mode is an operating mode in which the reconfigurable battery system 100 normally discharges to load 102. Furthermore, the second discharge mode is an operating mode in which the reconfigurable battery system 100 releases power in an efficient discharge mode.

[0024] Specifically, the bus switch 116 includes a first switch BS1 and a second switch BS2 that operate substantially simultaneously. In a discharge operation example, when the first switch BS1 electrically connects the first battery terminal 118 to the normal voltage bus 106 and the second switch BS2 electrically connects the second battery terminal 119 to the load bus 108 of the load 102, the reconfigurable battery system 100 transfers power to the load 102. As a charging operation example, when the first switch BS1 electrically connects the first battery terminal 118 to the high voltage bus 110 and the second switch BS2 electrically connects the second battery terminal 119 to the negative bus 111 of the charging station 104, the reconfigurable battery system 100 receives power from the charging station 104.

[0025] Those skilled in the art will understand that as batteries discharge, their voltage decreases, and as the battery discharge capacity nears its end, the battery voltage can drop to as low as 40% of its voltage at full charge. At this lower voltage, the battery current increases under constant power load, and this increased current generates significantly more heat in the battery and any device electrically connected to the battery compared to the heat generated when the battery voltage is higher and closer to the battery's full charge.

[0026] The adverse effects of this increased heat include, for example, energy loss leading to reduced battery efficiency, increased system cooling requirements necessitating more power, increased device current ratings, and accelerated device degradation resulting in shorter device cycle life. The reconfigurable battery system 100 addresses these issues by switching the discharge operation from a normal discharge mode when the battery cell array has a state of charge (SOC) level higher than a predetermined value, to a high-efficiency discharge mode when the battery cell array has a SOC level lower than a predetermined value.

[0027] The high-efficiency discharge mode causes the battery cell array 112 to generate a higher voltage and a correspondingly lower current, while discharging to the same load (i.e., load 102) at a lower state of charge level. This produces the same amount of power delivered to load 102 when the battery cell array 112 has a lower than predetermined state of charge level without generating any additional heat.

[0028] In this example, when the battery cell array 112 is configured in a first discharge mode (i.e., normal discharge mode), the switches between each battery cell within the battery cell array 112 are configured to electrically connect each battery cell in the first row of battery cells to form an electrically parallel connection between the first battery terminal and the second battery terminal. In this configuration, each battery cell in the first row of battery cells is connected in parallel between the first battery terminal 118 and the second battery terminal 119. Furthermore, if multiple rows of battery cells exist, each battery cell in each row of battery cells is also connected in parallel between the first battery terminal 118 and the second battery terminal 119.

[0029] Conversely, if the battery cell array 112 is configured in a second discharge mode (i.e., high-efficiency mode), the switches between each battery cell are configured to electrically connect each battery cell in the first row of battery cells to form an electrical series connection between the first battery terminal 118 and the second battery terminal 119. In this configuration, the electrical series connection includes all battery cells in the first row of battery cells. Furthermore, if multiple rows of battery cells are present, each battery cell in each row is also connected in series between the first battery terminal 118 and the second battery terminal 119.

[0030] In this example, when the reconfigurable battery system 100 is configured to operate in charging mode, the bus switch 116 is configured to electrically connect the first battery terminal 118 of the battery cell array 112 to the high-voltage bus 110. When the battery cell array 112 is configured in charging mode, similar to its configuration in a second discharging mode, the switch between each battery cell is configured to electrically connect each battery cell in the first row of battery cells to form an electrical series connection between the first battery terminal 118 and the second battery terminal 120. The electrical series connection includes all battery cells in the first row of battery cells. Furthermore, if multiple rows of battery cells are present, each battery cell in each row of battery cells is also connected in series between the first battery terminal 118 and the second battery terminal 119.

