U.S. patent application number 14/331049 was filed with the patent office on 2014-10-30 for battery assemblies.
The applicant listed for this patent is Valence Technology, Inc.. Invention is credited to Tage Bjorklund, Christopher Darilek, Joe Lamoreux, David St. Angelo, Lawrence Stone.
Application Number | 20140322567 14/331049 |
Document ID | / |
Family ID | 34396237 |
Filed Date | 2014-10-30 |
United States Patent
Application |
20140322567 |
Kind Code |
A1 |
Stone; Lawrence ; et
al. |
October 30, 2014 |
Battery Assemblies
Abstract
Electrical systems, power supply apparatuses, and power supply
operational methods are described. According to one aspect, an
electrical system includes an electrical entity configured to
utilize electrical energy, and wherein the electrical entity
comprises a communications interface, and a power supply apparatus
configured to provide the electrical energy for use by the
electrical entity, and wherein the power supply apparatus comprises
a support system, a plurality of battery assemblies configured to
be removably coupled with and supported by the support system,
wherein individual ones of the battery assemblies comprise at least
one rechargeable electrochemical device configured to provide the
electrical energy, at least one power terminal configured to couple
with the electrical entity and to provide the electrical energy
from the electrochemical device to the electrical entity, and a
communications interface configured to implement communications
with the communications interface of the electrical entity, and
wherein the electrical entity and the power supply apparatus are
configured to implement the communications comprising at least one
of status information regarding the power supply apparatus from the
power supply apparatus to the electrical entity and a command
regarding an operation of the power supply apparatus from the
electrical entity to the power supply apparatus.
Inventors: |
Stone; Lawrence; (Austin,
TX) ; Lamoreux; Joe; (Austin, TX) ; Darilek;
Christopher; (Austin, TX) ; Bjorklund; Tage;
(Cedar Park, TX) ; St. Angelo; David; (Austin,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Valence Technology, Inc. |
Las Vegas |
NV |
US |
|
|
Family ID: |
34396237 |
Appl. No.: |
14/331049 |
Filed: |
July 14, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13158279 |
Jun 10, 2011 |
8779718 |
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14331049 |
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10947602 |
Sep 21, 2004 |
7986124 |
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13158279 |
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60559171 |
Mar 31, 2004 |
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60505125 |
Sep 22, 2003 |
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Current U.S.
Class: |
429/61 ; 429/90;
429/92 |
Current CPC
Class: |
H01M 10/48 20130101;
H02J 7/0021 20130101; H02J 9/061 20130101; H02J 7/35 20130101; Y02B
10/70 20130101; Y02E 60/10 20130101; H02J 7/0016 20130101 |
Class at
Publication: |
429/61 ; 429/90;
429/92 |
International
Class: |
H01M 10/48 20060101
H01M010/48 |
Claims
1-103. (canceled)
104. A battery assembly comprising: a plurality of rechargeable
electrochemical devices individually configured to store electrical
energy; a power terminal configured to electrically couple with an
electrical entity configured to utilize the electrical energy and
to provide the electrical energy from the battery assembly to the
electrical entity; storage circuitry comprising a history of the
battery assembly including status information regarding a
characteristic of the battery assembly at a plurality of moments in
time, wherein the history of the storage circuitry also includes
temporal information comprising a plurality of temporal data
entries which identify the plurality of moments in time when the
status information regarding the characteristic of the battery
assembly was acquired for the history; and wherein the
characteristic comprises a common characteristic of the
rechargeable electrochemical devices, and the status information
comprises different values of the characteristic corresponding to
different individual ones of the rechargeable electrochemical
devices of the battery assembly.
105. The assembly of claim 104 wherein an individual one of the
rechargeable electrochemical devices is a cell of the battery
assembly, wherein the values of the characteristic comprise values
of the characteristic of the cells at the plurality of moments in
time, and wherein the values of the characteristic corresponding to
an individual one of the moments in time comprise values of the
characteristic of respective ones of the cells of the battery
assembly at the individual one of the moments in time.
106. The assembly of claim 104 wherein the battery assembly further
comprises: a communications interface configured to output the
status information externally of the battery assembly and to
receive a command from externally of the battery assembly; and
control circuitry configured to control an operation of the battery
assembly responsive to the command.
107. The assembly of claim 104 wherein the storage circuitry stores
the values comprising capacity information of the individual ones
of the rechargeable electrochemical devices.
108. The assembly of claim 104 wherein the storage circuitry stores
the values comprising state of charge information of the individual
ones of the rechargeable electrochemical devices.
109. The assembly of claim 104 wherein the storage circuitry stores
the values comprising charge/discharge cycle information of the
individual ones of the rechargeable electrochemical devices.
110. The assembly of claim 104 wherein the storage circuitry stores
the values comprising charging current information of the
individual ones of the rechargeable electrochemical devices.
111. The assembly of claim 104 wherein the storage circuitry stores
the values comprising discharging current information of the
individual ones of the rechargeable electrochemical devices.
112. The assembly of claim 104 wherein the storage circuitry stores
the status information comprising temperature information of the
battery assembly.
113. The assembly of claim 104 wherein one of the temporal data
entries for an individual one of the moments in time is associated
with the values of the characteristic for the rechargeable
electrochemical devices at the individual one of the moments in
time.
114. The assembly of claim 113 wherein the one of the temporal data
entries comprises at least one of date and time information for the
individual one of the moments in time.
115. The assembly of claim 104 wherein the storage circuitry stores
the values at the plurality of moments in time which are determined
according to a period.
116. The assembly of claim 104 wherein the storage circuitry stores
the status information comprising a length of time of use of the
battery assembly.
117. The assembly of claim 104 wherein the battery assembly further
comprises a housing configured to house the rechargeable
electrochemical devices and the storage circuitry, and wherein the
power terminal is configured to conduct the electricity from the
rechargeable electrochemical devices externally of the housing.
118. The assembly of claim 104 wherein the status information
comprises different information regarding different characteristics
of the different individual ones of the rechargeable
electrochemical devices.
119. The assembly of claim 104 wherein some of the values of the
characteristic represent values for one of the rechargeable
electrochemical devices and others of the values of the
characteristic represent values for an other of the rechargeable
electrochemical devices.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent claims priority to U.S. Provisional Patent
Application Ser. No. 60/505,125, filed Sep. 22, 2003, entitled
"Large Format Secondary Battery", and U.S. Provisional Patent
Application Ser. No. 60/559,171, filed Mar. 31, 2004, entitled
"Electrical Systems, Power Supply Apparatuses, and Power Supply
Operations Methods," the disclosures of which are incorporated by
reference.
TECHNICAL FIELD
[0002] This invention relates to electrical systems, power supply
apparatuses, and power supply operational methods.
BACKGROUND OF THE DISCLOSURE
[0003] The use and reliance upon electrical devices continue to
increase as existing electrical devices are improved and new
electrical devices are introduced. For example, computing devices,
communications equipment and other devices which utilize electrical
energy for proper operation have experienced remarkable
improvements in recent decades. Enhanced processing capabilities,
bandwidth and other improvements have led to usage of the
electrical devices in more diverse applications by more users.
[0004] There have also been remarkable improvements with respect to
devices utilized to supply electrical energy to the electrical
devices. For example, the development and introduction of new
compositions have led to batteries of increased capacity, safety
and longevity. Rechargeable batteries have also experienced
improvements with respect to the number of charge and discharge
cycles which may be implemented as well as storage capacities of
the batteries themselves. Accordingly, batteries are used in an
increasing number of applications to provide operational energy for
associated electrical devices.
[0005] Some electrical device configurations which utilize
batteries may be in remote or relatively inaccessible
installations. For example, cell towers for wireless
telecommunications may be installed at large distances from service
centers, on tops of mountains, or at other locations of relative
inconvenience. In some of these applications, it may be desired to
provide continuous operability or to minimize downtimes. However,
some conventional configurations have a technician service the
batteries but service calls at remote or relatively inaccessible
installations may be time consuming and/or costly. Accordingly, at
least some aspects of the disclosure provide improved apparatus and
methods for supplying electrical energy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Preferred embodiments of the disclosure are described below
with reference to the following accompanying drawings.
[0007] FIG. 1 is an illustrative representation of an exemplary
power supply apparatus of an electrical system according to one
embodiment.
[0008] FIG. 2A is a functional block diagram of an exemplary
electrical entity of an electrical system according to one
embodiment.
[0009] FIG. 2B is a functional block diagram of an exemplary power
supply apparatus of an electrical system according to one
embodiment.
[0010] FIG. 3 is a map illustrating how FIGS. 3A-3HH are to be
assembled, and once assembled, FIGS. 3A-3HH illustrate exemplary
circuitry of a power supply apparatus according to one
embodiment.
