Buttery cell monitoring system

Abstract

To provide a battery cell monitoring system and a battery cell monitor that enable additional use or recycling recommendations.SOLUTION: In a battery monitor and control system, the battery monitor is typically connected to a battery at one or more terminals of a battery 13, to monitor the condition of the battery. The battery monitor includes one or more sensors 12, each sensing at least one parameter of the battery 13 connected to the monitor. The sensors 12, which serve as inputs to a controller 14, may be any suitable type of sensor, such as a temperature sensor, a voltage sensor, a current sensor, a coulomb sensor, etc., for sensing the battery condition. The controller monitors the sensors and records the data provided by the sensors, and also provides protection to prevent undesirable conditions. A power management device 24 typically provides verified voltage levels for all components of the battery monitor.SELECTED DRAWING: Figure 2

Description

Cross - reference to Related Applications

[0001]

[0001] This application claims priority to U.S. Provisional Patent Application No. 62 / 541,291, filed on August 4, 2017, entitled BATTERY MONITOR & SYSTEM FOR ENHANCED USE, which is incorporated herein by reference. Background of the Invention

[0002]

[0002] Some embodiments of the present invention relate to battery monitoring, and some aspects relate to battery recycling. Today, with the increasing expectations and use of battery systems, additional life cycle and event information is being required. The applicants recognize that the increase in explosion or energy release events is a major concern, but the products using these batteries are seeing an ever - increasing demand. With the addition of electric vehicles, thousands of cells per automotive battery are used to generate the power required for the entire system.

[0003]

[0003] Some of these systems are already being monitored, but the information is lost after the initial application. Batteries are manufactured as cells and then configured into modules, packs, and systems.

[0004]

[0004] In past generations of battery manufacturing, monitoring was a single task of voltage and current, but now the chemistry is more decisive and the limits are more important. The production materials are more flexible and tolerate manufacturing variations.

[0005]

[0005] Also, some embodiments of the present invention also relate to a method of identifying and ranking the life cycle and types of events that a battery has undergone. This method may enable recommendations for additional use or recycling.

[0006]

[0006] Some of the known problems with current systems include the limitations of the pack for single cell monitoring. Large scale battery systems are interconnected using series and parallel packs. Some of these systems have 7,700 individual battery cells that form one large scale battery pack. When a battery problem occurs, it affects the entire system and the system does not self - recover. All that current monitoring tracks is the performance of the battery while it is in the system.

[0007]

[0007] Another problem with current monitoring is that cell level problems and changes are not tracked. An example is the monitoring of parallel cells for performance where individual differences are observed as a whole. By tracking these types of changes, more information about usage and performance can be tracked over the life of the battery, from manufacturing to initial use, reuse or repair adjustment, diversion for recycling. This information can be used to improve the overall design and design requirements. Overview

[0008]

[0008] The first aspect of the present invention of this system utilizes secure NFC - type communication that does not require drawing current from the battery to inspect information regarding the battery. Both NFC and Laser P - Chip solutions have a memory that is dual - ported and includes control registers of the memory that enable the execution of multiple tasks by a second active monitor and can configure the second active monitor to execute multiple tasks. The first aspect of the present invention can monitor a battery that reaches a threshold or is triggered by an event. In embodiments where both NFC and high - frequency RFID are utilized, dual - ported memory is also used to prevent contention and data collision. The battery monitor reads Coulomb, current, voltage, temperature, charge rate, discharge rate, and self - resistance over time and stores it in an accumulator matrix. Also, the system can be programmed to read from NFC or P - Chip registers at regular time intervals and accumulate that data over time. According to these systems, self - power supply can be achieved using ambient power generation using P - chip that uses laser power and NFC that uses RF power.

[0009]

[0009] Another aspect of the present invention generates means for detecting and observing changes in battery parameters over the life and use of the battery. By accumulating data over time and observing the accumulator, the history of the usage case for that particular battery can be understood.

[0010]

[0010] Another aspect of the present invention generates a system for facilitating recycling. This system generates an easy - to - read and classify method for recycling. For the battery, it is possible to assign the end of life by closing the self - discharge resistance that consumes energy prior to the battery being cut, thereby preparing the battery for recycling. The secure NFC system can be read to determine the battery type, chemical properties, requirements, recycling method, and time limit until zero energy.

[0011]

[0011] Another aspect of the present invention facilitates the attachment of the present invention to a conventional battery cap. The chip fits easily between the current battery cap and the new cap. The switch can turn off the battery by interrupting the current flow, and the NFC coil can be easily incorporated from the top to read the battery. High-frequency data can be read from a certain distance for manufacturing and technical troubleshooting.

[0012]

[0012] Another aspect of the present invention is a means of ranking battery usage and life by tracking the distribution across types, manufacturing, and battery history. Some batteries will be better processed and will have additional life.

[0013]

[0013] Another aspect of the present invention includes a custom IC that includes all the circuitry necessary to enable a monitor and battery recycling system. Each can be easily used for newer battery systems, but the data can be retained within the battery to facilitate recycling.

[0014]

[0014] Another aspect of the present invention is a secure network for reading, reprogramming, and writing to these battery monitors. Updated patterns and triggers can be pushed for additional sensitivity either to accumulate data or to enable events.

[0015]

[0015] Another aspect of the present invention is the use of a self-healing switch. When batteries are configured in parallel, the battery can open to prevent the discharge of its paralleled batteries. Similarly, in a series configuration, if a battery is in a dangerous state or depleted, the battery can open internally but short-circuit to prevent damage to the circuit and allow the remaining batteries to continue operating.

