The present disclosure relates to the connection of batteries for receipt, storage, and withdrawal of power. Embodiments of the disclosure relate to battery banks, connector assemblies and battery connecting methods.
Recent advances in power distribution have utilized battery systems to store power generated and to deliver power as needed. These battery systems can include single-celled or multi-celled batteries, and they can take the form of nickel-metal-hydride or lithium ion batteries, for example.
Battery banks that include multiple individual batteries can be utilized for this purpose as well. Batteries within these banks may be single-celled batteries and can be aligned in parallel or series fashion, for example. Connecting the batteries within these banks to one another and/or to a power supply or receiver is not inconsequential. The present disclosure provides battery connector assemblies as well as battery connecting methods.
Methods for controlling the usage of individual and/or groups of batteries within a bank of batteries are provided. The methods can include: coupling an integrated circuit board to the batteries within the bank of batteries; monitoring the battery parameters of individual and/or groups of batteries within a bank of batteries; and engaging and/or disengaging the individual and/or groups of batteries through the circuit board.
Methods for connecting batteries are also provided. The methods can include: aligning a series of clamping assemblies along a rod configured to actuate the clamping assemblies between coupled and decoupled positions; providing a plurality of batteries, the batteries having posts; coupling individuals ones of the clamping assemblies to individuals ones of the battery posts to connect individual batteries.
Battery connector boards are provided. The boards can include at least one plate defining multiple openings configured to receive and electrically connect to a plurality of batteries, the plate including integrated circuitry configured to monitor and control individual and/or groups of batteries electrically coupled to the plate.
Battery banks are also provided. The banks can include: a plurality of batteries, at least a portion of which are aligned in columns; and; at least one battery connector assembly coupled to a column of batteries.
Battery connector assemblies are provided. The connector assemblies can include: a plurality of post coupling assemblies comprising a plurality of post clamping assemblies linked by individual rod assemblies, each of the rod assemblies including an actuator configured to couple/decouple the post clamping assemblies from battery posts.
Embodiments of the disclosure are described below with reference to the following accompanying drawings.
This disclosure is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
In developing banked battery supplies and storage it has been recognized that there may be obstacles to coupling individual batteries within the bank. These obstacles range from the physical limitations to repeated coupling and decoupling to the time consuming nature of coupling and decoupling larger banks. For example, in a bank containing 36 batteries there are 72 posts, and each post needs to be coupled to a grid individually; this is a time consuming process that manifests loose connections and/or wrong connections. Further, the connections made may not be able to be unmade. In some circumstances, coupling posts to grids are made with screw-type fittings and these fitting can become misthreaded and/or even cold-welded to the extent the grid cannot be decoupled from the battery without removing the post from the battery.
Embodiments of what is provided herein include connecting assemblies that can allow for the user to connect multiple batteries within a bank using a single actuator, without having to individually couple the individual posts of the batteries to a grid. Further, embodiments of the assemblies can provide a clamping engagement to the battery posts, thereby eliminating the misthread or cold-weld associated with the screw-type post fittings. As part of this disclosure, embodiments of the connector assemblies can also be configured to monitor battery parameters and engage and disengage discrete groups of batteries or single batteries alone as desired.
Battery banks are provided that can include a plurality of batteries. Individual batteries within the plurality can have at least two operable posts, negative and positive, for example. The batteries can be aligned as a column, and/or rows. Multiple columns may be provided and aligned to provide the batteries within the bank in columns and rows.
The banks can have at least one battery connector assembly coupled to a column of batteries within the bank. The battery connector assembly can include a clamping assembly and a rod assembly. The battery connector assembly can include an integrated circuit board. The batteries in the columns can be serially connected. The batteries in the columns can be connected in parallel.
The bank of batteries may also include a tray. The tray can be configured to receive a lower portion or base of the battery and/or align the batteries within the column. Where the batteries in the bank are aligned in rows, the tray can be configured to align the batteries in columns and rows. The tray can also be configured to retain battery fluid, for example, the tray can be constructed of acid resistant polymer material.
The battery banks, connector assemblies and battery connecting methods of the present disclosure are further described with reference to
Further, a tray (not shown) may be associated with each bank of multiple banks of batteries. The tray may define recesses configured to align individual batteries of the bank spatially in relation to one another. In accordance with example implementations, the tray may also be associated with the battery connecting assemblies of the present disclosure. The tray may also be configured to contain battery fluid such as electrolytes that may exit one or more batteries within the bank. The spatial alignment of the batteries by the tray can transfer to the spatial alignment of the posts of the batteries to the connector assemblies.
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The rod assembly can include a continuous rod extending from the actuator through the clamping assemblies to a terminus. As an example, at least a portion of the rod assembly can be insulative. The rod assembly can also include a plurality of sleeves spacing the clamping assemblies along the rod. Individual ones of the plurality of sleeves can be either conductive or insulative. The rod assembly can include at least one sleeve configured to receive the terminus of the rod, the terminus of the rod being threaded and the sleeve being configured to receive the threads.