[0011] FIG. 4 is a map illustrating how FIGS. 4A-4EE are to be
assembled, and once assembled, FIGS. 4A-4EE illustrate additional
exemplary circuitry of the power supply apparatus according to one
embodiment.
[0012] FIG. 5 is a map illustrating how FIGS. 5A-5P are to be
assembled, and once assembled, FIGS. 5A-5P illustrate additional
exemplary circuitry of the power supply apparatus according to one
embodiment.
[0013] FIG. 6 is a map illustrating how FIGS. 6A-6HH are to be
assembled, and once assembled, FIGS. 6A-6HH illustrate additional
exemplary circuitry of the power supply apparatus according to one
embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] This disclosure of the invention 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).
[0015] Exemplary embodiments described herein include electrical
systems which may include a power supply apparatus which supplies
operational electrical energy and an electrical entity which uses
operational electrical energy. In some arrangements, the power
supply apparatus may operate as a backup source of electrical
energy during a failure of another source of electrical energy
(e.g., failure of a grid or other power distribution system). Other
embodiments or implementations of the electrical systems,
electrical entities and power supply apparatuses are possible.
[0016] Referring initially to FIG. 1, a portion of an embodiment of
an electrical system 10 comprising an exemplary power supply
apparatus 12 is shown. Although not shown in FIG. 1, electrical
system 10 may further include an electrical entity 14 and/or a
system manager 16 (references 14, 16 are shown in an exemplary
configuration in FIG. 2A in accordance with one embodiment). System
10 may comprise a plurality of apparatuses 12 and respective
entities 14 in some embodiments. Power supply apparatus 12 may be
configured to supply electrical energy and the respective
electrical entity 14 may be configured to utilize the electrical
energy as operational energy. System manager 16 may monitor
operations of apparatus 12 and/or entity 14 and/or may provide
control signals to control apparatus 12 and/or entity 14. Other
electrical system 10 configurations are possible.
[0017] In one exemplary configuration, power supply apparatus 12
may be configured as a backup device, such as an uninterruptible
power supply, configured to provide electrical energy during an
absence of electrical energy from another source of electrical
energy, for example source 36 of FIG. 2A which may comprise a
primary source of electrical energy. Power supply apparatus 12 and
electrical entity 14 may be physically proximately located with
respect to one another in one embodiment. Apparatus 12 and entity
14 may be located in the same structure in one implementation. Any
other arrangements are possible wherein apparatus 12 may provide
electrical energy to entity 14.
[0018] In one more specific example, power supply apparatus 12 may
supply electrical energy to electrical entity 14 comprising
telecommunications equipment, such as a cell station and configured
to implement data, voice and/or other communications. According to
this example, apparatus 12 and entity 14 may be located at the same
cell station. As mentioned above, the examples are provided for
illustration and understanding of exemplary aspects of the
disclosure and other embodiments or aspects are possible.
[0019] An exemplary power supply apparatus 12 may include one or
more battery assemblies 20 (e.g., only one assembly 20 is shown in
the example of FIG. 1) and a support system 22 configured to
support the battery assemblies 20. For example, in one
configuration, support system 22 is a rack and battery assemblies
20 may individually include a respective housing 24 configured to
at least partially house components of the battery assembly 20 and
to removably couple with support system 22.
[0020] As discussed further below, individual ones of assemblies 20
may include electrochemical storage circuitry configured to store
electrical energy as well as control circuitry configured to
control and monitor operations of the respective assembly 20 and
communications circuitry configured to implement communications
externally of apparatus 12. In another possible embodiment, one
control circuit (e.g., within one of assemblies 20, associated with
support system 22 or otherwise provided) may control and monitor
operations of a plurality of assemblies 20, and accordingly,
control circuitry of one or more of assemblies 20 may be omitted.
Other configurations of support system 22 and battery assemblies 20
are possible.
[0021] If a plurality of battery assemblies 20 are coupled with
support system 22, different ones of the battery assemblies 20 may
be associated with the same entity 14 or different electrical
entities 14. For example, plural battery assemblies 20 may be
configured to provide electrical energy in series or in parallel
with respect to a common electrical entity 14, or alternatively,
two or more of the battery assemblies 20 may be arranged to provide
electrical energy to two or more different electrical entities 14
(not shown).
[0022] Referring to FIG. 2A, an exemplary configuration of
electrical entity 14 includes an entity controller 23, a
communications interface 25, one or more loads 26, 28, and charge
circuitry 30. Communications interface 25 may be coupled with a
communications system 32, and loads 26, 28 and charge circuitry 30
may be coupled with a power bus 34. Other configurations of
electrical entity 14 are possible including more, less or
alternative components or circuits.
[0023] Additional components or circuitry of electrical system 10
may also be provided as shown. For example, in the depicted
exemplary embodiment, a system manager 16 and an additional source
36 of electrical energy are shown coupled with the communications
system 32 and power bus 34, respectively. System manager 16 may be
locally or remotely located with respect to apparatus 12 and/or
entity 14. In one arrangement, system manager 16 may be operated by
a telecommunications entity and be located remotely from (e.g., at
a central office) and configured to monitor operations of a
plurality of installations of apparatuses 12 and respective
entities 14.
[0024] If provided, additional source 36 may be configured to
supply operational electrical energy to assemblies 20 of apparatus
12, and/or entity 14. Additional source 36 may supply power from an
appropriate grid or other electrical energy distribution system,
generator, or any other appropriate source of electrical energy
(e.g., solar). Charge circuitry 30 may be configured to use
electrical energy from additional source 36 to implement charging
of electrochemical devices of one or more assembly 20 of apparatus
12 described below.
[0025] Entity controller 23 comprises a control system including
circuitry configured to implement desired programming. For example,
the controller 23 may be implemented as a processor or other
structure configured to execute executable instructions including,
for example, software and/or firmware instructions. Other exemplary
embodiments of controller include hardware logic, PGA, FPGA, ASIC,
state machines, and/or other structures. These examples of entity
controller 23 are for illustration and other configurations are
possible.
[0026] Entity controller 23 may also access storage circuitry
configured to store electronic data and/or programming such as
executable instructions (e.g., software and/or firmware), data, or
other digital information and may include processor-usable media.
Processor-usable media includes any article of manufacture which
can contain, store, or maintain programming, data and/or digital
information for use by or in connection with an instruction
execution system including controller 23 in the exemplary
embodiment. For example, exemplary processor-usable media may
include any one of physical media such as electronic, magnetic,
optical, electromagnetic, infrared or semiconductor media. Some
more specific examples of processor-usable media include, but are
not limited to, a portable magnetic computer diskette, such as a
floppy diskette, zip disk, hard drive, random access memory, read
only memory, flash memory, cache memory, and/or other
configurations capable of storing programming, data, or other
digital information. The storage circuitry may be embodied within
entity controller 23 or otherwise accessible thereby.
[0027] Entity controller 23 may control appropriate operations
pertinent to the respective implementation or application of
electrical entity 14. For example, if electrical entity 14
comprises telecommunications equipment in one embodiment, entity
controller 23 may control routing of calls via appropriate control
of switches (not shown). Entity controller 23 may also process and
formulate communications communicated using interface 25.
[0028] In addition or alternatively, entity controller 23 may
effect or control operations with respect to power consumption by
electrical entity 14. For example, entity controller 23 may process
status information (e.g., regarding electrical energy received from
power supply apparatus 12, condition of storage circuitry 60
described below, etc.) and also communicate commands to apparatus
12 as described further below. According to an additional example,
entity controller 23 may also control operations of one or more
load 26, 28 of the electrical entity 14. In one embodiment, loads
26, 28 may be assigned respective priorities, and if appropriate,
entity 14 may selectively disable one or more of loads 26, 28 to
reduce a rate of electrical energy used by entity 14. In addition,
entity controller 23 may also control charge circuitry 30. Further
exemplary operations of control of entity controller 23 are
described below.
[0029] Communications circuitry of entity 14 including
communications interface 25 may provide bi-directional external
communications of electrical entity 14 with respect to one or more
assembly 20 of power supply apparatus 12, system manager 16 and/or
other external devices using communications system 32, for example.
Communications interface 25 may implement wired, wireless or any
other appropriate form of communications. In one exemplary
arrangement, entity 14 is configured to receive status information
from apparatus 12 and to communicate commands to apparatus 12 using
interface 25. Exemplary status includes electrical characteristics
of assembly 20 or electrical energy supplied using assembly 20
(e.g., voltage of one or more of electrochemical devices 62, charge
or discharge current with respect to electrochemical devices 62,
state of charge, remaining capacity, etc.), temperature conditions
of devices 62 of assembly 20, or any other desired information.
Exemplary commands communicated from entity 14 to one or more
assembly 20 may instruct the respective assembly 20 to go off-line
(e.g., open switching device 52 and/or enter sleep mode as
described further below) or other desired operations.