[0016] Another aspect of the present invention includes workflow integration for a broader view and knowledge base of the battery cell life cycle.

[0017]

[0017] Another aspect of the present invention is that the cryptographic security lock can be turned off. Examples used by the present applicants are TSA and security profiles, which will also operate in other applications that save manufacturing and battery life and enable additional information. FIG. 1 shows an embodiment of the prior art in which the system monitors individual cells of a battery one by one and is an addressable part by linear technology. In the prior art, the present applicants are looking at either a single cell system that is externally powered and externally monitored or a part that enables monitoring by the system. In either case, these types of systems are limited in terms of the data they monitor and the way they are controlled.

Brief Description of the Drawings

[0018]

Figure 1

[0018] FIG. 1 is a diagram showing a prior art embodiment of a battery monitor from linear technology that monitors individual cell voltages as prior art for system level design.

[0019]

Figure 2

[0019] FIG. 2 is a diagram showing an embodiment of a battery monitor and control system including a plurality of sensors and a plurality of switches for enhanced operation.

[0020]

Figure 3

[0020] FIG. 3 is a diagram showing an embodiment of secure NFC and cryptographic enabled communication, reprogramming, and data writing.

[0021]

Figure 4

[0021] Figures 4a and 4b are diagrams showing an embodiment of the mechanical connection means of the monitoring and control system to an existing battery assembly having an NFC coil on the top or side.

[0022]

Figure 5

[0022] Figure 5 is a diagram showing an embodiment of a secure network with just-in-time registration and cryptographic security for a battery monitoring system.

[0023]

Figure 6

[0023] Figure 6 is a diagram showing a cryptographic chip used to deliver a key to be compared with a pre-programmed and arranged embedded key within the chip.

[0024]

Figure 7

[0024] Figure 7 is a diagram showing an example of a system that searches for patterns and matches the patterns with events to track problems and analyze actions.

[0025]

Figure 8

[0025] Figure 8 is a diagram showing a combination of data from multiple workflows to obtain a better view of usage and changes over the lifespan.

[0026]

Figure 9

[0026] Figure 9 is a diagram showing an accumulator matrix, and this data storage method is designed to record data over time and accumulate the data in accumulator bins. This is a 3D perspective representation of the lifespan and history of the battery.

[0027]

Figure 10

[0027] Figure 10 is a diagram showing a parallel battery network that would have had difficulty reading out each individual battery in a conventional system.

[0028]

Figure 11

[0028] FIG. 11 is a diagram showing a battery scoring and ranking system that tracks various parameters, events, and usage history distributions to track the tip and tail of the overall distribution percentile.

[0029]

Figure 12

[0029] FIG. 12 is a diagram showing an example of an ID and protocol shared from a battery when requested.

[0030]

Figure 13

[0030] FIG. 13 is a diagram showing an embodiment of a battery care monitoring and tracking system. A battery manufacturer may wish to track individual interactions and events, score these events, and track them.

[0031]

Figure 14

[0031] FIG. 14 is a diagram showing an ASIC chip design having a dual-port memory for reading and configuring a second system for monitoring data and a first system that enables secure data communication and a zero-power interface.

[0032]

Figure 15

[0032] FIG. 15 is a diagram showing a chip layout for a photovoltaic power supply identification chip. This chip uses a modulated Laser LED for power and can also communicate with IR or RF.

[0033]

Figure 16

[0033] FIG. 16 is a diagram showing an embodiment of a communication format and modulation for the NFC and P-Chip protocols.

[0034]

Figure 17

[0034] FIG. 17 is a diagram showing a battery classification system that enables bin classification by enabling the pushing of batteries from a conveyor into bins by a plunger after reading NFC battery data.

[0035]

Figure 18

[0035] Figure 18 is a diagram showing an embodiment of a secure area that can read battery effectiveness and turn these batteries on and off as needed.

[0036]

Figure 19

[0036] Figure 19 is a diagram showing a P-Chip used as an IR transmitter and an RF transmitter.

[0037]

Figure 20

[0037] Figure 20 is a diagram showing battery commands and control structures that enable various programmable modes.

[0038]

Figure 21

[0038] Figures 21 to 23 are various diagrams of a controller chip for a battery monitor manufactured during the packaging of a lithium-ion battery.

Figure 22

[0038] Figures 21 to 23 are various diagrams of a controller chip for a battery monitor manufactured during the packaging of a lithium-ion battery.

Figure 23

[0038] Figures 21 to 23 are various diagrams of a controller chip for a battery monitor manufactured during the packaging of a lithium-ion battery.

[0039]

Figure 24

[0039] Figures 24 and 25 are diagrams showing the packaging for a lithium-ion battery including a port heating seal area.

Figure 25

[0039] Figures 24 and 25 are diagrams showing the packaging for a lithium-ion battery including a port heating seal area.

[0040]

Figure 26

[0040] Figure 26 is a diagram showing a sealed battery monitor inside a lead-acid battery.

[0041]

Figure 27

[0041] FIG. 27 is a diagram showing a dual - frequency tag configuration having different accesses to information that individual tags can be used as determined by arbitration logic. Detailed Description

[0042]

[0042] Next, refer in detail to the exemplary embodiments of the present invention, examples of which are shown in the accompanying drawings. It should be understood that other embodiments can be utilized and that structural and functional changes can be made without departing from the scope of each of the present invention. Further, the features of various embodiments can be combined or modified without departing from the scope of the present invention. Accordingly, the following description is presented by way of illustration only and is not intended to limit in any way the various alternatives and modifications that can still be made within the spirit and scope of the present invention as illustrated and which can be added to the illustrated embodiments.