The connector assembly can include a plate associated with at least some of the post coupling assemblies. The plate can be in electrical contact with at least one of the post clamping assemblies. The plate can include at least two plates, a supportive plate and a circuit board. The plate can be configured to facilitate the control and/or monitoring of one or more batteries connected to the post clamping assemblies.
Methods for connecting batteries are provided. The methods can include aligning a series of clamping assemblies along a rod configured to actuate the clamping assemblies between coupled and decoupled positions. The method can include providing a plurality of batteries, the batteries having posts. The method can also include coupling individuals ones of the clamping assemblies to individuals ones of the battery posts to connect individual batteries.
The methods for connecting batteries can also include engaging an actuator to couple or decouple the clamping assemblies from the battery posts. The clamping assemblies can be biased in the decoupled position, the engaging the actuator to couple the clamping assemblies to the battery posts can include applying force against the bias. The applying the force against the bias can include rotating the rod of the assembly along its lengthwise axis. According to example implementations, the rotating can engage a threaded sleeve at the rod terminus applying force to the clamping assemblies, for example. The coupling of the plurality of batteries can include manipulating a single actuator.
The methods of connecting batteries can also include associating a plate with the clamping assemblies, at least a portion of the plate being in electrical connection with at least some of the clamping assemblies. The plate can be configured to provide for the monitoring and/or control of battery parameters of individual batteries within and across columns, for example. The methods of connecting batteries can also include providing a plurality of connector assemblies, individual ones of the connector assemblies including the plurality of clamping assemblies aligned along the rod. The methods of connecting batteries can also include providing the plurality of batteries in columns of batteries, individual ones of the connector assemblies being associated with individual columns of batteries.
According to example implementations, the assemblies can be used to connect multiple batteries within a column or multiple columns as desired. Alternative implementations may connect batteries of the entire bank or portions of a bank. The batteries may be aligned in series or in parallel or combinations of both. Connector assemblies 16 can include post coupling assemblies 18 mechanically linked via rods 20. Individual ones of connector assemblies 16 can include an actuator assembly 22. Coupling assemblies 18 can be configured to move between an open and closed position in relation to posts 14 using rods 20 and actuator 22. In accordance with example implementations, coupling assemblies 18 can complete an electrical contact with posts 14 in the closed position and disconnect that electrical contact in the open position. Rods 20 may be insulative or conductive and may be constructed of multiple components, such as a pipe having a rod therein, for example. Actuator 22 can be mechanically connected to rods 20 providing for the opening and closing of assemblies 18.
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Battery connector boards are provided that can include at least one plate defining multiple openings configured to receive and electrically connect to a plurality of batteries. One or more of the multiple openings can be configured to conductively engage one or more posts of the plurality of batteries. The posts can be threaded and coupled to the plate via complimentary threaded nut.
The board can include at least two plates, an integrated circuit plate above a supportive plate. The integrated circuit plate can include integrated circuitry configured to monitor and control individual and/or groups of batteries electrically coupled to the plate. This integrated circuitry can include and/or be configured to interface with processing and/or memory circuitry. The plate can be configured as a circuit board array. The board can include vents configured to provide for the exchange of air between upper and lower surfaces of the plate.
The integrated circuitry can include one or more of jumpers, switches, shunts, and/or embedded fusing. The board of claim 21 further comprising PIN connectors. The board can include a plurality of switches, individual ones of the switches having a unique identifier. The board can also include bus connectors.
The processing and memory circuitry can be a part of a processing unit that can include one or more microprocessors, one or more support circuits, circuits that include power supplies, clocks, input/output interfaces, circuitry, and the like. Generally, all computer processing units described herein can be of the same general type. The processing and/or memory circuitry can include a memory that can include random access memory, read only memory, removable disc memory, flash memory, and various combinations of these types of memory. The memory can be referred to as a main memory and be part of a cache memory or buffer memory. The memory can store various software packages and components such as an operating system.
The processing and/or memory circuitry can be configured to monitor battery parameters and/or reconfigure battery connections to the board. The battery parameters can include one or more of temperature, thermal conductivity, voltage, current, and/or impedence.
Methods for controlling the usage of individual and/or groups of batteries within a bank of batteries are provided. The methods can include coupling an integrated circuit board to the batteries within the bank of batteries. The coupling the integrated circuit board to the batteries can include mechanically engaging individual posts of the batteries with individual openings within the circuit board. The method can also include providing conductive material along the edges of the board defining the openings.
The methods can also include monitoring the battery parameters of individual and/or groups of batteries within a bank of batteries using the integrated circuit board, for example. The monitoring the battery parameters can include monitoring one or more of the temperature, thermal conductivity, voltage, current, and/or impedence associated with batteries. The monitoring the can include one or more of storing the battery parameter data with memory circuitry and/or comparing stored battery parameter data with standard battery parameter data using processing circuitry, for example. The methods can also include engaging and/or disengaging the individual and/or groups of batteries using the circuit board.
The methods can also include processing battery parameter data using processing circuitry to engage and/or disengage the individual and/or groups of batteries.