[0030] Entity 14 comprises a plurality of loads 26, 28 in the
illustrated embodiment and may be referred to as entity loads. The
other depicted components including entity controller 23, and
communications interface 25, may also be referred to as loads.
Other possible configurations of entity 14 may include a single
load. Loads 26, 28 utilize electrical energy during operations of
entity 14. Loads 26, 28 may receive operational electrical energy
(e.g., 48 Volts DC) from power bus 34 for example supplied by the
power supply apparatus 12. Further, other components including
entity controller 23 and communications interface 25 may also
receive operational electrical energy from power bus 34 (e.g., at
reduced voltages in one embodiment).
[0031] In the described telecommunications equipment embodiment,
loads 26, 28 may comprise switching or other circuitry configured
to enable telecommunications using entity 14. Loads 26, 28 may be
assigned priorities and be selectively individually shut down to
reduce usage of electrical energy by entity 14. For example, if
storage capacity of one or more assembly 20 of apparatus 12 falls,
entity controller 23 may individually shut down one or more loads
26, 28 from lowest to highest priorities. In one more specific
exemplary implementation, controller 23 may process received status
information of one or more assembly 20 of apparatus 12 and effect
or adjust an operation of entity 14 responsive to received status
information. In one configuration, controller 23 may adjust energy
usage of entity 14 responsive to the processing. One exemplary
operation includes curtailment of energy usage by one or more of
the loads 26, 28 responsive to one or more assembly 20 supplying
energy approaching an end of charge, low voltage, excessive
temperature, excessive discharge current, or other status, and also
perhaps an absence of electrical energy from source 36. Another
operation which may be effected responsive to received status
information includes turning on or off charge circuitry 30. Other
embodiments are possible.
[0032] Charge circuitry 30 is coupled with and controlled by entity
controller 23 in the illustrated embodiment. Charge circuitry 30 is
also coupled with power bus 34 to charge electrochemical devices of
one or more assembly 20 of apparatus 12 using electrical energy
from source 36 in one embodiment. Entity controller 23 may
selectively enable and disable charge circuitry 30, for example,
based upon status information received from one or more assembly 20
of apparatus 12.
[0033] Communications system 32 may be arranged in any appropriate
configuration to communicate data intermediate one or more assembly
20 of power supply apparatus 12, entity 14, system manager 16,
and/or any other appropriate device. Communications system 32 may
provide bi-directional or uni-directional communications with
respect to any device coupled therewith in possible
implementations. Further, any appropriate data may be communicated
using communications system 32.
[0034] Power bus 34 conducts direct current electrical energy
intermediate one or more assembly 20 of apparatus 12, entity 14 and
source 36 in the described embodiment. In the described exemplary
telecommunications embodiment, power bus 34 provides direct current
electrical energy at 48 Volts from apparatus 12 to entity 14
although electrical energy having other electrical characteristics
is possible in other embodiments.
[0035] Referring to FIG. 2B, additional details regarding an
exemplary configuration of one embodiment of a battery assembly 20
of power supply apparatus 12 are shown. As mentioned above, plural
assemblies 20 may be provided for a single apparatus 12 and have
the same configuration. Additional configurations of apparatus 12
are possible, for example, wherein plural assemblies 20 of
apparatus 12 are configured differently from one another (e.g.,
with or without control circuitry, having different numbers or
configurations of electrochemical devices, etc.).
[0036] The illustrated assembly 20 includes positive and negative
power terminals 40, 42, a communications interface 44, control
circuitry 46 (including a state of charge gauge and communications
processor 48 and a cell measurement and balance processor 50 in the
illustrated embodiment), a switching device 52, an auxiliary power
supply 54, a user switch 56, electrical energy storage circuitry 60
comprising a plurality of rechargeable electrochemical devices 62,
a communications bus 64, one or more temperature sensors 66 and a
current measurement device 68. Other configurations of battery
assembly 20 are possible including more, less or alternative
components or circuits.
[0037] Positive and negative power terminals 40, 42 are configured
to couple with power bus 34. Electrical energy stored within
circuitry 60 may be provided via power terminals 40, 42 and power
bus 34 to electrical entity 14. Further, electrical energy for
charging storage circuitry 60 may be received by power terminals
40, 42 from power bus 34.
[0038] Communications circuitry of assembly 20 includes
communications interface 44 which may provide bi-directional
communications of assembly 20 with respect to electrical entity 14,
system manager 16, other assemblies 20 and/or other external
devices using communications system 32, for example. Communications
interface 44 may implement wired, wireless or any other appropriate
form of communications. In one example, communications interface 44
comprises an RS-485 interface. Interface 44 may output status
information compiled by control circuitry 46 for communication to
entity 14 and/or system manager 16 and receive commands from entity
14 and/or system manager 16 in one embodiment.
[0039] Control circuitry 46 includes plural processors 48, 50
individually configured to execute desired programming and to
exchange communications with one another in the depicted
embodiment. Portions of control circuitry 46 configured to execute
programming may be referred to as processing circuitry. Processors
48, 50 may also comprise internal storage circuitry comprising
processor-usable media configured to store data, programming, or
other information similar to storage circuitry of entity 14 in one
embodiment. Other configurations of control circuitry 46 or
additional components of control circuitry 46 are possible
including, for example, hardware circuitry (e.g., ASIC, FPGA,
analog or logic circuitry) and/or hardware in combination with
circuitry configured to execute programming. For example, in the
embodiments of FIGS. 3-6 described below, control circuitry in
addition to processors 48, 50 is provided. The additional control
circuitry may also control and monitor operations of the respective
assembly 20.
[0040] Appropriate storage circuitry may be utilized to provide a
history of operations of assembly 20. For example, processors 48,
50 may be configured to store date and time information for
electrical and/or environmental characteristics of the respective
assembly 20 (e.g., overvoltage, undervoltage, state of charge,
capacity, temperature, etc.) at plural moments in time during
plural operational modes of assembly 20 (e.g., normal and sleep
modes). A history may be generated comprising electrical and/or
environmental characteristics at desired moments in time (e.g.,
periodic).
[0041] In one embodiment, processor 48 is configured to implement
external communications via communications interface 44, control
switching device 52, control power supply 54, and monitor switch
56. Processor 50 may be configured to monitor status of assembly 20
including characteristics of electrical energy of assembly 20
(e.g., operation of power supply 54, voltage of one or more of
electrochemical devices 62, charge or discharge current with
respect to electrochemical devices 62, etc.), environmental
conditions of assembly 20 (e.g., temperature sensing), state of
switching device 52, and/or whether a load and/or charge circuitry
is coupled with power terminals 40, 42. Control circuitry 46 may
also be configured to control and/or monitor additional operations
of the respective assembly and control sleep mode operations
according to the exemplary embodiments of FIGS. 3-6. Control
circuitry 46 may process commands received from interface 44 and
effect at least one operation of assembly 20 responsive to the
commands (e.g., open switching device 52, enter sleep mode,
etc.).
[0042] Switching device 52 is coupled in series with negative power
terminal 42 and a negative node of the electrical energy storage
circuitry 60. Switching device 52 is controlled by control
circuitry 46 to permit selective charging/discharging of electrical
energy of storage circuitry 60.
[0043] During normal operation of assembly 20, switching device 52
may be closed to permit charging or discharging of storage
circuitry 60. Further, switching device 52 may be controlled to
reduce or prevent detrimental operation of assembly 20. For
example, switching device 52 may be opened during periods of
storage or inactivity of assembly 20 to reduce discharge of
electrical energy from storage circuitry 60. Switching device 52
may be opened responsive to monitored operation of assembly 20
detecting a triggering event. For example, switching device 52 may
be opened if one or more electrochemical devices 62 of storage
circuitry 60 enter an over or under voltage condition or if
excessive current is being conducted to or from storage circuitry
60. Further, switching device 52 may be opened during a temperature
overage condition of assembly 20. Switching device 52 may be opened
responsive to external communications received within assembly 20
(e.g., responsive to a command received from electrical entity 14).
Additional control of switching device 52 is possible.
[0044] Switching device 52 may be embodied as a bistable contractor
in one implementation. Only a brief current pulse into a coil of
the device 52 is utilized to change the state of the device 52 in
the described exemplary implementation. In one embodiment, a
positive current pulse closes the device 52 and a negative current
pulse opens the device 52 and the device 52 remains in its present
condition during an absence of coil current.
[0045] Power supply 54 may be referred to as an auxiliary power
supply. Power supply 54 is configured to provide operational
electrical energy for use by circuitry of assembly 20. For example,
power supply 54 may be configured to provide direct current
voltages of 3.3 V, 5 V, 6 V, or 75 V and a peak-to-peak alternating
current voltage of 12 V in the embodiment of FIGS. 3-6 described
below. In one embodiment, power supply 54 converts the voltage of
the electrical energy of storage circuitry 60 to +6 Vdc and which
is further regulated by respective regulators to 3.3V and 5V (U8,
U16 of FIGS. 3A, 3B, respectively).