[0043]

[0043] FIG. 2 shows a system diagram for the battery monitor 10. The system can include many of the components described below, which can be included on the monitor or within the chipset. The monitor 10 can typically be connected to the battery at one or more terminals of the battery, etc., to monitor the state of the battery and, in some cases, to provide protection against undesirable states.

[0044]

[0044] The battery monitor 10 can include one or more sensors 12. These sensors 12 can be configured to respectively detect at least one parameter of the battery 13 connected to the monitor 10. The sensor 12 can be any suitable type of sensor such as a temperature sensor, a voltage sensor, a current sensor, a Coulomb sensor, etc., for detecting the state of the battery.

[0045]

[0045] The sensor 12 can function as an input to the controller 14. The controller 14 may be any suitable microcontroller further described below. The controller 14 can be configured to monitor the sensor, record the data provided by the sensor, and in some situations, provide protection to prevent an undesirable state. The controller 14 can be configured using one or more communication interfaces facilitated by one or more transceivers 16 and one or more antennas 18. The transceiver 16 can include BTLE and Zigbee (registered trademark) Mesh transceivers for special operations and network functions. The antenna 18 can include a mesh antenna, a BLE antenna, and / or any other suitable antenna. The communication interface can be provided on the substrate of the controller chip 14 or on an individual chip 16. For example, the controller 14 can include a wireless communication interface that can be further configured to supply independent power to the controller. The wireless communication interface can be a type of radio frequency identification (RFID) communication interface such as a near-field communication (NFC) interface. The NFC interface can include an NFC coil 20 for receiving RF signals and can be configured to supply independent power to the controller when the RF signal is received by the coil 20. The controller 14 can further include a wired connection 22 such as a single-wire communication connection.

[0046]

[0046] In an embodiment, the monitor includes a temperature sensor 12 that enables reading the temperature of the battery while the battery is discharging and while the battery is charging. The controller 14 can be enabled by a first level of security that monitors the temperature to determine a potentially unsafe or undesirable state such as the temperature reaching a predetermined threshold. The controller 14 can then act to prevent an undesirable state by activating the outputs described below.

[0047]

[0047] Sensor 12 can include a circuit mechanism for collecting highly accurate voltage measurement values. This sensor circuit mechanism enables calibration and reference-based measurement at battery terminals and the like by utilizing built-in voltage references for low and high voltages. The readings can be statistically averaged by controller 14, and the offset from the measured reference can also be referenced. A highly accurate A / D register can be used by a cascaded multiple 12-bit A / D converter. These converters are used together with a voltage reference to further increase accuracy by allowing for slight variations due to temperature and voltage to be compensated. The resistance is calculated using a high-resolution A / D converter, and the current flowing through a switch acting as a shunt is measured. Using the exact voltage between both ends of the shunt, the Coulomb is calculated over time. The current over time represents the Coulomb for both charging and discharging. 1 Coulomb / second is 1 Amp, and also represents 1 C of charge or discharge. By counting the Coulomb, microcontroller 14 can predict the state of charge of the battery. Battery life is provided as a first application for this technology, but this same technology can be used for supercapacitors. By observing the Coulomb over time, an image of the battery capacity is constructed. By observing this image over time, changes can be observed and usage thresholds for recycling can be set.

[0048]

[0048] The battery monitor 10 can include power management 24. The power management 24 can typically provide a verified voltage level for all components of the battery monitor. The power management 24 can enable a buck-boost converter for ambient power generation that can lower the operation of one cell down to 2 VDC. In an embodiment, the optional battery cell 32 can be dedicated to powering a monitor for a dedicated battery. The cell 32 can supply dedicated power to the monitor 10 not only when an NFC field is present, but also to always guarantee power. This can be for monitoring the cell for engineering purposes and data collection purposes. The controller 14 is enabled along with the FLASH, and thus the controller 14 can be securely reprogrammed. The NFC protocol and tokens enable security and can also present other data, such as a serial number, to a second RFID high-frequency protocol for reading at a greater distance. Given the security of NFC communication compared to high-frequency communication, NFC may be the only communication enabled for writing to the controller 14.

[0049]

[0049] In an embodiment, the monitor 10 can be configured to function and still be controlled even when disconnected from a power source, and the figure shows a switch to power management where the power supply is cut off when requested. This monitor is designed to communicate comprehensively and to be updated as the applicants further learn and various users further learn by analyzing the data.

[0050] Monitor 10 can include one or more outputs configured to be controlled by controller 14. The controller 14 can control a self-discharge resistance switch 26 that can open and close across the terminals of the battery or cell to selectively drain the battery or cell when an undesirable condition is detected. Monitor 10 can include a bypass switch 28 that bypasses the battery or cell to avoid complete loss of power when an undesirable condition, such as a series connection of a series of batteries or cells, is detected. The monitor can include a power management switch 30 for selectively controlling the power input from power management 24. Each of these switches can be controlled by the controller and can be programmed to activate or deactivate based on various detected conditions, as further described below.

