Battery Housing Control Electronics Integration
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Solution Overview
Problem
High capacity secondary batteries face challenges with inadequate protection from impact shock, overheating, inefficient power conversion, lack of smart features, and inefficient cell balance converters that consume excessive power and produce electromagnetic interference (EMI).
Innovation Solution
The integration of lithium-ion (Li-Ion) batteries within a housing with advanced control electronics, including an LC resonant converter, high-density bidirectional MOSFET switches, and a microprocessor for thermal protection, along with a smart bus interface and visual state of charge indicators, addresses these issues by ensuring efficient power management, protection, and smart connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple high capacity cells are packed into a housing to increase battery capacity, then the energy storage increases, but the protection from impact shock and overheating becomes inadequate
Solution Approach 1:
The battery housing is divided into multiple compartments or sections, each containing individual cells or groups of cells. This segmentation allows for better thermal management by isolating heat sources and improves mechanical protection by distributing impact forces across separate sections rather than allowing a single point of failure to affect the entire battery pack.
2Stability of the object's composition
If passive cell balance converters are used to balance charge between cells, then the charge balancing function is achieved, but power is dissipated leading to inefficiency
Solution Approach 1:
The patent replaces passive resistive balancing (which dissipates energy as heat) with an active electronic switching system using MOSFETs and control circuitry. This electronic system can transfer charge between cells through switching operations rather than resistive dissipation, significantly reducing energy loss while maintaining charge balance stability.
3Power
If cell balance converters based on hard switching topology are used, then power conversion is achieved, but a large amount of EMI is produced
Solution Approach 1:
The patent employs soft switching techniques with controlled periodic operation of MOSFETs, using resonant circuits and timing control to transition switching operations away from hard switching. This periodic, controlled switching reduces electromagnetic interference while maintaining effective power conversion capability for cell balancing operations.
4Power
If commercially available converters are used for cell balancing, then conversion function is provided, but power consumption exceeds 120 mW or design limitations prevent operation at 33V or no isolation is provided
Solution Approach 1:
The patent implements a self-contained battery management system where the cell balancing converter is integrated directly into the battery housing with isolated power supply and control circuitry. The system uses the battery's own voltage ranges (up to 33V) to operate the converter, providing self-service functionality without external power sources, achieving low power consumption through efficient switching design, and maintaining electrical isolation for safety.
5Adaptability or versatility
If multiple bidirectional switches are integrated with bus bar inside battery for individual control of charge and discharge paths, then individual cell control is achieved, but the complexity and space requirements increase
Solution Approach 1:
The patent integrates multiple bidirectional MOSFET switches and their associated control circuitry directly onto or alongside the bus bar structure, merging the switching elements with the electrical connection pathways. This integration reduces the overall space requirements and simplifies the device complexity by eliminating separate mounting and connection structures for each switch while maintaining individual cell control capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides efficient, low-noise power conversion, effective thermal protection, and smart battery management, reducing power consumption and EMI while enhancing safety and usability through integrated control electronics and smart features.
Implementation Method 1
An LC resonant converter is disposed within the housing. The LC resonant converter maintains all cells at the same potential voltage and state of charge.
Implementation Method 2
A MOSFET switch and an inductor (L) are in a series loop with the battery. A first diode and the capacitor (C) are in parallel with the MOSFET switch.
Data Source
AI summary
Rechargeable cells in cylindrical form are arranged within frames in a honeycomb structure and coupled by connecting straps outside the frames to form cell pack. Several cell packs, an electronic switch and control circuit are integrated into the battery housing. A bus bar extends around the perimeter of the housing. A high density MOSFET switch is coupled between the bur bar and the battery contact. A high power electronic clamp disposed across the battery terminals absorbs or redirects transients. An active, high-efficiency, low-noise cell balance converter or a LC based resonant converter may also be provided. For advanced battery applications a +5V CAN bus interface is provided via two circular connectors. Thermistors are provided for use in a thermal protection scheme.