[0046] Power supply 54 may receive operational electrical energy
from source 36 and/or storage circuitry 60. Power supply 54 may be
selectively deactivated to conserve electrical energy in at least
one embodiment and as discussed further below (e.g., in sleep
mode).
[0047] User switch 56 may be controlled by a user to effect desired
operations of assembly 20. For example, if assembly is in sleep
mode to conserve electrical energy, user switch 56 may be depressed
by the user to awake circuitry of assembly 20 from sleep mode and
to enter a higher level of operation. Other operations may be
controlled by user switch 56.
[0048] Electrical energy storage circuitry 60 comprises one or more
rechargeable electrochemical device 62 coupled in any appropriate
series and/or parallel configuration corresponding to the
electrical entity 14 being powered. In the exemplary
telecommunications equipment application, storage circuitry 60
includes sixteen electrochemical devices 62 coupled in series and
configured to provide direct current electrical energy of
approximately 48 Volts for use by electrical entity 14.
[0049] In the depicted exemplary embodiment, individual ones of the
electrochemical devices 62 are configured to provide direct current
electrical energy having a voltage of 3 Volts. Electrochemical
devices 62 may individually comprise a plurality of electrochemical
cells coupled in series and/or parallel. Exemplary electrochemical
cells (e.g., 18650 format cells) comprise lithium Saphion.RTM.
cells available from Valence Technology, Inc. In the described
embodiment, individual ones of electrochemical devices 62 comprise
thirty-five of such cells coupled in parallel. Other embodiments
are possible wherein electrochemical cells of other chemistries or
configurations may be utilized.
[0050] Exemplary cells of devices 62 described above include a
positive electrode, a negative electrode, and an electrolyte in
ion-transfer relationship with each electrode. As used herein, the
word "include," and its variants, is intended to be non-limiting,
such that recitation of items in a list is not to the exclusion of
other like items that may also be useful in the materials,
compositions, devices, and methods described herein. As mentioned
above, two or more electrochemical cells may be combined in
parallel or series, or "stacked," so as to create a multi-cell
device 62. Other embodiments are possible.
[0051] Exemplary electrode active materials described herein may be
used in the negative electrode, the positive electrode, or both
electrodes of a cell. Preferably, the active materials are used in
the positive electrode (As used herein, the terms "negative
electrode" and "positive electrode" refer to the electrodes at
which oxidation and reduction occur, respectively, during
discharge; during charging, the sites of oxidation and reduction
are reversed). The terms "preferred" and "preferably" as used
herein refer to embodiments of the invention that afford certain
benefits, under certain circumstances. However, other embodiments
may also be preferred, under the same or other circumstances.
Furthermore, the recitation of one or more preferred embodiments
does not imply that other embodiments are not useful and is not
intended to exclude other embodiments.
[0052] Electrochemical cells may include alkali metal-containing
electrode active material. In one embodiment, the active material
is represented by the nominal general formula (I):
[A.sub.a,D.sub.d]M.sub.m(XY.sub.4).sub.pZ.sub.e, (I)
wherein: [0053] (i) A is selected from the group consisting of
elements from Group I of the Periodic Table, and mixtures thereof,
and 0<a.ltoreq.9; [0054] (ii) D is at least one element with a
valence state of .gtoreq.2+, and 0.ltoreq.d.ltoreq.1; [0055] (iii)
M includes at least one redox active element, and
1.ltoreq.m.ltoreq.3; [0056] (iv) XY.sub.4 is selected from the
group consisting of X'[O.sub.4-x,Y'.sub.x],
X'[O.sub.4-y,Y'.sub.2y], X''S.sub.4,
[X.sub.z''',X'.sub.1-z]O.sub.4, and mixtures thereof, wherein:
[0057] (a) X' and X''' are each independently selected from the
group consisting of P, As, Sb, Si, Ge, V, S, and mixtures thereof;
[0058] (b) X'' is selected from the group consisting of P, As, Sb,
Si, Ge, V, and mixtures thereof; [0059] (c) Y' is selected from the
group consisting of a halogen, S, N, and mixtures thereof; and
[0060] (d) 0.ltoreq.x.ltoreq.3, 0.ltoreq.y.ltoreq.2,
0.ltoreq.z.ltoreq.1, and 1.ltoreq.p.ltoreq.3; and [0061] (v) Z is
OH, a halogen, or mixtures thereof, and 0.ltoreq.e.ltoreq.4;
wherein A, D, M, X, Y, Z, a, d, x, y, z, p and e are selected so as
to maintain electroneutrality of the material.
[0062] The term "nominal general formula" refers to the fact that
the relative proportion of atomic species may vary slightly on the
order of 2 percent to 5 percent, or more typically, 1 percent to 3
percent. The composition of A, D, M, XY.sub.4 and Z of general
formulas (I) through (V) herein, as well as the stoichiometric
values of the elements of the active material, are selected so as
to maintain electroneutrality of the electrode active material. The
stoichiometric values of one or more elements of the composition
may take on non-integer values.
[0063] For all embodiments described herein, A is selected from the
group consisting of elements from Group I of the Periodic Table,
and mixtures thereof (e.g. A.sub.a=A.sub.a-a'A'.sub.a', wherein A
and A' are each selected from the group consisting of elements from
Group I of the Periodic Table and are different from one another,
and a'<a). As referred to herein, "Group" refers to the Group
numbers (i.e., columns) of the Periodic Table as defined in the
current IUPAC Periodic Table. (See, e.g., U.S. Pat. No. 6,136,472,
Barker et al., issued Oct. 24, 2000, incorporated by reference
herein.) In addition, the recitation of a genus of elements,
materials or other components, from which an individual component
or mixture of components can be selected, is intended to include
all possible sub-generic combinations of the listed components, and
mixtures thereof.
[0064] In one embodiment, A is selected from the group consisting
of Li (Lithium), Na (Sodium), K (Potassium), and mixtures thereof.
A may be mixture of Li with Na, a mixture of Li with K, or a
mixture of Li, Na and K. In another embodiment, A is Na, or a
mixture of Na with K. In one preferred embodiment, A is Li.
[0065] A sufficient quantity (a) of moiety A should be present so
as to allow all of the "redox active" elements of the moiety M (as
defined herein below) to undergo oxidation/reduction. In one
embodiment, 0<a.ltoreq.9. In another embodiment,
0<a.ltoreq.2. Unless otherwise specified, a variable described
herein algebraically as equal to ("="), less than or equal to
(".ltoreq."), or greater than or equal to (".gtoreq.") a number is
intended to subsume values or ranges of values about equal or
functionally equivalent to said number.
[0066] Removal of an amount of A from the electrode active material
is accompanied by a change in oxidation state of at least one of
the "redox active" elements in the active material, as defined
herein below. The amount of redox active material available for
oxidation/reduction in the active material determines the amount
(a) of the moiety A that may be removed. Such concepts are, in
general application, well known in the art, e.g., as disclosed in
U.S. Pat. No. 4,477,541, Fraioli, issued Oct. 16, 1984; and U.S.
Pat. No. 6,136,472, Barker, et al., issued Oct. 24, 2000, both of
which are incorporated by reference herein.
[0067] In general, the amount (a) of moiety A in the active
material varies during charge/discharge. Where the active materials
are synthesized for use in preparing an alkali metal-ion battery in
a discharged state, such active materials are characterized by a
relatively high value of "a", with a correspondingly low oxidation
state of the redox active components of the active material. As the
electrochemical cell is charged from its initial uncharged state,
an amount (b) of moiety A is removed from the active material as
described above. The resulting structure, containing less amount of
the moiety A (i.e., a-b) than in the as-prepared state, and at
least one of the redox active components having a higher oxidation
state than in the as-prepared state, while essentially maintaining
the original values of the remaining components (e.g. D, M, X, Y
and Z). The active materials of this invention include such
materials in their nascent state (i.e., as manufactured prior to
inclusion in an electrode) and materials formed during operation of
the battery (i.e., by insertion or removal of A).
[0068] For all embodiments described herein, D is at least one
element having an atomic radius substantially comparable to that of
the moiety being substituted (e.g. moiety M and/or moiety A). In
one embodiment, D is at least one transition metal. Examples of
transition metals useful herein with respect to moiety D include,
without limitation, Nb (Niobium), Zr (Zirconium), Ti (Titanium), Ta
(Tantalum), Mo (Molybdenum), W (Tungsten), and mixtures thereof. In
another embodiment, moiety D is at least one element characterized
as having a valence state of .gtoreq.2+ and an atomic radius that
is substantially comparable to that of the moiety being substituted
(e.g. M and/or A). With respect to moiety A, examples of such
elements include, without limitation, Nb (Niobium), Mg (Magnesium)
and Zr (Zirconium). Preferably, the valence or oxidation state of D
(V.sup.D) is greater than the valence or oxidation state of the
moiety (or sum of oxidation states of the elements consisting of
the moiety) being substituted for by moiety D (e.g. moiety M and/or
moiety A).