The methods can also include transferring power between portions of the board. The transferring can include open/closing individual or groups of switches in the board.
In accordance with other embodiments of the disclosure and with reference to
Plate 72 can also be configured to monitor and control the use of banks, discrete portions of banks, and/or individual batteries within banks. For example, plate 72 can include one or more bus connectors 78 that can be configured as PIN connectors having designated pins associated with designated control or monitoring parameters. In other embodiments, connectors 78 may be part of a processing and memory device associated with plate 72 that may be accessed from a separate processing device for example. In these embodiments, the processing and memory device of plate 72 may collect and store data as a result of monitoring and/or controlling the batteries and may provide the collected data to the separate processing device. Furthermore, in some cases, the processing and memory device of plate 72 may analyze the collected data and take action based on the analysis. For example, the processing and memory device of plate 72 may analyze the collected data, determine that an undesirable condition exists, and, in response, generate an alarm.
Either one or both of plates 62 and 72 can include vents 80 to allow for heat removal from a battery bank. Further, plate 72 can include jumpers 82 that can allow for the transfer of power between sections such as rows of batteries. These jumpers may be moveable as well. Further, plate 72 can include embedded fusing to allow for the isolation of predefined regions upon current overload.
According to example implementations, plate 72 can include switches having identifiers that provide for the isolation of individual cells along the coupling assembly. In accordance with an example implementation, all rods of connector assemblies associated with assembly 70 can be insulative. Plate 72 can have conductive contact with coupling assemblies and provide for conduction between posts via lines within plate 72. These conductive lines may have switches therein (e.g., IGBTs) and be identified as a region or sector of the battery bank. According to example implementations, plate 72 can be monitored via a computer to determine battery parameters, and using the computer, individual batteries or groups of batteries may be taken off-line or returned to being on-line as desired by an operator. As an example, for batteries in serial connection conductive lines can be included in plate 72 that overlap predetermined batteries within a series and these conductive lines can include switches that can be manipulated via a processor. To remove a specific battery from a serial group of batteries, one or more of the switches can be engaged to isolate the battery from the series, without disabling the rest of the batteries of the series. Similarly, one or more of the switches can be engaged to remove one of the batteries of a parallel connection of batteries from the parallel connection.
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Plate 102 can also be configured to monitor and control the use of banks, discrete portions of banks, and/or individual batteries within banks. For example, plate 102 can include one or more bus connectors 108 that can be configured as PIN connectors having designated pins associated with designated control or monitoring parameters. In other embodiments, connectors 108 may be part of a processing and memory device associated with plate 102 that may be accessed from a separate processing device for example. In these embodiments, the processing and memory device of plate 102 may collect and store data as a result of monitoring and/or controlling the batteries and may provide the collected data to the separate processing device. Furthermore, in some cases, the processing and memory device of plate 102 may analyze the collected data and take action based on the analysis. For example, the processing and memory device of plate 102 may analyze the collected data, determine that an undesirable condition exists, and, in response, generate an alarm.
Either one or both of plates 92 and 102 can include vents 110 to allow for heat removal from a battery bank. Further, plate 102 can include jumpers 112 that can allow for the transfer of power between sections such as rows of batteries. These jumpers may be moveable as well. Further, plate 102 can include embedded fusing to allow for the isolation of predefined regions upon current overload. According to example implementations, plate 102 can include switches having identifiers that provide for the isolation of individual cells or posts of cells.
According to example implementations, plate 102 can be monitored via a computer to determine battery parameters, and using the computer, individual cells, batteries and/or groups of batteries may be taken off-line or returned to being on-line as desired by an operator. As an example, for batteries in serial connection conductive lines can be included in plate 102 that overlap predetermined batteries within a series and these conductive lines can include switches that can be manipulated via a processor. To remove a specific cell or battery from a serial group of batteries, one or more of the switches can be engaged to isolate the cell or battery from the series, without disabling the rest of the batteries of the series. Similarly, one or more of the switches can be engaged to remove one of the batteries of a parallel connection of batteries from the parallel connection.
As another example, plate 102 can have shunts incorporated therein consistent with serial or parallel design of the bank. Power may be provided via these shunts to an entirety or discrete portions of the bank to facilitate equalization of the bank or portions of the bank as desired. In accordance with example implementations, using the shunts specific batteries or groups of batteries may be bypassed. In particular embodiments, batteries may be removed from parallel configurations.
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In compliance with the statute, embodiments of the invention have been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the entire invention is not limited to the specific features and/or embodiments shown and/or described, since the disclosed embodiments comprise forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
This application claims priority to U.S. Provisional Patent Application No. 61/509,953 filed Jul. 20, 2011, entitled “Battery Connector Assemblies and Battery Connecting Methods” and U.S. Provisional Patent Application No. 61/547,299 filed Oct. 14, 2011, entitled “Battery Connector Assemblies and Battery Connecting Methods”, the entirety of each of which is incorporated by reference herein.
Number | Date | Country | |
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61509953 | Jul 2011 | US | |
61547299 | Oct 2011 | US |