[0051]

[0051] In an embodiment, components of the controller 14 and / or the monitor 10 can be powered by an NFC communication field. When an NFC field is present, the NFC coil can receive power and program the controller to perform certain functions, such as writing to an NFC memory. When a high-frequency chip is read, the high-frequency chip accesses the same memory using a determined and pre-programmed specific access. This can be simply the SKU or the serial number data for that cell. This memory can be dual-ported to enable the controller 14 to observe these changes and also to enable reconfiguration of its operation or programming. An example of this would be writing to NFC during production to monitor self-discharge. The monitor 10 then consumes and records data over time until the power is depleted. The same type of NFC write can enable the self-discharge resistor 26 for recycling and shredding. The self-discharge resistor 26 is first activated to discharge the battery, and then, after the battery has discharged and its voltage naturally rises and potentially becomes a potential energy hazard, the voltage is read using NFC prior to shredding to prevent ignition. Another command from the microcontroller 14 can close the bypass switch 28 to short-circuit the battery externally and also open the battery internally. It should be noted that in these test states, the data can be programmed to be presented to a high-frequency tag to read the test results at a certain distance, such as when walking to an inventory warehouse. As used herein, the term tag can mean both an antenna or coil and a chip or semiconductor connected to the coil. As shown in FIG. 27, the monitor 10 can include both a high-frequency tag 38 and an NFC coil 20 to enable both NFC communication and high-frequency communication. FIG. 27 shows two tag antennas 20, 38 connected to one chip 42. The chip 42 is actually two combined chips, both of which can be used as tags.The memory arbitration controller enables each communication means to communicate as necessary at any step of the use case, namely during production, manufacturing, reuse, recycling, testing, and troubleshooting. Access via high-frequency communication that is permitted by the monitor may sometimes be restricted. For example, high-frequency communication may restrict access to the controller 14 such that the programming of the monitor is not an option from high-frequency communication. In another example, high-frequency communication may be limited to access to data that has already been collected. This allows for fast data collection via high-frequency communication, while NFC communication cannot tolerate the parasitic power drawn from the battery 13. The tag reader is connected to the cloud and presents the real-time test data to the cloud database.

[0052]

[0052] The controller 14 has a single-wire addressable network interface 22. The single-wire addressable network interface 22 may be an I2C interface, and the command set can report the address and then report the data related to each individual battery. In an embodiment, the sensor 12 includes an accelerometer for monitoring impact events and motion events.

[0053]

[0053] The NFC coil 20 can be attached to the cap or side of the battery using a small amount of ferrite or isolated pressurized iron below the NFC coil 20 to enable good NFC reading and writing (as shown in FIGS. 4a and 4b). The ferrite or isolated pressurized iron operates for low-frequency tags and high-frequency tags for attachment to metal. This is achieved by isolating the coil 20 from the battery or terminal metal.

[0054]

[0054] Figure 3 shows a process of securely reading and verifying monitor 10 using the NFC protocol to open channels for specific data and data segments. For example, mobile device 36 may have NFC capabilities, and communication to battery monitor 10 can be enabled. Designated or limited access to monitor 10 and its functions can be given to different parties. For example, the manufacturer can have specific access, the OEM can have specific access, the recycler can have specific access, and a second user can have specific access. For each read, the manufacturer can update the firmware in battery 13 using new firmware and thresholds of learned understanding from the field since this data is collected in the same way. The cryptographic code and authentication application in monitor 10 enable a secure handshake when the recorded data is read. The application can send the recorded data to the applicant's database using this channel, enabling statistics and learning for individual users over time or usage throughout its life. As shown in Figure 3, the verification process can start when the NFC field is powered up by mobile device 36. The NFC transceiver 16 of monitor 10 can respond to the field with an ID and cryptographic code. The software of mobile device 36, such as a mobile application, can then send the ID to a designated address on the Internet where verification occurs. The application can then receive the ID and cryptographic code, and the application sends it back to the NFC transceiver 16 to code monitor 10.

[0055]

[0055] Figure 4a shows the use of a monitor connected to the battery cap 40. The controller 14 is powered from across the battery 13 when enabled, or powered by the NFC field when read. Figure 4b shows a side-mounted version where the controller 14 remains disposed on the cap 40 but the coil 20 is placed on the side of the cell. These coils 20 can be isolated from metal using either space or ferrite or pressurized isolation iron to ensure communication. A simple plastic cap provides sufficient space in the cap for good NFC reading. This image only shows low-frequency tags, but both low-frequency and high-frequency tags can be used to add flexibility. This is referred to in Figure 27.

[0056]

[0056] Figure 5 shows a method of using AWS (“Amazon Web Services”) and Just In Time Registration with the monitor 10. This method helps manage software by connecting devices, applications, and help, and maintaining mobile images and shadow devices for verification and secure firmware update control. This system is scalable and, once the serverless framework is set up, can be easily and simply developed comprehensively. The Atmel Crypto chip can be used for additional cryptographic security to update the IOT firmware shown in Figure 6. As shown, when the target key is presented, the key is passed. If they match, a secure pipeline is generated. This enables a secure network that can be used to monitor the battery in real time when read, reused, or retasked.

[0057]

[0057] FIG. 7 shows a method of pattern matching and anomaly tracking that can be used to surface problems and enable potential solutions to the problems. By finding patterns, activities, social groups, defect states, impacts, and side effects in the data, the identification of levels of importance in the data set is facilitated. The data collected by the controller 14 can be monitored to recognize patterns and states. Under various conditions, messages sent via communication to the network can be notified to the identified parties or can be pre-programmed. A series of patterns are pre-loaded and triggers are set to enable the communication and recording of data received by the controller 14. Monitor 10 has several programmable power modes for storing all off when read by NFC for writing at update or event, and for recording important data from always all on monitoring. Triggers and actions are programmed with specific effects and monitoring conditions are set.