[0069] While not wishing to be held to any one theory, with respect
to moiety A, it is thought that by incorporating a dopant (D) into
the crystal structure of the active material, wherein the amount
(a) of moiety A initially present in the active material is
substituted by an amount of D, the dopant will occupy sites in the
active material normally occupied by A, thus substantially
increasing the ionic and electrical conductivity of the active
material. Such materials additionally exhibit enhanced electrical
conductivity, thus reducing or eliminating the need for
electrically conductive material (e.g. carbon) in the electrode.
Reduction or elimination of carbonaceous materials in secondary
electrochemical cells, including those disclosed herein, is
desirable because of the long-term deleterious effects carbonaceous
materials produce during the operation of the electrochemical cells
(e.g. promotion of gas production within the electrochemical cell).
Reduction or elimination of the carbonaceous material also permits
insertion of a greater amount of active material, thereby
increasing the electrochemical cell's capacity and energy
density.
[0070] Moiety A may be partially substituted by moiety D by
aliovalent or isocharge substitution, in equal or unequal
stoichiometric amounts. "Isocharge substitution" refers to a
substitution of one element on a given crystallographic site with
an element having the same oxidation state (e.g. substitution of
Ca.sup.2+ with Mg.sup.2+). "Aliovalent substitution" refers to a
substitution of one element on a given crystallographic site with
an element of a different oxidation state (e.g. substitution of
Li.sup.+ with Mg.sup.2+).
[0071] For all embodiments described herein where moiety A is
partially substituted by moiety D by isocharge substitution, A may
be substituted by an equal stoichiometric amount of moiety D,
whereby the active material is represented by the nominal general
formula (II):
[A.sub.a-f,D.sub.d]M.sub.m(XY.sub.4).sub.pZ.sub.e, (II)
wherein f=d.
[0072] Where moiety A of general formula (II) is partially
substituted by moiety D by isocharge substitution and d.noteq.f,
then the stoichiometric amount of one or more of the other
components (e.g. A, M, XY.sub.4 and Z) in the active material is
adjusted in order to maintain electroneutrality.
[0073] For all embodiments described herein where moiety A is
partially substituted by moiety D by aliovalent substitution,
moiety A may be substituted by an "oxidatively" equivalent amount
of moiety D, whereby the active material is represented by the
nominal general formula (III):
[ A a - f V A , D d V D ] M m ( XY 4 ) p Z e , ( III )
##EQU00001##
wherein f=d, V.sup.A is the oxidation state of moiety A (or sum of
oxidation states of the elements consisting of the moiety A), and
V.sup.D is the oxidation state of moiety D.
[0074] Where moiety A of general formula (III) is partially
substituted by moiety D by aliovalent substitution and d.noteq.f,
then the stoichiometric amount of one or more of the other
components (e.g. A, M, XY.sub.4 and Z) in the active material is
adjusted in order to maintain electroneutrality.
[0075] In one embodiment, moiety M is partially substituted by
moiety D by aliovalent or isocharge substitution, in equal or
unequal stoichiometric amounts. In this embodiment, d.gtoreq.0,
wherein moiety A may be substituted by moiety D by aliovalent or
isocharge substitution, in equal or unequal stoichiometric amounts.
Where moieties M and A are both partially substituted by moiety D,
the elements selected for substitution for each moiety may be the
same or different from one another.
[0076] For all embodiments described herein where moiety M is
partially substituted by moiety D by isocharge substitution, M may
be substituted by an equal stoichiometric amount of moiety D,
whereby M=[M.sub.m-u,D.sub.v], wherein u=v. Where moiety M is
partially substituted by moiety D by isocharge substitution and
u.noteq.v, then the stoichiometric amount of one or more of the
other components (e.g. A, M, XY.sub.4 and Z) in the active material
is adjusted in order to maintain electroneutrality.
[0077] For all embodiments described herein where moiety M is
partially substituted by moiety D by aliovalent substitution,
moiety M may be substituted by an "oxidatively" equivalent amount
of moiety D, whereby
[ M m - u V M , D v V D ] , ##EQU00002##
wherein u=v, V.sup.M is the oxidation state of moiety M (or sum of
oxidation states of the elements consisting of the moiety M), and
V.sup.D is the oxidation state of moiety D.
[0078] Where moiety M is partially substituted by moiety D by
aliovalent substitution and u.noteq.v, then the stoichiometric
amount of one or more of the other components (e.g. A, M, XY.sub.4
and Z) in the active material is adjusted in order to maintain
electroneutrality.
[0079] In this embodiment, moiety M and (optionally) moiety A are
each partially substituted by aliovalent or isocharge substitution.
While not wishing to be held to any one theory, it is thought that
by incorporating a dopant (D) into the crystal structure of the
active material in this manner, wherein the stoichiometric values M
and (optionally) A are dependent on (reduced by) the amount of
dopant provided for each crystallographic site, that the dopant
will occupy sites in the active material normally occupied by
moiety M and (optionally) moiety A. First, where
V.sup.D>V.sup.A, doping sites normally occupied by A increases
the number of available or unoccupied sites for A, thus
substantially increasing the ionic and electrical conductivity of
the active material. Second, doping the M sites reduces the
concentration of available redox active elements, thus ensuring
some amount of A remains in the active material upon charge,
thereby increasing the structural stability of the active material.
Such materials additionally exhibit enhanced electrical
conductivity, thus reducing or eliminating the need for
electrically conductive material in the electrode.
[0080] In all embodiments described herein, moiety M is at least
one redox active element. As used herein, the term "redox active
element" includes those elements characterized as being capable of
undergoing oxidation/reduction to another oxidation` state when the
electrochemical cell is operating under normal operating
conditions. As used herein, the term "normal operating conditions"
refers to the intended voltage at which the cell is charged, which,
in turn, depends on the materials used to construct the cell.
[0081] Redox active elements useful herein with respect to moiety M
include, without limitation, elements from Groups 4 through 11 of
the Periodic Table, as well as select non-transition metals,
including, without limitation, Ti (Titanium), V (Vanadium), Cr
(Chromium), Mn (Manganese), Fe (Iron), Co (Cobalt), Ni (Nickel), Cu
(Copper), Nb (Niobium) Mo (Molybdenum), Ru (Ruthenium), Rh
(Rhodium), Pd (Palladium), Os (Osmium), Ir (Iridium), Pt
(Platinum), Au (Gold), Si (Silicon), Sn (Tin), Pb (Lead), and
mixtures thereof. Also, "include," and its variants, is intended to
be non-limiting, such that recitation of items in a list is not to
the exclusion of other like items that may also be useful in the
materials, compositions, devices, and methods of this
invention.
[0082] In one embodiment, moiety M is a redox active element. In
one subembodiment, M is a redox active element selected from the
group consisting of Ti.sup.2+, V.sup.2+, Cr.sup.2+, Mn.sup.2+,
Fe.sup.2+, Co.sup.2+, Ni.sup.2+, Cu.sup.2+, Mo.sup.2+, Si.sup.2+,
Sn.sup.2+, and Pb.sup.2+. In another subembodiment, M is a redox
active element selected from the group consisting of Ti.sup.3+,
V.sup.3+, Cr.sup.3+, Mn.sup.3+, Fe.sup.3+, Co.sup.3+, Ni.sup.3+,
Mo.sup.3+, and Nb.sup.3+.
[0083] In another embodiment, moiety M is a mixture of redox active
elements or a mixture of at least one redox active element and at
least one non-redox active element. As referred to herein,
"non-redox active elements" include elements that are capable of
forming stable active materials, and do not undergo
oxidation/reduction when the electrode active material is operating
under normal operating conditions.
[0084] Among the non-redox active elements useful herein include,
without limitation, those selected from Group 2 elements,
particularly Be (Beryllium), Mg (Magnesium), Ca (Calcium), Sr
(Strontium), Ba (Barium); Group 3 elements, particularly Sc
(Scandium), Y (Yttrium), and the lanthanides, particularly La
(Lanthanum), Ce (Cerium), Pr (Praseodymium), Nd (Neodymium), Sm
(Samarium); Group 12 elements, particularly Zn (Zinc) and Cd
(Cadmium); Group 13 elements, particularly B (Boron), Al
(Aluminum), Ga (Gallium), In (Indium), Tl (Thallium); Group 14
elements, particularly C (Carbon) and Ge (Germanium), Group 15
elements, particularly As (Arsenic), Sb (Antimony), and Bi
(Bismuth); Group 16 elements, particularly Te (Tellurium); and
mixtures thereof.
