Self-discharge for high voltage battery packs

Patent metadata

Field	Value
Publication number	US-9614383-B2
Application number	US-201313784542-A
Country	US
Kind code	B2
Filing date	Mar 4, 2013
Priority date	May 19, 2012
Publication date	Apr 4, 2017
Grant date	Apr 4, 2017

Abstract

A system and method for providing energy management and maintenance of a high energy battery pack through use self-discharge features and processes. A battery pack is configured with self-discharger enabled-components that selectively discharge energy from the battery pack without the battery pack providing operational power.

First claim

What is claimed as new and desired to be protected by Letters Patent of the United States is:

1. A self-dischargeable rechargeable high-voltage battery pack, comprising:
a plurality of series-coupled energy storage elements;
a housing enclosing and sealing said plurality of series-coupled energy storage elements with a plurality of exterior walls;
an operational port coupled to a portion of a first particular one exterior wall of said plurality of exterior walls, said operational port providing an energy transfer with respect to said plurality of series-coupled energy storage elements;
a self-discharger, responsive to a self-discharge signal, initiating an internal dissipation of energy at an intentional self-discharge rate of at least 5 W from said plurality of series-coupled energy storage elements while said self-discharge signal is asserted without said energy transfer through said operational port, wherein said internal dissipation of energy is disabled when said self-discharge signal is not asserted; and
a battery precharger mechanism coupled to said plurality of series-coupled energy storage elements selectively limiting a current flow from said plurality of series-coupled energy storage elements in a first mode wherein said self-discharger includes said battery precharger mechanism in a second mode that constantly dissipates energy from all said series-coupled energy storage elements at once.

2. The self-dischargeable rechargeable high-voltage battery pack of claim 1 further comprising a motion sensor detecting an acceleration profile associated with a collision event wherein said self-discharge signal is asserted automatically in response to said collision event.

3. The self-dischargeable rechargeable high-voltage battery pack of claim 1 further comprising a battery management system disposed within said housing and coupled to said self-discharger, said battery management system asserting said self-discharge signal until a discharge endpoint is reached wherein said battery management system stops asserting said self-discharge signal.

4. The self-dischargeable rechargeable high-voltage battery pack of claim 2 further comprising a battery management system disposed within said housing and coupled to said self-discharger and to said motion sensor, said battery management system asserting said self-discharge signal in response to said collision event until a discharge endpoint is reached wherein said battery management system stops asserting said self-discharge signal.

5. The self-dischargeable rechargeable high-voltage battery pack of claim 1 further comprising a battery balancing mechanism coupled to said plurality of series-coupled energy storage elements selectively individually balancing a voltage of said plurality of series-coupled energy storage elements in a third mode wherein said self-discharger includes said battery balancing mechanism in said second mode that constantly dissipates energy from all said series-coupled energy storage elements at once.

6. The self-dischargeable rechargeable high-voltage battery pack of claim 1 further comprising an operating environment including an electric motor coupled to said operational port, said electric motor operable by said energy transfer from said plurality of series-coupled energy storage elements.

7. The self-dischargeable rechargeable high-voltage battery pack of claim 6 wherein said operational port includes a power connector and a communications interface and wherein said operating environment provides said self-discharge signal through said communications interface.

8. The self-dischargeable rechargeable high-voltage battery pack of claim 1 wherein said internal dissipation of energy from the plurality of series-coupled energy storage elements occurs at a self-discharge rate of 5-50 W.

9. The self-dischargeable rechargeable high-voltage battery pack of claim 1 further comprising a processing system coupled to said pluralities of series-coupled energy storage elements, said processing system including a power conserving operating mode reducing an internal power dissipation of said pluralities of series-coupled energy storage elements wherein said self-discharger selectively actuates, in response to said self-discharge signal, a power consuming operating mode for said pluralities of series-coupled energy storage elements that disables said power conserving operating mode and wherein said self-discharger enables said power conserving operating mode when said self-discharge signal is not enabled.

10. The self-dischargeable rechargeable high-voltage battery pack of claim 1 wherein said operational port includes a power connector and a communications interface and further comprising a service unit separate from a battery management system, the service unit coupled to said operational port and asserting said self-discharge signal through said communications interface.

11. A self-dischargeable rechargeable high-voltage battery pack, comprising:
a plurality of battery modules serially coupled to each other;
inside each of the plurality of battery modules, a plurality of series-coupled energy storage elements;
a housing enclosing and sealing said plurality of battery modules with a plurality of exterior walls;
an operational port coupled to a portion of a first particular one exterior wall of said plurality of exterior walls, said operational port providing an energy transfer with respect to said pluralities of series-coupled energy storage elements;
a self-discharger, responsive to a self-discharge signal, initiating an internal dissipation of energy at an intentional self-discharge rate of at least 5 W from said pluralities of series-coupled energy storage elements while said self-discharge signal is asserted without said energy transfer through said operational port, wherein said internal dissipation of energy is disabled when said self-discharge signal is not asserted; and
a plurality of energy dissipative elements selectively functionally coupled to said pluralities of series-coupled energy storage elements, wherein each of the plurality of energy dissipative elements is installed at a respective one of the plurality of battery modules, wherein said self-discharger selectively enables said energy dissipative elements to dissipate energy from said pluralities of series-coupled energy storage elements in response to said assertion of said self-discharge signal, said plurality of energy dissipative elements not dissipating energy from said plurality of series-coupled energy storage elements when said self-discharge signal is not asserted.

12. The self-dischargeable rechargeable high-voltage battery pack of claim 11 further comprising a processing system coupled to said pluralities of series-coupled energy storage elements, said processing system including a power conserving operating mode reducing an internal power dissipation of said pluralities of series-coupled energy storage elements wherein said self-discharger selectively actuates, in response to said self-discharge signal, a power consuming operating mode for said pluralities of series-coupled energy storage elements that disables said power conserving operating mode and wherein said self-discharger enables said power conserving operating mode when said self-discharge signal is not enabled.

13. The self-dischargeable rechargeable high-voltage battery pack of claim 11 , wherein said operational port includes a power connector and a communications interface and further comprising a service unit separate from a battery management system, the service unit coupled to said operational port and asserting said self-discharge signal through said commu

Assignees

• Tesla Motors Inc

Inventors

• Boggs Brian Stuart
• Darragh Joseph Michael
• Paryani Anil
• Chou Chuen

Classifications

• H02J7/70

  characterised by the mechanical construction · CPC title

• B60L3/0046

  relating to electric energy storage systems, e.g. batteries or capacitors · CPC title

• B60L58/10

  for monitoring or controlling batteries · CPC title

• B60L53/16

  Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles · CPC title

• B60L3/00

  Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption (methods or circuit arrangements for monitoring or controlling batteries or fuel cells B60L58/00) · CPC title