[0058]

[0058] Figure 8 shows an example of how the workflow is tracked across various use cases and users. Typically, the battery is tracked separately from the original manufacturer, the battery is packaged and tested again, then tested again by the OEM at the time of implementation, and further tested again during retasking and recycling. In an embodiment, a method is provided for storing and sharing this information over the life of the cell. The data can be collected for analysis and machine business learning by the controller and associated memory, and can also be used to improve specifications and usage. Also, this data can be used to demonstrate the best working chemical properties and the manufacturing method that proves to be the most reliable. This method can work down to the best manufacturer and battery for each specific function. This integrated view will provide the learning for all to be applied. The first secure and local communication (such as NFC) enables a second less secure RFID access to the presented data in a different and different programmable state.

[0059]

[0059] An accumulator matrix is shown in Figure 9. The accumulator matrix represents bins of information that enable ranking and scoring the intensity of use for this battery. This matrix is designed to accumulate life critical situations over the life of the battery and life specific events such as individual workflow transitions. The matrix is temperature and charge by the bins recorded as events. The distribution of this data represents the signature of the life and processing of that battery within the environment and application. The applicants require this data across one workflow to determine the best applications and thresholds for reuse and recycling.

[0060]

[0060] Figure 10 shows a parallel battery pack that can monitor individual cells and can also be tracked within a parallel configuration. A plurality of monitors 10 tied to individual batteries or cells can then be connected via a communication network 50. The network may be a single-wire network, NFC, or DC backscatter via a DC bus. It should be noted that this may be a single RFID technology or multiple low and high frequency access.

[0061]

[0061] Figure 11 shows a soundness scoring formula to enable battery life, usage harshness, and experience ranking. Distributions are evaluated and these show the mean using the tips and tails of the distribution curve. This represents the signature of the battery life and also shows the factors affecting the life of individual types of batteries. In an embodiment, the system can include or utilize a database of millions of batteries and types to enable a better understanding of the limits for making better batteries and the design methods. In an alternative embodiment, the data can be used to define thresholds for fitness for recycling and reuse. The algorithm accesses and uses an accumulator matrix with internal resistance, temperature, charge-discharge rate, aging, and activity acceleration to determine and rank the soundness score. This also serves as a means to define who manufactures the best batteries and the chemical properties and manufacturing methods that are best over time. This information will be used to improve these processes and methods.

[0062]

[0062] Figure 12 shows the representation of battery health and care scoring. This score determines how the battery has been maintained, which monitors events and service interactions within the workflow to indicate its purpose, as the person in contact with the battery, as well as the battery life, can also be affected. Batteries with poor maintenance can be re-rated, while well-maintained batteries can have an extended life. Figure 13 shows the byte count and protocol for the register. Figure 13 shows the primary and secondary registers to enable a transfer methodology for secure data transfer over the life of the battery monitor. This method maintains the secondary register in a complete state until the primary register is updated and verified by a checksum. When verified, the secondary register is also updated. This process maintains data integrity during power failures, read or write errors, minor power failures or accident events.

[0063]

[0063] Figure 14 shows the ASIC layout for a single-chip design for the controller 14. The single-chip design includes, on a single chip, the multiple features shown in and described with reference to FIG. 2. The NFC controller is included on the substrate of the single chip and is fundamental to the design along with the controller 14. NFC can utilize dual-ported memory for NFC that enables control and typical NFC read and write. This chip incorporates all of the sensors and registers referred to in this document and tracks workflow and lifetime data over their use. The arbitration interrupt logic permits memory access to multiple systems. This arbitration logic can be programmed either by direct I2C programming or by NFC local communication. By programming, the system can determine, for example, what can be utilized for different ports if the applicants add access to another tag technology for longer ranges. High-frequency tags would be a good example of adding another access. To add flexibility, two I / O controls can be added by an additional I / O controller. FIG. 15 shows a communication protocol for backscatter communication in addition to a typical NFC protocol.

[0064]

[0064] FIG. 17 shows a system 60 and method for classifying and reading batteries during production. This system 60 uses a larger antenna 62 for NFC reading of individual batteries being conveyed on a long conveyor 64. The antenna reads the type, life, and charge state of individual batteries and collects all data prior to reuse or recycling when classifying the batteries into a charging bin 66 or a waste bin 68, etc. In the event that a battery is scheduled for recycling, the sorter opens the output and selects an internal discharge process to remove energy prior to shredding. The batteries can be discharged, but since they generate voltage over time even after that process, this process can usually be a cause of problems. The internal discharge circuit enables a simple recycling process. The type classification by battery chemistry, size, manufacturer, or other criteria becomes extremely simple. FIGS. 18a and 18b show methods for inspecting batteries for security purposes and further to test these batteries to verify that they are manufactured as intended. FIG. 18a shows a security monitor 70 that can provide the state of the battery by reading the state through an NFC antenna disposed within a screen zone. FIG. 18b shows a conveyor having an NFC antenna disposed in a screen zone 72 that can perform both reading of the battery state and transmission of commands to the battery, such as turning off the battery. These batteries can be disabled by enabling an internal switch using an encryption password as described above if transportation is not intended. These batteries can be enabled again after transfer or a security process through tamper monitoring and verification.

[0065]

[0065] Figures 21 to 25 collectively show the battery monitor 10 manufactured inside the casing of a lithium-ion battery. Figures 21 and 22 show the conductive tab 80 surrounded by thermoplastic layers 82 on both sides. This thermoplastic layer 82 is sealed to prevent the battery electrolyte from passing along the metal tab. The thermoplastic seal is designed to be sealed again once the pattern is sealed to hold the electrolyte. To seal the chip 84 inside the battery, the applicants have to connect it to these tabs. The tab design and stamping are designed to be able to couple the chip 84 to the tab 80. The method of constructing the tab 80 so that the chip can be assembled is to first bond a thermoplastic layer that holds the tab 80 in place to the tab 80. The tab 80 can be mechanically coupled to the circuit board as needed. The thermoplastic 82 can act as a circuit board for a simple design.