[0085] In one embodiment, M=MI.sub.nMII.sub.o, wherein
0<o+n.ltoreq.3 and each of o and n is greater than zero
(0<o,n), wherein MI and MII are each independently selected from
the group consisting of redox active elements and non-redox active
elements, wherein at least one of MI and MII is redox active. MI
may be partially substituted with MII by isocharge or aliovalent
substitution, in equal or unequal stoichiometric amounts.
[0086] For all embodiments described herein where MI is partially
substituted by MII by isocharge substitution, MI may be substituted
by an equal stoichiometric amount of MII, whereby
M=MI.sub.n-oMII.sub.o. Where MI is partially substituted by MII by
isocharge substitution and the stoichiometric amount of MI is not
equal to the amount of MII, whereby M=MI.sub.n-oMII.sub.o and
o.noteq.p, then the stoichiometric amount of one or more of the
other components (e.g. A, D, XY.sub.4 and Z) in the active material
is adjusted in order to maintain electroneutrality.
[0087] For all embodiments described herein where MI is partially
substituted by MII by aliovalent substitution and an equal amount
of MI is substituted by an equal amount of MII, whereby
M=MI.sub.n-oMII.sub.o, then the stoichiometric amount of one or
more of the other components (e.g. A, D, XY.sub.4 and Z) in the
active material is adjusted in order to maintain electroneutrality.
However, MI may be partially substituted by Mil by aliovalent
substitution by substituting an "oxidatively" equivalent amount of
MII for MI, whereby
M = MI n - o V MI MII o V MII , ##EQU00003##
wherein V.sup.MI is the oxidation state of MI, and V.sup.MII is the
oxidation state of MII.
[0088] In one subembodiment, MI is selected from the group
consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Mo, Si, Pb, Mo, Nb,
and mixtures thereof, and MII is selected from the group consisting
of Be, Mg, Ca, Sr, Ba, Sc, Y, Zn, Cd, B, Al, Ga, In, C, Ge, and
mixtures thereof. In this subembodiment, MI may be substituted by
MII by isocharge substitution or aliovalent substitution.
[0089] In another subembodiment, MI is partially substituted by MII
by isocharge substitution. In one aspect of this subembodiment, MI
is selected from the group consisting of Ti.sup.2+, V.sup.2+,
Cr.sup.2+, Mn.sup.2+, Fe.sup.2+, Co.sup.2+, Ni.sup.2+, Cu.sup.2+,
Mo.sup.2+, Si.sup.2+, Sn.sup.2+, Pb.sup.2+, and mixtures thereof,
and Mil is selected from the group consisting of Be.sup.2+,
Mg.sup.2+, Ca.sup.2+, Sr.sup.2+, Ba.sup.2+, Zn.sup.2+, Cd.sup.2+,
Ge.sup.2+, and mixtures thereof. In another aspect of this
subembodiment, MI is selected from the group specified immediately
above, and MII is selected from the group consisting of Be.sup.2+,
Mg.sup.2+, Ca.sup.2+, Sr.sup.2+, Ba.sup.2+, and mixtures thereof.
In another aspect of this subembodiment, MI is selected from the
group specified above, and Mil is selected from the group
consisting of Zn.sup.2+, Cd.sup.2+, and mixtures thereof. In yet
another aspect of this subembodiment, MI is selected from the group
consisting of Ti.sup.3+, V.sup.3+, Cr.sup.3+, Mn.sup.3+, Fe.sup.3+,
Co.sup.3+, Ni.sup.3+, Mo.sup.3+, Nb.sup.3+, and mixtures thereof,
and MII is selected from the group consisting of Sc.sup.3+,
Y.sup.3+, B.sup.3+, Al.sup.3+, Ga.sup.3+, In.sup.3+, and mixtures
thereof.
[0090] In another embodiment, MI is partially substituted by MII by
aliovalent substitution. In one aspect of this subembodiment, MI is
selected from the group consisting of Ti.sup.2+, V.sup.2+,
Cr.sup.2+, Mn.sup.2+, Fe.sup.2+, Co.sup.2+, Ni.sup.2+, Cu.sup.2+,
Mo.sup.2+, Si.sup.2+, Sn.sup.2+, Pb.sup.2+, and mixtures thereof,
and MII is selected from the group consisting of Sc.sup.3+,
Y.sup.3+, B.sup.3+, Al.sup.3+, Ga.sup.3+, In.sup.3+, and mixtures
thereof. In another aspect of this subembodiment, MI is a 2+
oxidation state redox active element selected from the group
specified immediately above, and MII is selected from the group
consisting of alkali metals, Cu.sup.1+, Ag.sup.1+ and mixtures
thereof. In another aspect of this subembodiment, MI is selected
from the group consisting of Ti.sup.3+, V.sup.3+, Cr.sup.3+,
Mn.sup.3+, Fe.sup.3+, Co.sup.3+, Ni.sup.3+, Mo.sup.3+, Nb.sup.3+,
and mixtures thereof, and MII is selected from the group consisting
of Be.sup.2+, Mg.sup.2+, Ca.sup.2+, Sr.sup.2+, Ba.sup.2+,
Zn.sup.2+, Cd.sup.2+, Ge.sup.2+, and mixtures thereof. In another
aspect of this subembodiment, MI is a 3+ oxidation state redox
active element selected from the group specified immediately above,
and MII is selected from the group consisting of alkali metals,
Cu.sup.1+, Ag.sup.1+ and mixtures thereof.
[0091] In another embodiment, M=M1.sub.qM2.sub.rM3.sub.s,
wherein:
[0092] (a) M1 is a redox active element with a 2+ oxidation
state;
[0093] (b) M2 is selected from the group consisting of redox and
non-redox active elements with a 1+ oxidation state;
[0094] (c) M3 is selected from the group consisting of redox and
non-redox active elements with a 3+ oxidation state; and
[0095] (d) at least one of p, q and r is greater than 0, and at
least one of M1, M2, and M3 is redox active.
[0096] In one subembodiment, M1 is substituted by an equal amount
of M2 and/or M3, whereby q=q-(r+s). In this subembodiment, then the
stoichiometric amount of one or more of the other components (e.g.
A, XY.sub.4, Z) in the active material is adjusted in order to
maintain electroneutrality.
[0097] In another subembodiment, M.sup.1 is substituted by an
"oxidatively" equivalent amount of M.sup.2 and/or M.sup.3,
whereby
M = M 1 q - r V M 1 - s V M 1 M 2 r V M 2 M 3 s V M 3 ,
##EQU00004##
wherein V.sup.M1 is the oxidation state of M1, V.sup.M2 is the
oxidation state of M2, and V.sup.M3 is the oxidation state of
M3.
[0098] In one subembodiment, M1 is selected from the group
consisting of Ti.sup.2+, V.sup.2+, Cr.sup.2+, Mn.sup.2+, Fe.sup.2+,
Co.sup.2+, Ni.sup.2+, Cu.sup.2+, Mo.sup.2+, Si.sup.2+, Sn.sup.2+,
Pb.sup.2+, and mixtures thereof; M2 is selected from the group
consisting of Cu.sup.1+, Ag.sup.1+ and mixtures thereof; and M3 is
selected from the group consisting of Ti.sup.3+, V.sup.3+,
Cr.sup.3+, Mn.sup.3+, Fe.sup.3+, Co.sup.3+, Ni.sup.3+, Mo.sup.3+,
Nb.sup.3+, and mixtures thereof. In another subembodiment, M1 and
M3 are selected from their respective preceding groups, and M2 is
selected from the group consisting of Li.sup.1+, K.sup.1+,
Na.sup.1+, Ru.sup.1+, Cs.sup.1+, and mixtures thereof.
[0099] In another subembodiment, M1 is selected from the group
consisting of Be.sup.2+, Mg.sup.2+, Ca.sup.2+, Sr.sup.2+,
Ba.sup.2+, Zn.sup.2+, Cd.sup.2+, Ge.sup.2+, and mixtures thereof;
M2 is selected from the group consisting of Cu.sup.1+, Ag.sup.1+
and mixtures thereof; and M3 is selected from the group consisting
of Ti.sup.3+, V.sup.3+, Cr.sup.3+, Mn.sup.3+, Fe.sup.3+, Co.sup.3+,
Ni.sup.3+, Mo.sup.3+, Nb.sup.3+, and mixtures thereof. In another
subembodiment, M1 and M3 are selected from their respective
preceding groups, and M2 is selected from the group consisting of
Li.sup.1+, K.sup.1+, Na.sup.1+, Ru.sup.1+, Cs.sup.1+, and mixtures
thereof.