[0031] In the charging mode configuration, the battery cell array 112 is configured to allow charging of the battery cell array at a higher voltage (i.e., a higher voltage value) than would be normally possible if each individual battery cell were charged individually at its rated voltage. Those skilled in the art will understand that the voltage across the terminals of multiple battery cells connected in series is equal to the total voltage of the combination of the individual voltages of each battery cell. For example, if four battery cells are connected in series and each battery cell has a voltage of 5 volts, the total voltage produced by the combination of the series-connected battery cells is 20 volts. As a result, the battery cell array 112 can be charged at a voltage higher than the rated voltage of each individual battery cell. Because power equals voltage multiplied by current, the same amount of power can be delivered to the battery cell array 112 (i.e., charging), while a higher voltage and a lower current value are delivered from the charging station 104 to the battery cell array 112. Because the current is lower for the same amount of power, the battery cell array 112 can be charged more efficiently because the lower current generates less heat. Assuming the same available charging current limitation applies to the charging station, this also causes the battery cell array 112 to be charged in a shorter time (i.e., faster) than required by conventional methods. In this example, the number of battery cells arranged in a battery cell row is directly related to the maximum charging voltage, which can be used to effectively and quickly charge the battery cell array 112. Using this technique, the battery cell array 112 can be configured to charge at two, four, six, eight, etc., times the rated voltage of each individual battery. Typically, the charging voltage can be increased by twice the number of battery cells in a row. This technique also allows charging the battery cell array 112 with a higher amount of power because this configuration allows the same amount of current used during normal charging to be used while using a voltage higher than the rated voltage of each individual battery cell.

[0032] In this example, controller 114 can be any type of control device, such as a microprocessor, application-specific integrated circuit (ASIC), programmable gate array (PGA), logic circuit, or other similar device. Controller 114 communicates with at least one switch and bus switch 116 between each battery cell in the battery cell array 112. Controller 114 can be configured to control the switches and bus switches 116 between each battery cell based on the operation of the battery cell array 112 in a first discharge mode, a second discharge mode, or a charging mode. Controller 114 can also be configured to determine the state of charge (SOC) level within the battery cell array 112 and select either the first discharge mode or the second discharge mode in response to the SOC level within the battery cell array 112.

[0033] The controller 114 can also be configured as a control system including a switch controller (not shown), a battery system controller (not shown), and a vehicle controller (not shown). These controllers can be standalone devices, modules, components, sub-components, or modules of the controller 114. Typically, the first switch BS1, the second switch BS2, and the switches within the battery cell array 112 are controlled by the switch controller, which is a controller of the battery system controller. The battery system controller can receive command signals from the vehicle controller and other sensors within or associated with the reconfigurable battery system 100. As an example, the battery system controller can receive command signals including voltage, current, state of charge, temperature, pressure, and other information related to the reconfigurable battery system 100, the electric vehicle 101, and the load 102.

[0034] Those skilled in the art will understand that the circuits, components, modules, and / or devices associated with the reconfigurable battery system 100 are described as signaling to each other, wherein signaling communication refers to any type of communication and / or connection between circuits, components, modules, and / or devices that allows circuits, components, modules, and / or devices to transmit signals and / or information to and / or receive such signals and / or information from another circuit, component, module, and / or device. Communication and / or connection can be along any signal path between circuits, components, modules, and / or devices that allows signals and / or information to be transmitted from one circuit, component, module, and / or device to another and includes wireless or wired signal paths. Signal paths can be physical, such as wires, electromagnetic waveguides, cables, terminals with attachments and / or electromagnetic or mechanical coupling, semiconductor or dielectric materials or devices, or other similar physical connections or couplings. Furthermore, signal paths can be non-physical, such as free space (in the case of electromagnetic propagation) or information paths via digital components, where communication information is transmitted from one circuit, component, module, and / or device to another in different digital formats without the need for direct electromagnetic connections.