[0066]

[0066] Also, the tab 80 is also designed to allow welding interconnects or snap-like details for interconnecting these circuits from individual electrode tabs. This allows the sealing of the FET switch 86 in the same way and allows the addition of sensors or other devices for sensing the battery state. The smaller additional tabs drawn from the battery are for antenna and coil connections. The figure shows two connections, but it is also possible to use four or more connections for multiple inputs.

[0067]

[0067] The figure shows direct stamping onto the thermoplastic, but it is also possible to use a thin PCBA-like Kapton as an alternative.

[0068]

[0068] When two or three tabs are used, the system can use a thermoplastic top layer and bond to hold two tables together, seal the entire circuit from the electrolyte, and apply pressure to utilize an overlapping connector system to enable the interconnections shown as snap interconnections.

[0069]

[0069] The 12VDC battery diagram in FIG. 26 shows the enclosed RFID sensors / monitors 90 placed in individual cells. The plastic enclosure protects the electronics and ambient power generation circuits while the electrodes are connected to the individual cells. According to this design, the sensors and RFID can be placed within the electrolyte, and the interconnections to the cells enable monitoring while being of the same materials used within the battery. The battery can be a 12, 24, 48 or larger battery. The number of cells is not critical, but the interconnections for monitoring are important.

[0070]

[0070] In one aspect of the systems and methods described herein, the battery monitor and related methods can be used for battery recycling purposes. The disclosed monitor and methods enable classification capabilities, making recycling easier. The sorter (FIG. 17) shows an economical and rapid way to determine cell chemistry and cell state.

[0071]

[0071] In another aspect of the present disclosure, the monitor 10 and methods described herein can be used for a second life application. A classification process similar to the classification process mentioned above can provide classification by chemical properties, and there may be additional cell grading. Classification of the batteries by key characteristics that ensure the batteries behave in a complementary manner for remanufacturing and diversion becomes easier (e.g., the batteries will have similar capacity and expected life characteristics).

[0072]

[0072] In another aspect of the present disclosure, the monitor 10 can be installed in the battery during the initial production of the battery by the manufacturer. This is important because the present invention must be applied to the battery during initial manufacturing in order to be available for remanufacture, diversion and recycling, and any other future applications. An advantage for the new battery industry is that once the cell is constructed, it is immediately charged and discharged to determine the appropriate capacity. According to the present invention, efficiency can be improved by monitoring overvoltage, direct current resistance (DCR), and heat / thermal. An important advantage of the present invention is revealed when the cell is stored for three weeks to inspect for HSD (high self-discharge) after production. Today, manufacturers use robotic devices to periodically inspect the battery voltage during this three-week period to ensure that no HSD occurrence exists. By using this monitor, the entire process can be modified. All cells can be monitored at a much faster rate and with much higher efficiency, at a cost of just a few pennies, without the need for expensive robotic devices and labor costs. The applicants can provide the ability to display "all" cells under test at once and / or the ability to display only cells outside of set programmable parameters. Even just the cost savings in this step can easily justify the additional cost of integrating the applicants' technology into those cells. Grading / ranking and life determination over the distribution, such as of batteries, over use will be of extremely valuable.

[0073]

[0073] In another aspect of the present disclosure, the monitor 10 and method described herein can be used for high-reliability requirement applications and tracking. This example can be seen in military applications such as when a soldier on the battlefield selects a pack for use in an exercise. The present invention provides a monitoring system that will indicate whether a battery pack is fully charged even if the capacity at a particular ampere draw as required is several hours (in practice, a determination of how much longer the battery can be used under pre-set conditions). They can see the life experience of the battery and its level of deterioration. Life ranking information for these batteries is available and will simply manage the inventory. The data can be utilized to determine whether the pack can be used as is (whether all cells are operating according to specifications), whether the pack should be repaired (whether some cells may need to be replaced to meet the specifications), or whether the pack should be discarded (if the pack does not meet the specifications and cannot be brought into an appropriate operating state).

[0074]

[0074] In another aspect of the present disclosure, the monitor 10 can be powered via near-field communication (NFC) by configuring registers that implement a monitoring function. The monitor 10 can be powered by a battery or by NFC. This system has dual-ported memory and thus both functions are fully possible and can operate independently.

[0075]

[0075] In another aspect of the present disclosure, an application - specific integrated circuit (ASIC) chip is used that enables a low - cost battery monitor for reading out many characteristics and situations of battery life. This chip can be utilized in any battery for warranty determination, life, installation data, manufacturing, place of purchase, record - keeping, quick voltage checks, and other aspects. This chip can be used in rechargeable chemistries, lead - acid batteries (with watering and care), and alkaline and / or primary batteries. Using this information along with a safety mechanism, cells in a series configuration can be short - circuited, or cells in a parallel configuration can be opened. Thereby, the battery or module can disable all cells that may exist outside of defined parameters while continuing to function. In a single battery cell, this information can be used to disable the cell to protect the product that is powered by it.

[0076]

[0076] In another aspect of the present disclosure, a communication method is provided that enables a test process that can be turned on and off at different points in the workflow and the life of the battery. This communication method allows for cell - by - cell data collection through the recycling process and permits R&D feedback opportunities that do not yet exist.

[0077]

[0077] In another aspect of the present disclosure, the monitor 10 and method described herein are applied to existing products in the market. This can be applied to individual cells if they are accessible, or to groups / modules / packs of cells if individual cell access is not achievable.