[0100] In another subembodiment, M1 is selected from the group
consisting of Ti.sup.2+, V.sup.2+, Cr.sup.2+, Mn.sup.2+, Fe.sup.2+,
Co.sup.2+, Ni.sup.2+, Cu.sup.2+, Mo.sup.2+, Si.sup.2+, Sn.sup.2+,
Pb.sup.2+, and mixtures thereof; M2 is selected from the group
consisting of Cu.sup.1+, Ag.sup.1+, and mixtures thereof; and M3 is
selected from the group consisting of Sc.sup.3+, Y.sup.3+,
B.sup.3+, Al.sup.3+, Ga.sup.3+, In.sup.3+, and mixtures thereof. In
another subembodiment, M1 and M3 are selected from their respective
preceding groups, and M2 is selected from the group consisting of
Li.sup.1+, K.sup.1+, Na.sup.1+, Ru.sup.1+, Cs.sup.1+, and mixtures
thereof.
[0101] In all embodiments described herein, moiety XY.sub.4 is a
polyanion selected from the group consisting of
X'[O.sub.4-x,Y'.sub.x], X'[O.sub.4-y,Y.sub.2y], X''S.sub.4,
[X.sub.z''',X'.sub.1-z]O.sub.4, and mixtures thereof, wherein:
[0102] (a) X' and X''' are each independently selected from the
group consisting of P, As, Sb, Si, Ge, V, S, and mixtures thereof;
[0103] (b) X'' is selected from the group consisting of P, As, Sb,
Si, Ge, V, and mixtures thereof; [0104] (c) Y' is selected from the
group consisting of a halogen, S, N, and mixtures thereof; and
[0105] (d) 0.ltoreq.x.ltoreq.3, 0.ltoreq.y.ltoreq.2, and
0.ltoreq.z.ltoreq.1.
[0106] In one embodiment, 1.ltoreq.p.ltoreq.3. In one
subembodiment, p=1. In another subembodiment, p=3.
[0107] In one embodiment, XY.sub.4 is selected from the group
consisting of X'O.sub.4-xY'.sub.x, X'O.sub.4-yY'.sub.2y, and
mixtures thereof, and x and y are both 0. Stated otherwise,
XY.sub.4 is a polyanion selected from the group consisting of
PO.sub.4, SiO.sub.4, GeO.sub.4, VO.sub.4, AsO.sub.4, SbO.sub.4,
SO.sub.4, and mixtures thereof. Preferably, XY.sub.4 is PO.sub.4 (a
phosphate group) or a mixture, of PO.sub.4 with another anion of
the above-noted group (i.e., where X' is not P, Y' is not O, or
both, as defined above). In one embodiment, XY.sub.4 includes about
80% or more phosphate and up to about 20% of one or more of the
above-noted anions.
[0108] In another embodiment, XY.sub.4 is selected from the group
consisting of X'[O.sub.4-x,Y'.sub.x], X'[O.sub.4-y,Y'.sub.2y], and
mixtures thereof, and 0<x.ltoreq.3 and 0<y.ltoreq.2, wherein
a portion of the oxygen (O) in the XY.sub.4 moiety is substituted
with a halogen, S, N, or a mixture thereof.
[0109] In all embodiments described herein, moiety Z (when
provided) is selected from the group consisting of OH (Hydroxyl), a
halogen, or mixtures thereof. In one embodiment, Z is selected from
the group consisting of OH, F (Fluorine), Cl (Chlorine), Br
(Bromine), and mixtures thereof. In another embodiment, Z is OH. In
another embodiment, Z is F, or a mixture of F with OH, Cl, or Br.
Where the moiety Z is incorporated into the active material, the
active material may not take on a NASICON or olivine structural
where p=3 or d=1, respectively. It is quite normal for the symmetry
to be reduced with incorporation of, for example, halogens.
[0110] The composition of the electrode active material, as well as
the stoichiometric values of the elements of the composition, are
selected so as to maintain electroneutrality of the electrode
active material. The stoichiometric values of one or more elements
of the composition may take on non-integer values. Preferably, the
XY.sub.4 moiety is, as a unit moiety, an anion having a charge of
-2, -3, or -4; depending on the selection of X', X'', X''' Y', and
x and y. When XY.sub.4 is a mixture of polyanions such as the
preferred phosphate/phosphate substitutes discussed above, the net
charge on the XY.sub.4 anion may take on non-integer values,
depending on the charge and composition of the individual groups
XY.sub.4 in the mixture.
[0111] In one particular embodiment, the electrode active material
has an orthorhombic-dipyramidal crystal structure and belongs to
the space group Pbnm (e.g. an olivine or triphylite material), and
is represented by the nominal general formula (II):
[A.sub.a,D.sub.d]M.sub.mXY.sub.4Z.sub.e, (IV)
[0112] wherein:
[0113] (a) the moieties A, D, M, X, Y and Z are as defined herein
above;
[0114] (b) 0<a.ltoreq.2, 0.ltoreq.d.ltoreq.1, 1<m.ltoreq.2,
and 0<e.ltoreq.1; and [0115] (c) the components of the moieties
A, D, M, X, Y, and Z, as well as the values for a, d, m and e, are
selected so as to maintain electroneutrality of the compound.
[0116] In one particular subembodiment, A of general formula (IV)
is Li, 0.5<a.ltoreq.1.5, M=MI.sub.n-pMII.sub.o, wherein o=p,
0.5<n.ltoreq.1.5, 0<o.ltoreq.0.1, MI is a 2+ oxidation state
redox active element selected from the group consisting of
Ti.sup.2+, V.sup.2+, Cr.sup.2+, Mn.sup.2+, Fe.sup.2+, Co.sup.2+,
Ni.sup.2+, Cu.sup.2+, Mo.sup.2+, Si.sup.2+, Sn.sup.2+, and
Pb.sup.2+ (preferably Fe.sup.2+), MII is selected from the group
consisting of Be.sup.2+, Mg.sup.2+, Ca.sup.2+, Sr.sup.2+,
Ba.sup.2+, Zn.sup.2+, Cd.sup.2+, Ge.sup.2+, and mixtures thereof
(preferably Mg.sup.2+ or Ca.sup.2+), XY.sub.4.dbd.PO.sub.4, and
e=0.
[0117] In another particular subembodiment, A of general formula
(IV) is Li, 0<a.ltoreq.1, M=MI.sub.n-pMII.sub.o, wherein o=p,
0<o.ltoreq.0.5, MI is Fe.sup.2+, MII is selected from the group
consisting of Be.sup.2+, Mg.sup.2+, Ca.sup.2+, Sr.sup.2+,
Ba.sup.2+, and mixtures thereof (preferably Mg.sup.2+ or
Ca.sup.2+), XY.sub.4.dbd.PO.sub.4, and d,e=0.
[0118] In another particular embodiment, the electrode active
material has a rhombohedral (space group R-3) or monoclinic (space
group Pbcn) NASICON structure, and is represented by the nominal
general formula (V):
[A.sub.a,D.sub.d]M.sub.m(XY.sub.4).sub.3Z.sub.e, (V)
[0119] wherein:
[0120] (a) the moieties A, D, M, X, Y and Z are as defined herein
above;
[0121] (b) 0<a.ltoreq.5, 0.ltoreq.d.ltoreq.1; 1<m.ltoreq.3,
and 0<e.ltoreq.4; and
[0122] (c) the components of the moieties A, D, M, X, Y, and Z, as
well as the values for a, d, m and e, are selected so as to
maintain electroneutrality of the compound.
[0123] In one particular subembodiment, A of general formula (V) is
Li, M is selected from the group consisting of Ti.sup.3+, V.sup.3+,
Cr.sup.3+, Mn.sup.3+, Fe.sup.3+, Co.sup.3+, Ni.sup.3+, Mo.sup.3+,
Nb.sup.3+, and mixtures thereof (preferably V.sup.3+),
XY.sub.4.dbd.PO.sub.4, and e=0. In another particular
subembodiment, A of general formula (V) is Li, M is selected from
the group consisting of Ti.sup.3+, V.sup.3+, Cr.sup.3+, Mn.sup.3+,
Fe.sup.3+, Co.sup.3+, Ni.sup.3+, Mo.sup.3+, Nb.sup.3+, and mixtures
thereof (preferably V.sup.3+), XY.sub.4.dbd.PO.sub.4, and
d,e=0.
[0124] The following applications describe additional details of
active materials and method of forming active materials and
compounds according to exemplary aspects: International Publication
No. WO01/54212, entitled "Lithium-Based Electrochemically Active
Materials And Preparation Thereof," published Jul. 26, 2001,
listing Jeremy Barker and M. Yazid Saidi as inventors;
International Publication No. WO98/12761, entitled
"Lithium-Containing, Lithium-Intercalating Phosphates And Their Use
As The Positive Or Negative Electrode Material In A Lithium
Secondary Battery," published Mar. 26, 1998, listing M. Yazid Saidi
and Jeremy Barker as inventors; International Publication No.
