When batteries are exposed to cold temperatures, their electrolytes are susceptible to freezing. A frozen electrolyte solution has a high viscosity and a high internal resistance, which resists the flow of electrons and chemical ions between positive and negative electrodes, reducing battery function. A battery may be warmed to restore function.
Embodiments of this disclosure relate generally to the field of battery heating systems, and more specifically to internal battery heating systems.
Many different battery heating systems are described in the prior art. The prior art systems are typically configured with a heating element coupled to the battery to be heated. For example, U.S. Pat. Nos. 9,831,534 and 10,069,176, both to Beuning et al., disclose systems and methods for heating a battery using a separate heating element. Both of these patents are incorporated herein by reference in their entirety.
Other prior art battery heating systems include U.S. Pat. No. 6,259,229 to Ashtiani et al., which discloses a circuit with a variable frequency half-bridge configuration that heats a string of Li-Ion batteries. U.S. Pat. No. 8,452,490 to Lakirovich et al. discloses an electronic circuit that includes a plurality of switch and diode pairs in a stacked configuration connected to an inductor and two batteries. U.S. Pat. No. 9,214,706 to Xu et al. discloses a battery heating circuit with two batteries each connected in series to a two-way switch and a shared charge storage component. U.S. Patent Publication 2014/0285135 to Ji et al. discloses a solid-state heating method whereby electricity is shuttled back and forth between cells of a battery.
In an embodiment, an internal battery heating system is provided. The system includes a heating circuit electrically coupled with a core battery. The heating circuit includes an electrical conversion device for alternately raising and lowering a voltage of the heating circuit, and an electrochemical sub-cell for alternately discharging from, and charging to, the core battery. A controller is adapted to command the electrical conversion device for alternately raising and lowering the voltage of the heating circuit to charge and discharge the core battery, thereby internally heating the core battery.
In another embodiment, an internal battery heating system includes a core battery electrically coupled to a heating circuit. The heating circuit includes a plurality of electrochemical sub-cells each electrically coupled to the heating circuit via a pair of switches, such that the plurality of electrochemical sub-cells may alternate between a parallel arrangement and a series arrangement. A controller is adapted to provide coordinated switching of the pair of switches for each of the plurality of electrochemical sub-cells for alternating between the parallel arrangement and the series arrangement, such that in the parallel arrangement, the core battery discharges to the plurality of electrochemical sub-cells, and in the series arrangement, the core battery charges from the plurality of electrochemical sub-cells, thereby internally heating the core battery.
In yet another embodiment, an internal battery heating system includes a heating circuit comprising an electrical conversion device switchably connected to a first battery module via a first switch, a plurality of additional battery modules electrically coupled with the heating circuit in a parallel configuration, and a controller adapted to instruct the electrical conversion device to alternately raise and lower a voltage from the first battery module for alternately charging and discharging the plurality of additional battery modules.
In another embodiment, an internal battery heating system includes a first battery module, a second battery module, a third battery module, and a fourth battery module, each electrically coupled to a controller. The system further includes a first switch, a second switch, a third switch, and a fourth switch electrically coupled to the first battery module, the second battery module, the third battery module, and the fourth battery module, respectively, for switching electrical coupling of each battery between a heating circuit and a power terminal. An electrical conversion device is electrically coupled to the fourth battery module for alternately raising and lowering the voltage of the heating circuit, and a controller is configured to control the electrical conversion device, the first switch, the second switch, the third switch, and the fourth switch, such that the first battery module, the second battery module, and the third battery module are independently heated or independently coupled to the electrical power terminal for providing electrical power.
Illustrative embodiments of the present disclosure are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:
Battery heating may be performed with a separate heating element that is powered either by the battery itself or by an external power source. Powering a heater with the battery itself assumes that the battery can provide enough current to operate the heater, but under extremely cold conditions this may not be the case. Alternatively, the heater is powered using an external electrical power source, assuming that one is available and that personnel are available to operate the external electrical power source. For an aircraft, a typical external power source is a ground power cart, but these are not commonly available at many small airports and in remote, cold-temperature locations.