[0078]

[0078] In another aspect of the present disclosure, an application of the present invention to various electronic devices and / or components is provided. Using this application, the amount of current draw and the voltage applied to various electronic components within the device can be measured. The data can be used to determine root - cause analysis failures within the device.

[0079]

[0079] In another aspect, by using the monitor 10 and the setpoint capability together with a discharge resistor that acts as a balance bleed resistor, the ICC can be used as a balancer for the battery system, and this unit acts as a wireless balancing network. By enabling battery safety, even if one of the balancers fails, the Applicants can use the monitor's software to calculate the differential voltage of the known reporting balancers in the group for the unit that no longer reports, so as to know whether the Applicants are still operating at a safety level that guarantees the best resistance, and further calculate the known total voltage sum and the lost difference to switch that resistance over time.

[0080]

[0080] In another aspect of the present disclosure, the monitor 10 and related methods disclosed herein can be applied to battery shipping and transport safety. During transport, by monitoring the cells, information can be sent to a central battery management system (BMS) and provided to the driver, checkpoint / scale operator, TSA agent, Public Service Commission Officers or any other responsible party. This can report possible dangerous conditions and / or whether the battery is within safe shipping parameters. The cell battery management system CBMS, together with the BCM, will improve the performance and the quality of the information provided.

[0081]

[0081] Another aspect has a plurality of interfaces representing various capabilities for forming a greater capability. Low-frequency communication is inexpensive and can be implemented in a system for direct monitoring. High-frequency tags are not so expensive, but the transmitters are more expensive and are more suitable for production and manufacturing solutions. The combination of these systems, together with a dual-ported programmable memory, provides a solution suitable for engineers in circuit monitoring, production testing, recycling classification and general flexibility.

[0082] Terms indicating directions such as "vertical direction", "horizontal direction", "top", "bottom", "upper part", "lower part", "inside", "towards the inside", "outside", and "towards the outside" are used to assist in the description of the present invention based on the orientation of the embodiments shown in the figures. The use of terms indicating directions should not be construed as limiting the present invention to any particular orientation(s).

[0083]

[0083] The above description is of the current embodiments of the present invention. Various modifications and changes can be made without departing from the spirit and broader aspects of the present invention as defined in the appended claims, which are to be construed in accordance with the laws of patent law, including the doctrine of equivalents. The present disclosure is provided for illustrative purposes and should not be construed as an exhaustive description of all embodiments of the present invention, or as limiting the scope of the claims to the specific elements shown in the figures or described in connection with these embodiments. For example, without limitation, any individual element(s) of the invention described can be replaced with alternative elements that provide substantially the same functionality or otherwise appropriate operation. This includes currently known alternative elements such as those that would be considered known to those skilled in the art, and also potentially developed alternative elements such as those that would be recognized as alternatives by those skilled in the art when developed. Further, the disclosed embodiments include multiple features that are described in concert and that are thought to provide a set of advantages in concert. The present invention is not limited to only those embodiments that include all of these features or that provide all of the advantages recited, except as clearly shown in the scope of the issued patent. For example, all references to singular claim elements using "one", "the", or "said" should not be construed as limiting that element to the singular. [Items of the Invention] [Item 1] A battery monitoring device, a controller, One or more sensors connected to the controller, each configured to detect at least one parameter of the battery, A memory configured to receive and store data based on the detected parameter, A first communication interface configured to transmit and receive data via a wireless network, the wireless network comprising a radio frequency field configured to supply power to the battery monitor and components of the battery monitor, A battery monitoring device comprising the same. [Item 2] The battery monitor according to item 1, further comprising a second communication interface, the second communication interface being a wired interface. [Item 3] The battery monitor according to item 1, further comprising a second communication interface, the second communication interface being a high-frequency tag. [Item 4] The battery monitor according to item 1, further comprising one or more output switches controlled by the controller. [Item 5] The battery monitor according to item 4, wherein the one or more output switches include a self-discharge switch configured to apply a resistance across both ends of the terminals of the battery and activate a circuit for drawing power from the battery. [Item 6] The battery monitor according to item 5, wherein the controller is programmed to activate the self-discharge switch in response to an undesirable state. [Item 7] The battery monitor according to item 4, wherein the one or more output switches include a bypass switch configured to activate a circuit for bypassing the battery in contact with the battery monitor. [Item 8] The battery monitor according to item 7, wherein the controller is programmed to activate the bypass switch in response to an undesirable state. [Item 9] The battery monitor according to item 1, further comprising a dedicated power source configured to supply power to the controller. [Item 10] The battery monitor according to item 9, wherein the dedicated power source comprises a single battery cell placed in a battery monitored by the battery monitor. [Item 11] The battery monitor according to item 1, wherein the wireless communication interface comprises a near-field communication interface. [Item 12] The battery monitor according to item 11, wherein the near-field communication interface is placed on the same microchip as the controller. [Item 13] The battery monitor according to item 11, wherein the controller is configured to be powered on in response to the presence of a near-field communication field. [Item 14] The battery monitor according to item 11, further comprising a near-field communication coil connected to the controller. [Item 15] The battery monitor according to item 14, wherein the near-field communication coil is isolated from the conductive material of the battery terminal.

Claims

1. A battery cell monitoring system, comprising a plurality of battery cell monitors, each battery cell monitor being configured to be electrically connected to each of the battery cells in a battery pack having a plurality of electrically interconnected battery cells, each battery cell monitor comprising one or more sensors connected to a controller, each sensor being configured to detect at least one parameter of each battery cell monitored by the battery cell monitoring device, a memory configured to receive and store data based on the at least one detected parameter, the memory being configured to store a battery cell ID associated with each battery cell, a controller configured to receive sensor information during operation and store the sensor information in the memory over time, a history of sensor information for each battery cell being recorded in the memory of each battery cell monitor, a communication interface configured to communicate non - contact with a remote device the at least one parameter of each battery cell and the battery cell ID, the communication with the remote device being performed without a direct electrical connection. Communication interface, A battery cell monitoring system including the above components.