[0035] exist Figure 2 The present disclosure shows an example system block diagram of an embodiment of a reconfigurable battery system 100 with a battery cell array 200. In this example, the battery cell array 200 is in signal communication with a bus switch 116, wherein the bus switch 116 is configured to select between a normal voltage bus 106 and a high voltage bus 110. The battery cell array 200 includes a first battery terminal 118 and a second battery terminal 119. In this example, the battery cell array 200 is configured as a 4×5 battery cell array, which includes twenty (20) battery cells B. 11 B 12 B 13 B14 B 15 B 21 B 22 B 23 B 24 B 25 B 31 B 32 B 33 B 34 B 35 B 41 B 42 B 43 B 44 and B 45 And fifteen (15) switches S 11 S 12 S 13 S 14 S 15 S 21 S 22 S 23 S 24 S 25 S 31 S 32 S 33 S 34 and S 35 Each switch is electrically connected between adjacent battery cells in a column. In this example, battery cell array 200 includes five (5) columns of battery cells. The first column of battery cells 202 includes battery cell B. 11 B 21 B 31 and B 41 and switch S 11 S 21 and S 31 The second row of battery cells 204 includes B 12 B 22 B 32 and B 42 and S 12 S 22 and S 32 The third row of battery cells 206 includes B 13 B 23 B 33 and B 43 and S 13 S 23 and S 33 The fourth column of battery cells 208 includes B. 14 B 24 B 34 and B 44 and S 14 S 24 and S34 The fifth column of battery cells 210 includes B. 15 B 25 B 35 and B 45 and S 15 S 25 and S 35 In this example, all columns of battery cells 202, 204, 206, 208, and 210 are electrically connected between the first battery terminal 118 and the second battery terminal 119. As previously described, each battery cell B 11 B 12 B 13 B 14 B 15 B 21 B 22 B 23 B 24 B 25 B 31 B 32 B 33 B 34 B 35 B 41 B 42 B 43 B 44 and B 45 It can be a single battery cell (i.e., a single battery) or a battery cell module (i.e., a single battery cell module that includes more than one battery cell in a module).

[0036] Go to Figures 3A-3C The present disclosure illustrates an example system block diagram of another embodiment of a reconfigurable battery system 100, specifically a battery cell array 300. As previously described, the battery cell array 300 may include any number of battery cells and switches, and typically comprises 2×N×M battery cells arranged in one or more rows of battery cells, where N is the number of battery cells in each row of multiple rows of battery cells, and M is the number of rows of battery cells. Both N and M are equal to at least one (1), such that the smallest battery cell array 112 is a 2×1 battery cell array. In this example, for ease of illustration, the battery cell array 300 is a 2×3 battery cell array, including battery cell B. 11 B 21 B 12 B 22 B 13 and B 23 And switches S1, S2, and S3. Battery cell B 11 and B 21 And switch S1 is arranged in the first column 302 of battery cell B.12 and B 22 And switch S2 is arranged in the second column 304 of the battery cell, and battery cell B 13 and B 23 And switch S3 is arranged in the third column 306 of the battery cell. In this example, bus switch 116 is an SPDT switch and each switch S1, S2 and S3 of battery cell array 112 is a DPDT switch.

[0037] exist Figure 3A In this embodiment, the battery cell array 300 is configured to be in a first discharge mode according to the present disclosure. As previously described, the first discharge mode may be a normal discharge mode, wherein the battery cell array 300 generates an output power signal 308, which is equal to the voltage across the second battery terminal 119 and the first battery terminal 118 multiplied by the current generated by the battery cell array 300. The output power signal 308 is transmitted to the normal voltage bus 106 when the bus switch 116 electrically connects the first battery terminal 118 to the normal voltage bus 106 via the first switch BS1 and the second battery terminal 119 to the load bus 108 via the second switch BS2. The output power signal 308 is then transmitted to the load 102.

[0038] In the first discharge mode, battery cell B 11 and B 21 The switch S1 between them is configured to switch each battery cell B in the first column 302. 11 and B 21 The battery cells are electrically connected in parallel between the first battery terminal 118 and the second battery terminal 119. Specifically, the battery cells B in the first column 302... 11 and B 21 They are connected in parallel between the first battery terminal 118 and the second battery terminal 119. Similarly, battery cell B... 12 and B 22 The second switch S2 between them is configured to switch each battery cell B in the second column 304. 12 and B 22 The battery is electrically connected in parallel between the first battery terminal 118 and the second battery terminal 119. Furthermore, battery cell B... 13 and B 23 The third switch S3 is configured to switch each battery cell B in the third column 306. 13 and B 23 The electrical connection is configured to form an electrical parallel connection between the first battery terminal 118 and the second battery terminal 119.

[0039] The result is that each battery cell B 11 B 21B 12 B 22 B 13 and B 23 They are configured to be connected in parallel between the first battery terminal 118 and the second battery terminal 119. In this example, the discharge voltage at the normal voltage bus 106 is equal to that of each battery cell B. 11 B 21 B 12 B 22 B 13 and B 23 The rated voltage.