In some known arrangements, a separate heater is powered by a cold battery, with power being incrementally increased until the battery reaches its normal operating temperature. However, a substantial amount of stored electrical energy within the battery may be expended to power the separate heater, and some of the heat emitted by the separate heater is wasted. As a result, much of the state of charge of the battery may be depleted by the time the battery is warmed to its normal operating temperature.
Embodiments of the present disclosure provide a plurality of electrochemical sub-cells or battery modules arranged with switches and, optionally, electrical conversion devices (e.g., a DC-DC converter) to form a heating circuit. In certain embodiments, the plurality of batteries include one or more core batteries arranged in parallel with one or more electrochemical sub-cells (see e.g.,
Instead of using a heating element, the one or more electrochemical sub-cells are used to act as a load (e.g., a current sink for discharging) from the core battery, or to act as a supply (e.g., a current source for charging) to the core battery (see e.g.,
A trade-off of not using an external power source and load bank to produce cycling between charging and discharging is that some of the energy stored in the core battery is consumed through the charge/discharge of its cells to self-heat the battery. Self-heating is limited by losses from each charge/discharge step (e.g., electrochemical energy converted into heat in the core battery, electrochemical sub-cell, DC-DC converter, or controller); in practice, however, only a portion of the core battery's stored energy is needed for preheating to achieve a minimum operating temperature and voltage.
Controller 110 provides control of all components of system 100, including a heating circuit 101 and a timer/indicator circuit 102. Controller 110 may include programmable memory, a processor, and electronics for carrying out automated control of system 100 components, such as an integrated circuit or a printed circuit board including a microcontroller, microprocessor, or programmable logic controller (PLC), for example. Controller 110 may provide over-voltage and current limit protection to prevent damage to the core battery and the sub-cells.
Heating circuit 101 includes switch 180, DC-DC converter 140, and sub-cell 130. When the internal heating function is activated, heating circuit 101 is connected to the core battery 120 via switch 180. DC-DC converter 140, under control of controller 110, is configured to raise/lower the voltage of heating circuit 101 to drive charging/discharging of core battery 120. DC-DC converter 140 is an example of an electrical conversion device, such as an electronic circuit or electromechanical device that converts a source of direct current (DC) from one voltage level to another. An example is a buck-boost converter that combines a buck (step-down) converter with a boost (step-up) converter.
Timer/indicator circuit 102 includes a timer 160, a heater-timer-enable switch 165, and an indicator 170. Timer 160 is electrically coupled with controller 110 for activating internal battery heating system 100 for a duration based on information received from temperature sensor 150 and voltage sensor 155 or based on a predetermined amount of time. Temperature sensor 150 is for example a thermocouple or resistance-temperature-detector (RTD). Heater-timer-enable switch 165 is a user-activated switch (e.g., a physical switch or a networked remote-access switch) that enables a user to activate internal battery heating system 100. Indicator 170 provides an indication when internal battery heating system 100 is active. Indicator 170 may include one or more lights to indicate when the battery is warming or when the battery has reached its minimum operating temperature, for example.
In operation, when a battery is cold-soaked (e.g., −40° C.), heater-timer-enable switch 165 is activated by a user, which activates timer 160 to draw a small current from core battery 120 and activate controller 110 and indicator 170. Controller 110 determines if the temperature of core battery 120 is below a predetermined threshold (e.g., −10° C.) via temperature sensor 150. If so, controller 110 sends a signal to switch 180 commanding it to close heating circuit 101 and the higher voltage of core battery 120 is used to charge sub-cell 130 through the DC-DC converter 140. Controller 110 monitors the voltage of sub-cell 130 and when the voltage reaches a predetermined level (e.g., an over-voltage limit), DC-DC converter 140 is commanded to switch the role of core battery 120 from serving as a source providing electrical current to serving as a load receiving electrical current. Controller 110 commands DC-DC converter 140 to raise the voltage of the heating circuit 101 to drive the current to core battery 120. Controller 110 monitors the voltage of sub-cell 130, and as it approaches a pre-defined cut-off voltage (e.g., an under-voltage limit), the charge/discharge cycle is repeated.
Meanwhile, the temperature of core battery 120 is monitored via temperature sensor 150 and cycling of charging/discharging is repeated until a predetermined minimum temperature (e.g. +10° C.) is reached. Controller 110 may determine a rate of cycling based on various factors, for example predetermined charge/discharge periods, a predetermined minimum voltage of core battery 120, or a duty cycle based on one or more temperature thresholds of core battery 120 (see e.g., U.S. Pat. Nos. 9,831,534 and 10,069,176, to Beuning et al., which are incorporated by reference).