2. The battery cell monitoring system according to claim 1, wherein each of the plurality of battery cell monitors includes a dedicated power source.

3. Each of the plurality of battery cell monitors includes an NFC coil that supplies power in response to the presence of an NFC field, The communication interface is configured to communicate non - contact with an RFID reader that communicates with a cloud database the at least one parameter of each battery cell and the battery cell ID. The battery cell monitoring system according to claim 1.

4. Each battery cell monitor includes an enclosure for protecting each of the controller, the one or more sensors, the memory, and the communication interface, the enclosure being supported by each battery cell, the enclosure including an electrical coupling between the one or more sensors and each battery cell. The battery cell monitoring system according to claim 1.

5. The battery cell monitoring system according to claim 1, wherein each battery cell monitor includes an accelerometer for monitoring impact events and motion events.

6. The battery cell monitoring system according to claim 1, wherein the memory of each of the plurality of battery cell monitors includes an accumulator matrix configured to store battery information detected over time for each battery cell by the sensor.

7. The communication interface of each battery cell monitor is configured to communicate with the spaced-apart devices without a wiring harness, the communication interface is configured to transmit the battery cell ID, receive first authentication information associated with a first access level among a plurality of access levels, receive second authentication information associated with a second access level among the plurality of access levels, transmit a first set of battery cell data in response to the reception of the first authentication information, and transmit a second different set of battery cell data in response to the reception of the second authentication information The battery cell monitoring system according to claim 1, which is configured as described above.

8. The battery cell monitoring system according to claim 1, wherein the memory of each battery cell monitor is configured to include battery cell life cycle data indicating the battery cell life cycle state of each battery cell.

9. Each of the plurality of battery cell monitors includes a respective self-discharge resistance switch and a respective controller, The battery cell monitoring system according to claim 8, wherein each controller is configured to close each self-discharge resistance switch to prepare each battery cell for recycling in response to specific battery cell life cycle data.

10. The battery cell monitoring system includes a plastic seal associated with each battery cell monitor, the plastic seal being configured to be attached to each battery cell, The battery cell monitoring system according to claim 1, wherein each plastic seal includes one or more conductive tabs surrounded by a plastic layer configured to protect and seal each battery cell monitor without preventing electrical connection to the electrodes of each battery cell.

11. The battery cell monitoring system according to claim 10, wherein the one or more conductive tabs include at least one of a tab for an antenna and a tab for coil connection.

12. The battery cell monitoring system according to claim 1, wherein each of the plurality of battery cell monitors includes a photovoltaic battery cell information chip.

13. A battery cell monitor configured to be attached to individual battery cells in a battery pack and configured to be electrically coupled to the electrodes of the battery cells, A sensor configured to detect parameters of individual battery cells in a battery pack, A memory configured to store a battery cell ID associated with an individual battery cell in a battery pack and to receive and store battery cell data based on the detected parameters, A controller configured to receive sensor information during operation and store the sensor information as battery cell data in the memory over time, A controller in which a history of sensor information for individual battery cells is recorded in the memory of the associated battery cell monitor together with the battery cell ID for that individual battery cell, A communication interface configured to wirelessly transmit the battery cell ID and the battery cell data, A battery cell monitor comprising:

14. Comprising a support structure configured to be attached to the battery cell and arranged to house the controller, the memory, and the sensor, The battery cell monitor according to claim 13, wherein the support structure includes at least one conductive element configured to electrically couple the controller and the sensor to the electrodes of the battery cell.

15. The battery cell monitor according to claim 13, including a dedicated power source.

16. The battery cell monitor includes an NFC coil that supplies power in response to the presence of an NFC field, The battery cell monitor according to claim 13, wherein the communication interface is configured to communicate the battery cell data and the battery cell ID in a non-contact manner to an RFID reader that communicates with a cloud database.

17. The battery cell monitor according to claim 13, including an accelerometer for monitoring impact events and motion events.

18. The battery cell monitor according to claim 13, wherein the memory includes an accumulator matrix configured to store battery information detected by the sensor over time regarding the battery cell.

19. The battery cell monitor according to claim 13, wherein the memory is configured to include battery cell life cycle data indicating a battery cell life cycle state of the battery cell.

20. The battery cell monitor includes a self-discharge resistance switch, The battery cell monitor according to claim 19, wherein the controller is configured to close the self-discharge resistance switch to prepare the battery cell for recycling in response to specific battery cell life cycle data.

21. The communication interface is configured to communicate with a remote device without a wiring harness, The communication interface, transmits the battery cell ID, receives first authentication information associated with a first access level among a plurality of access levels, receives second authentication information associated with a second access level among the plurality of access levels, transmits a first set of battery cell data in response to the reception of the first authentication information, and transmits a second different set of battery cell data in response to the reception of the second authentication information The battery cell monitor according to claim 13, configured as such.

22. The battery cell monitor according to claim 13, wherein the controller is configured to set a recycling threshold based on a change in battery capacity of the battery cell over time.

23. The battery cell monitor includes an arbitration interrupt logic module, The memory is a dual-port read / write memory, The battery cell monitor according to claim 13, wherein the arbitration interrupt logic module is configured to control read / write access based on a use case state identifier.

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