[0040] exist Figure 3B In this embodiment, the battery cell array 300 is configured to be in a charging mode according to the present disclosure. As previously described, the charging mode is a high-efficiency charging mode, which allows the battery cell array 300 to be charged effectively and quickly using a voltage higher than the voltage rating of a single battery cell of the battery cell array 300.

[0041] In charging mode, bus switch 116 is configured to electrically connect the first battery terminal 118 of battery cell array 300 to high-voltage bus 110, wherein battery cell array 300 is configured to charge at a high voltage value. Specifically, in charging mode, when bus switch 116 electrically connects the first battery terminal 118 to high-voltage bus 110 via first switch BS1 and electrically connects the second battery terminal 119 to negative bus 111 via second switch BS2, battery cell array 300 receives power signal 310 from charging station 104.

[0042] In this example, battery cell B 11 and B 21 The first switch S1 between them is configured to switch the battery cell B in the first column 302 to the battery cell B. 11 and B 21 The battery is electrically connected in series between the first battery terminal 118 and the second battery terminal 119. Similarly, battery cell B... 12 and B 22 The second switch S2 is configured to switch the battery cell B in the second column 304 to the battery cell B. 12 and B 22 The battery is electrically connected in a series connection between the first battery terminal 118 and the second battery terminal 119. Furthermore, battery cell B... 13 and B 23 The third switch S3 is configured to switch the battery cell B in the third column 306. 13 and B 23 The electrical connection is configured to form an electrical series connection between the first battery terminal 118 and the second battery terminal 119.

[0043] The result is that each battery cell in the column is configured to be connected in series between the first battery terminal 118 and the second battery terminal 119. In this example, the charging voltage from the high-voltage bus 110 can be twice that of each individual battery cell B. 11 B 21 B 12 B 22 B 13 and B 23 The rated voltage allows the charging station 104 to charge the battery cell array 300 with a higher voltage charging power signal 310 in a shorter time than conventional charging methods, under the same charging station current limit.

[0044] exist Figure 3C In this embodiment, the battery cell array 300 is configured to be in a second discharge mode according to the present disclosure. As previously described, the second discharge mode is a high-efficiency discharge mode, wherein the battery cell array 300 generates a new output power signal 312, which is again equal to the voltage across the second battery terminal 119 and the first battery terminal 118 multiplied by the current generated by the battery cell array 300, wherein the voltage across the second battery terminal 119 and the first battery terminal 118 is higher than that when the battery cell array 300 has a state of charge level below a predetermined value. Figure 3A The voltage described. When bus switch 116 electrically connects the first battery terminal 118 to the normal voltage bus 106, this new output power signal 312 is transmitted to the normal voltage bus 106. The new output power signal 312 is then transmitted to the load 102.

[0045] In the first discharge mode, for the second discharge mode, bus switch 116 is configured to electrically connect the first battery terminal 118 of the battery cell array 300 to the high-voltage bus 110, wherein the battery cell array 300 is configured to charge at a high voltage value. Again, when bus switch 116 electrically connects the first battery terminal 118 to the normal voltage bus 106 via the first switch BS1 and the second battery terminal 119 to the load bus 108 via the second switch BS2, a new output power signal 312 is transmitted to the normal voltage bus 106.

[0046] Similar to the first charging mode, in this example, battery cell B 11 and B 21 The first switch S1 between them is configured to switch the battery cell B in the first column 302 to the battery cell B. 11 and B 21 The battery is electrically connected in series between the first battery terminal 118 and the second battery terminal 119. Similarly, battery cell B... 12 and B 22 The second switch S2 is configured to switch the battery cell B in the second column 304 to the battery cell B. 12and B 22 The battery is electrically connected in a series connection between the first battery terminal 118 and the second battery terminal 119. Furthermore, battery cell B... 13 and B 23 The third switch S3 is configured to switch the battery cell B in the third column 306. 13 and B 23 The electrical connection is configured to form an electrical series connection between the first battery terminal 118 and the second battery terminal 119.