Once the predetermined temperature is exceeded, controller 110 deactivates internal battery heating system 100 and indicator 170 changes its indication. For example, indicator 170 may change color or change from a continuous illumination to an intermittent illumination (e.g., flashing). Core battery may then be connected via switches (not shown) to power terminals (not shown) for providing electrical power.
Following preheating, sub-cell 130 may be isolated via switch 180 to open the heating circuit 101. In certain embodiments, sub-cell 130 may be configured with smaller capacity (e.g., less total Amp-hours (Ah)) than core battery 120 to reduce unnecessary space, weight, and cost for a feature that may be used only occasionally. For example, a 7.2V 40 Ah core battery may be used with a 3.6V 2 Ah sub-cell (if one sub-cell is used). By incorporating DC-DC converter 140, heating circuit 101 may have the same number of sub-cells in series as the number of cells in series in the core battery. The DC-DC converter provides a voltage boost that enables the sub-cells to discharge to the core battery. Over-voltage and current limit protection are used to prevent overcharge of the sub-cells.
Switches used in different embodiments disclosed herein, including first, second, third, and fourth switches 281, 282, 283, 284, may include combinations of switching devices such as relays, transistors (e.g., field-effect transistors), and diodes, without departing from the scope hereof. The switches may be configured as pairs of switches; for example, first and second switches 281, 282 form a first pair of switches for alternating series and parallel arrangements of first sub-cell 231. Similarly, third and fourth switches 283, 284 form a second pair of switches for alternating series and parallel arrangements of second sub-cell 232.
In operation, control of first, second, third, and fourth switches 281, 282, 283, 284 is coordinated by controller 110 such that one or more of first, second, and third sub-cells 231, 232, 233 may be configured in parallel (as depicted in
In certain embodiments, controller 110 provides coordinated commands to first, second, third, and fourth switches 281, 282, 283, 284 for dynamically cycling the charging/discharging of core battery 120 based on signals received from voltage sensor 155, a voltage sensor 175, and temperature sensor 150.
In operation, when DC-DC converter 140 is coupled to fourth battery module 424 via switch 480, controller 110 may instruct DC-DC converter 140 to step down voltage from fourth battery module 424, which drives current from the other modules arranged in parallel (e.g., first, second, and third modules 421, 422, 423) thereby charging fourth battery module 424. Conversely, controller 110 may instruct DC-DC converter 140 to boost voltage from fourth module 424, which drives current to first, second, and third modules 421, 422, 423 thereby discharging fourth battery module 424. By cycling the charging and discharging of fourth battery module 424 with that of the additional modules, heat is generated from friction of the electron and ion movement within heating circuit 101. Rates of charging/discharging are determined by controller 110 based on signals received from voltage sensor 155 and temperature sensor 150. When core battery preheating is not required, switch 480 decouples the DC-DC converter from fourth module 424.
In certain embodiments, voltage sensor 175 is electrically coupled to fourth module 424 for determining its voltage, which may be used to compare with the voltage of other modules (e.g., first module 421). When system 400 is actively preheating, first, second, third and fourth modules 421-424 are not used for providing power, and the modules are isolated from the battery's power terminals (e.g., via a switch, not shown).
In operation, system 500 cycles charging/discharging between fourth battery module 424 and one or more of first, second, and third modules 581, 582, 583. For example, as depicted in
As depicted in
Combinations of features from the above embodiments may be formed to provide additional embodiments (not shown) without departing from the scope hereof. For example, systems 400, 500, and 700 (
Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present disclosure. Embodiments of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.
It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.
This application is a continuation of U.S. patent application Ser. No. 16/162,849 entitled Internal Battery Heating and filed Oct. 17, 2018, which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/573,904 entitled Internal Battery Heating and filed Oct. 18, 2017, the disclosure of which is herein incorporated by reference in its entirety.
Number | Date | Country | |
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62573904 | Oct 2017 | US |
Number | Date | Country | |
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Parent | 16162849 | Oct 2018 | US |
Child | 17861753 | US |