[0047] Similarly, the result is that each battery cell in the column is configured to be connected in series between the first battery terminal 118 and the second battery terminal 119. In this example, the output voltage from the first battery terminal 118 can be the voltage of each battery cell B. 11 B 21 B 12 B 22 B 13 and B 23 It has more than twice the available voltage, thus allowing the battery cell array 300 to provide a relatively constant new output power signal 312 to the load 102 when the state of charge level of the battery cell array 300 drops below a predetermined value.

[0048] In these examples, the predetermined value of the state of charge level of the battery cell array 300 can be a percentage threshold of the full state of charge of the battery cell array 300. This percentage threshold can be predefined based on the design of the battery cells and / or the battery cell array 300.

[0049] In these configurations, controller 114 is configured to control the switches and bus switches 116 between each pair of adjacent battery cells in each column based on the operation of the battery cell array 300 in a first discharge mode, a second discharge mode, or a charging mode. Controller 114 is also configured to determine the state of charge level within the battery cell array 300 and select either the first discharge mode or the second discharge mode in response to the state of charge level within the battery cell array 300.

[0050] Turn Figure 4The diagram illustrates an example of an implementation of a method 400 for operating a reconfigurable battery system 100 according to the present disclosure. Method 400 begins by electrically connecting a first battery terminal 118 402 to a normal voltage bus 106 when the battery cell arrays 112, 200, or 300 are configured to operate in a first discharge mode, and approximately simultaneously, electrically connecting each battery cell in each row of cells to form an electrically parallel connection between the first battery terminal 118 and the second battery terminal 119, wherein each battery cell in each row of cells is connected in parallel between the first battery terminal 118 and the second battery terminal 119. Method 400 then transmits an output power signal 308 404 to a load 102 and monitors (via decision step 406) the state of charge (SOC) level of the battery cell arrays 112, 200, or 300 to determine if the SOC level is below a predetermined value. If the SOC level is below the predetermined value, a second discharge mode is selected 408. Method 400 then transmits a new output power signal 312 410 to the load 102. Method 400 then determines (via decision step 412) whether battery cell arrays 112, 200, or 300 require charging. If battery cell arrays 112, 200, or 300 require charging, method 400 electrically connects the first battery terminal 414 to the high-voltage bus 110, and substantially simultaneously electrically connects each battery cell in the first column of battery cells to form an electrical series connection between the first battery terminal and the second battery terminal, wherein the electrical series connection includes all battery cells in the first column of battery cells. Those skilled in the art will understand that if the reconfigurable battery system 100 is already in the second discharge mode, only the first battery terminal 118 is connected to the high-voltage bus 110, because the battery cells of battery cell arrays 112, 200, or 300 are configured in series. Method 400 then receives a charging power signal 310 416 from charging station 104 and charges battery cell arrays 112, 200, or 300. Method 400 then returns to step 402 and the method is repeated.

[0051] If battery cell arrays 112, 200, or 300 do not require charging in decision step 412, method 400 returns to step 410 and continues to send a new output power signal 312 to load 102, and method 400 repeats. If, in decision step 406, the state of charge level does not drop below a predetermined value, method 400 returns to step 404 and continues to transmit output power 404 to the electrical load, and the method repeats.

[0052] exist Figure 5The present disclosure illustrates a flowchart of an example embodiment of another operation method 500 of a reconfigurable battery system 100. Method 500 is initiated by loading data 502 into a controller 114. The loaded data includes, for example, a reference voltage (V) for triggering reconfiguration of the reconfigurable battery system 100. ref Battery voltage limit (V) UL ), Battery voltage lower limit (V) LL The controller 114 sets the battery cell arrays 112, 200, or 300 and the operating mode (MODE), where MODE specifies whether the battery cell arrays 112, 200, or 300 are being charged or discharged. The controller 114 then determines (in decision step 504) whether MODE is in discharge mode. If MODE is in discharge mode, the controller 114 sets the reconfigurable battery system 100's battery cell arrays 112, 200, or 300 and bus switch 116 to the previously configured settings 506. Figure 3A The example shown describes the first discharge mode. The controller 114 then receives the battery voltage (V) measured by the battery voltage sensor 508. b The battery voltage sensor may be part of or associated with the reconfigurable battery system 100. The controller 114 then (in decision step 510) sets the V... b With V REF Compare to determine V b Is it less than or equal to V? REF If V b Greater than V REF Then the controller 114 continues to maintain the reconfigurable battery system 100 in the first discharge mode, and the method returns to measuring V again. b Step 508.

[0053] Conversely, if V b Less than or equal to V REF Then the controller 114 will reconfigure the battery cell array 112, 200 or 300 of the reconfigurable battery system 100 and the bus switch 116 512 into a second discharge mode to increase the previously mentioned discharge mode. Figure 3B The example shown describes the discharge voltage. Controller 114 (in decision step 514) then V b With V LL Comparison to determine V b Is it less than or equal to V? LL V LL Let V be the cutoff voltage, and if V b Less than or equal to V LL If the controller 114 stops the discharge of battery cell arrays 112, 200 or 300, the process ends.

[0054] Conversely, if controller 114 determines (in decision step 504) that MODE is not in discharge mode, controller 114 sets the bus switch 116 of battery cell arrays 112, 200, or 300 and the reconfigurable battery system 100 to enter charging mode. Once in charging mode, the controller receives 518V from the battery voltage sensor. b and V b With V UL Compare (in decision step 520). If V b Less than or equal to V UL Then the controller 114 will reconfigure the bus switch 116 of the battery cell array 112, 200 or 300 and the reconfigurable battery system 100 to high-voltage charging, as previously mentioned. Figure 3C The example shown describes the process. The method ends after charging.

[0055] Conversely, if controller 114 determines (in decision step 520) V b Greater than V UL If the controller 114 stops charging the battery cell arrays 112, 200, or 300, the process ends.

[0056] It should be understood that various aspects or details of this disclosure may be changed without departing from the scope of this disclosure. This disclosure is not exhaustive and does not limit the claimed disclosure to the precise form of the disclosure. Furthermore, the foregoing description is for illustrative purposes only and is not intended to be limiting. Modifications and variations are possible based on the foregoing description, or may be obtained by practicing this disclosure. The claims and their equivalents define the scope of this disclosure. Furthermore, although these techniques have been described in language specific to structural features and / or methodological behavior, it should be understood that the appended claims are not necessarily limited to the described features or actions. Rather, these features and actions are described as exemplary embodiments of such techniques.

[0057] With regard to the terms “including,” “comprising,” “having,” “containing,” and variations thereof as used herein, such terms are intended to be inclusive in a manner similar to the term “including” as an open transitional word without excluding any additional or other elements. Furthermore, unless explicitly stated otherwise, conditional language such as “can,” “may,” “possibly,” or “may” is understood in context to indicate that some examples include (while others do not) certain features, elements, and / or steps. Therefore, such conditional language is generally not intended to imply that certain features, elements, and / or steps are necessary in any way for one or more examples, or that one or more examples must include logic for making decisions with or without user input or prompts, regardless of whether certain features, elements, and / or steps are included or will be performed in any particular example. Unless explicitly stated otherwise, conjunctional language such as the phrase “at least one of X, Y, or Z” should be understood to indicate that an item, term, etc., can be X, Y, or Z, or a combination thereof.

Claims

1. A reconfigurable battery system, comprising: A battery cell array configured to operate in a first discharge mode, a second discharge mode, and a charging mode, wherein the battery cell array comprises: Multiple battery cells, arranged in at least a first column between a first battery terminal and a second battery terminal; and A switch, located between each battery cell within the first row of battery cells; Normal voltage bus and load bus, which are configured to be connected to the load in the first discharge mode and the second discharge mode; High-voltage bus and negative bus, which are configured to be connected to the charging station in the charging mode; A bus switch that communicates signalically with the battery cell array at the first battery terminal and the second battery terminal, wherein the bus switch is configured to select between electrically connecting the first battery terminal and the second battery terminal to the normal voltage bus and the load bus in the first discharge mode and the second discharge mode, and electrically connecting to the high voltage bus and the negative bus in the charging mode; and A controller that communicates signals with the switch and the bus switch, wherein the controller is configured to: Set the bus switch to a specific position; The switch is configured to provide the first discharge mode, the second discharge mode, or the charging mode; Determine the state of charge level within the battery cell array during discharge operation; The discharge voltage of the battery cell array is monitored during the discharge operation; and In response to the state of charge level being lower than or equal to a predetermined value, the battery cell array is switched from the first discharge mode to the second discharge mode, wherein: In the first discharge mode, the controller controls the switch between every two adjacent battery cells in the first row of battery cells to electrically connect each battery cell in the first row of battery cells in a parallel configuration between the first battery terminal and the second battery terminal. In the second discharge mode, the controller controls the switch between every two adjacent battery cells in the first row of battery cells to electrically connect each battery cell in the first row of battery cells in a series configuration between the first battery terminal and the second battery terminal, thereby increasing the voltage provided by the reconfigurable battery system; and In the charging mode, the controller controls the switch between every two adjacent battery cells in the first column of battery cells to electrically connect each battery cell in the first column of battery cells into the series configuration, thereby enabling the battery cell array to be charged quickly at a voltage higher than the individual battery cell ratings.

2. The reconfigurable battery system according to claim 1, wherein the bus switch is a single-pole double-throw switch, i.e., an SPDT switch.

3. The reconfigurable battery system according to claim 1, wherein the switch between each battery cell is a double-pole double-throw switch, i.e., a DPDT switch.

4. The reconfigurable battery system of claim 1, further comprising: The controller communicates signals with the switches and bus switches between each battery cell; The controller is configured as follows: The switch and bus switch between each battery cell are controlled based on the operation of the battery cell array in the first discharge mode, the second discharge mode, or the charging mode. Determine the state of charge level within the battery cell array; and The first discharge mode or the second discharge mode is selected in response to the state of charge level within the battery cell array.

5. The reconfigurable battery system of claim 1, wherein the bus switch is configured to electrically connect the battery cell array to the normal voltage bus when the battery cell array is configured in the first discharge mode or the second discharge mode.

6. The reconfigurable battery system according to claim 5, wherein: The battery cell array is configured to be in the first discharge mode; and The switch between each battery cell electrically connects each battery cell in the first row of battery cells to form an electrically parallel connection between the first battery terminal and the second battery terminal.

7. The reconfigurable battery system according to claim 5, wherein: The battery cell array is configured in the second discharge mode; and The switch between each battery cell electrically connects each battery cell in the first row of battery cells to form an electrical series connection between the first battery terminal and the second battery terminal.

8. The reconfigurable battery system of claim 1, wherein the bus switch is configured to electrically connect the battery cell array to the high-voltage bus when the battery cell array is configured to be charged at a high voltage value.

9. The reconfigurable battery system of claim 8, wherein the switch between each battery cell electrically connects each battery cell in the first row of battery cells to form an electrical series connection between the first battery terminal and the second battery terminal.

10. A reconfigurable battery system comprising: A battery cell array configured to operate in a first discharge mode, a second discharge mode, and a charging mode, wherein the battery cell array comprises: Multiple battery cells are arranged in multiple rows between the second battery terminal and the first battery terminal; and A switch, which is located between each battery cell in each column of the multiple rows of battery cells; and Normal voltage bus and load bus, which are configured to be connected to the load in the first discharge mode and the second discharge mode; High-voltage bus and negative bus, which are configured to be connected to the charging station in the charging mode; A bus switch that communicates signaling with the battery cell array at the first battery terminal and the second battery terminal, wherein the bus switch is configured to select between electrically connecting the first battery terminal and the second battery terminal to the normal voltage bus and the load bus in the first discharge mode and the second discharge mode, and electrically connecting to the high voltage bus and the negative bus in the charging mode; and A controller that communicates signals with the switch and the bus switch, wherein the controller is configured to: Set the bus switch to a specific position; The switch is configured to provide the first discharge mode, the second discharge mode, or the charging mode; Determine the state of charge level within the battery cell array during discharge operation; The discharge voltage of the battery cell array is monitored during the discharge operation; and In response to the state of charge level being lower than or equal to a predetermined value, the battery cell array is switched from the first discharge mode to the second discharge mode, wherein: In the first discharge mode, the controller controls the switch between every two adjacent battery cells in the multi-row battery cells to electrically connect each battery cell in the multi-row battery cells in a parallel configuration between the first battery terminal and the second battery terminal. In the second discharge mode, the controller controls the switch between every two adjacent battery cells in the multi-row battery cells to electrically connect each battery cell in the multi-row battery cells in a series configuration between the first battery terminal and the second battery terminal, thereby increasing the voltage provided by the reconfigurable battery system; and In the charging mode, the controller controls the switch between every two adjacent battery cells in the multi-row battery cells to electrically connect each battery cell in the multi-row battery cells into the series configuration, thereby enabling the battery cell array to be charged quickly at a voltage higher than the individual battery cell ratings.

11. The reconfigurable battery system of claim 10, wherein: The battery cell array comprises 2×N×M battery cells; N is the number of battery cells in each column of the multi-column battery cells; and M is the number of columns of battery cells.

12. The reconfigurable battery system of claim 10, further comprising a controller that signals to communicate with the switches and bus switches between each battery cell, wherein the controller is configured to control the switches and bus switches between each battery cell based on the operation of the battery cell array in the first discharge mode, the second discharge mode, or the charging mode.

13. The reconfigurable battery system of claim 10, wherein the bus switch is configured to electrically connect the battery cell array to the normal voltage bus when the battery cell array is configured in the first discharge mode or the second discharge mode.

14. The reconfigurable battery system of claim 13, wherein: The battery cell array is configured in the first discharge mode; and The switch between each battery cell electrically connects each battery cell in each column of the multi-row battery cells to form an electrically parallel connection between the first battery terminal and the second battery terminal.

15. The reconfigurable battery system according to claim 13, wherein: The battery cell array is configured in the second discharge mode; The switch between each battery cell electrically connects each battery cell in each column of the multi-row battery cells to form a configuration that creates multiple electrical series connections between the first battery terminal and the second battery terminal.

16. The reconfigurable battery system of claim 10, wherein the bus switch is configured to electrically connect the battery cell array to the high-voltage bus when the battery cell array is configured to be charged at a high voltage value.

17. The reconfigurable battery system of claim 16, wherein the switch between each battery cell electrically connects each battery cell in each column of the multiple rows of battery cells to form a configuration that creates a plurality of electrical series connections between the first battery terminal and the second battery terminal.

18. A method for charging or discharging a reconfigurable battery system having a battery cell array configured to operate in a first discharge mode, a second discharge mode, or a charging mode, wherein the battery cell array has a plurality of battery cells arranged in at least a first column of battery cells between a first battery terminal and a second battery terminal, the method comprising: The battery cell array is configured to operate in a first discharge mode, a second discharge mode, and a charging mode, wherein the battery cell array includes a plurality of battery cells, and the plurality of battery cells are arranged in one or more rows of battery cells electrically connected to a first battery terminal and a second battery terminal. The first battery terminal is connected to the normal voltage bus via a bus switch, and the second battery terminal is connected to the load bus to supply power to the load; During operation in the first discharge mode, the state of charge level and discharge voltage level of the battery cell array are monitored, wherein in the first discharge mode, each battery cell in the first row of one or more rows of battery cells is connected in parallel between the first battery terminal and the second battery terminal. It has been determined that the charge state level has dropped below a predetermined value; and In response to determining that the charge state level has dropped below the predetermined value: By reconfiguring the battery cells in the first row of battery cells from a parallel configuration to a series configuration between the first battery terminal and the second battery terminal, the battery cell configuration is changed from the first discharge mode to the second discharge mode; and The transition from the first discharge mode to the second discharge mode is increased by the voltage provided by the reconfigurable battery; and The battery cell array is configured in the charging mode by connecting the battery cells in the first column of battery cells in the series configuration, so that the battery cell array can be charged quickly at a voltage higher than the individual battery cell ratings.

19. The method of claim 18, wherein electrically connecting each battery cell in the first row of battery cells to form an electrical series connection between the first battery terminal and the second battery terminal comprises: Determine the state of charge level within the battery cell array; and A second discharge mode is selected in response to the charge state level being lower than or equal to a predetermined value.

20. The method of claim 19, further comprising: Transmit the new output power signal to the load; The configuration of electrically connecting the first battery terminal to the high-voltage bus and electrically connecting each battery cell in the first row of battery cells to form an electrical series connection between the first battery terminal and the second battery terminal includes: Determine whether the battery cell array needs charging; and The charging mode is selected in response to determining that the battery cell array needs to be charged.

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