WO00/01024, entitled "Lithium-Containing Silicon/Phosphates, Method
Of Preparation, And Uses Thereof," published Jan. 6, 2000, listing
Jeremy Barker and M. Yazid Saidi as inventors; International
Publication No. WO00/31812, entitled "Lithium-Based Phosphates For
Use In Lithium Ion Batteries And Method Of Preparation," published
Jun. 2, 2000, listing Jeremy Barker and M. Yazid Saidi as
inventors; International Publication No. WO00/57505, entitled
"Lithium-Containing Phosphate Active Materials," published Sep. 28,
2000, listing Jeremy Barker as inventor; International Publication
No. WO02/44084, entitled "Methods Of Making Lithium Metal Compounds
Useful As Cathode Active Materials," published Jun. 6, 2002,
listing Jeremy Barker and M. Yazid Saidi as inventors;
International Publication No. WO03/085757, entitled "Batteries
Comprising Alkali-Transition Metal Phosphates And Preferred
Electrolytes," published Oct. 16, 2003, listing M. Yazid Saidi and
Haitao Huang as inventors; International Publication No.
WO03/085771, entitled "Alkali-Iron-Cobalt Phosphates And Related
Electrode Active Materials," published Oct. 16, 2003, listing M.
Yazid Saidi and Haitao Huang as inventors; International
Publication No. WO03/088383, entitled "Alkali-Transition Metal
Phosphates Having A+3 Valence Non-Transition Element And Related
Electrode Active Materials," published Oct. 23, 2003, listing M.
Yazid Saidi and Haitao Huang as inventors; U.S. Pat. No. 6,528,033,
issued Mar. 4, 2003, entitled "Method Of Making Lithium Containing
Materials," listing Jeremy Barker, M. Yazid Saidi, and Jeffrey
Swoyer as inventors; U.S. Pat. No. 6,387,568, issued May 14, 2002,
entitled "Lithium Metal Flurophosphate Materials And Preparation
Thereof," listing Jeremy Barker, M. Yazid Saidi, and Jeffrey Swoyer
as inventors; U.S. Publication No. 2003/0027049, published Feb. 2,
2003, entitled "Alkali/Transition Metal Halo- And
Hydroxyl-Phosphates And Related Electrode Materials," listing
Jeremy Barker, M. Yazid Saidi, and Jeffrey Swoyer as inventors;
U.S. Publication No. 2002/0192553, published Dec. 19, 2002,
entitled "Sodium Ion Batteries," listing Jeremy Barker, M. Yazid
Saidi, and Jeffrey Swoyer as inventors; U.S. Publication No.
2003/0170542, published Sep. 11, 2003, entitled "Alkali Transition
Metal Phosphates And Related Electrode Active Materials," listing
Jeremy Barker, M. Yazid Saidi, and Jeffrey Swoyer as inventors; and
U.S. patent application Ser. No. 09/484,799, entitled
"Lithium-Based Active Materials and Preparation Thereof", listing
Jeremy Barker as an inventor, filed Jan. 18, 2000, now U.S.
Publication No. 2003/0129492, the teachings of all of which are
incorporated herein by reference.
[0125] According to one aspect for forming an electrode, the active
material may be combined with a polymeric binder (e.g.
polyvinylidene difluoride (PVdF) and hexafluoropropylene (HFP)) in
order to form a cohesive mixture. The mixture is then placed in
electrical communication with a current collector which, in turn,
provides electrical communication between the electrode and an
external load. The mixture may be formed or laminated onto the
current collector, or an electrode film may be formed from the
mixture wherein the current collector is embedded in the film.
Suitable current collectors include reticulated or foiled metals
(e.g. aluminum, copper and the like). An electrically conductive
diluent or agent (e.g. a carbon such as carbon black and the like)
may be added to the mixture so as to increase the electrical
conductivity of the electrode. In one embodiment, the electrode
material is pressed onto or about the current collector, thus
eliminating the need for the polymeric binder. In one embodiment,
the electrode contains 5 to 30% by weight electrically conductive
agent, 3 to 20% by weight binder, and the remainder being the
electrode active material.
[0126] To form an electrochemical cell, a solid electrolyte or an
electrolyte-permeable separator is interposed between the electrode
and a counter-electrode. In one embodiment, the electrolyte
contains a solvent selected from the group consisting of the
electrolyte comprises a lithium salt and a solvent selected from
the group consisting of dimethyl carbonate (DMC), diethylcarbonate
(DEC), dipropylcarbonate (DPC), ethylmethylcarbonate (EMC),
ethylene carbonate (EC), propylene carbonate (PC), butylene
carbonate, lactones, esters, glymes, sulfoxides, sulfolanes, and
mixtures thereof; and 5 to 65% by weight of an alkali metal salt.
Preferred solvent combinations include EC/DMC, EC/DEC, EC/DPC and
EC/EMC. In one embodiment, the counter-electrode contains an
intercalation active material selected from the group consisting of
a transition metal oxide, a metal chalcogenide, carbon (e.g.
graphite), and mixtures thereof. Counter electrodes, electrolyte
compositions, and methods for making the same, among those useful
herein, are described in U.S. Pat. No. 5,700,298, Shi et al.,
issued Dec. 23, 1997; U.S. Pat. No. 5,830,602, Barker et al.,
issued Nov. 3, 1998; U.S. Pat. No. 5,418,091, Gozdz et al., issued
May 23, 1995; U.S. Pat. No. 5,508,130, Golovin, issued Apr. 16,
1996; U.S. Pat. No. 5,541,020, Golovin et al., issued Jul. 30,
1996; U.S. Pat. No. 5,620,810, Golovin et al., issued Apr. 15,
1997; U.S. Pat. No. 5,643,695, Barker et al., issued Jul. 1, 1997;
U.S. Pat. No. 5,712,059, Barker et al., issued Jan. 27, 1997; U.S.
Pat. No. 5,851,504, Barker et al., issued Dec. 22, 1998; U.S. Pat.
No. 6,020,087, Gao, issued Feb. 1, 2001; and U.S. Pat. No.
6,103,419, Saidi et al., issued Aug. 15, 2000; all of which are
incorporated by reference herein.
[0127] Additional details of electrochemical cells composed of
electrodes (including polymer-type stacked cells and
cylindrical-type cells), electrolytes and other materials; among
those useful herein, are described in the following documents, all
of which are incorporated by reference herein: U.S. Pat. No.
4,668,595, Yoshino et al., issued May 26, 1987; U.S. Pat. No.
4,792,504, Schwab et al., issued Dec. 20, 1988; U.S. Pat. No.
4,830,939, Lee et al., issued May 16, 1989; U.S. Pat. No.
4,935,317, Fauteaux et al., issued Jun. 19, 1980; U.S. Pat. No.
4,990,413, Lee et al., issued Feb. 5, 1991; U.S. Pat. No.
5,037,712, Shackle et al., issued Aug. 6, 1991; U.S. Pat. No.
5,262,253, Golovin, issued Nov. 16, 1993; U.S. Pat. No. 5,300,373,
Shackle, issued Apr. 5, 1994; U.S. Pat. No. 5,399,447,
Chaloner-Gill, et al., issued Mar. 21, 1995; U.S. Pat. No.
5,411,820, Chaloner-Gill, issued May 2, 1995; U.S. Pat. No.
5,435,054, Tonder et al., issued Jul. 25, 1995; U.S. Pat. No.
5,463,179, Chaloner-Gill et al., issued Oct. 31, 1995; U.S. Pat.
No. 5,482,795, Chaloner-Gill., issued Jan. 9, 1996; U.S. Pat. No.
5,660,948, Barker, issued Sep. 16, 1995; U.S. Pat. No. 5,869,208,
Miyasaka, issued Feb. 9, 1999; U.S. Pat. No. 5,882,821, Miyasaka,
issued Mar. 16, 1999; U.S. Pat. No. 5,616,436, Sonobe. et al.,
issued Apr. 1, 1997; and U.S. Pat. No. 6,306,215, Larkin, issued
Oct. 23, 2001.
[0128] As mentioned above, individual cells of devices 62 may
comprise lithium. For a 1400 mAhr 18650 cell of an individual
device 62 containing LiFe.sub.0.95Mg.sub.0.05PO.sub.4 cathode
active material, where the LiFe.sub.0.95Mg.sub.0.05PO.sub.4
material has a specific capacity of 126 mAhr/gr when cycled at a
C/5 rate (5 hours to discharge--estimating the perfect capacity of
the material), and the cathode is loaded with 11.1 gr. of the
LiFe.sub.0.95Mg.sub.0.05PO.sub.4 material, the equivalent lithium
content is:
11.1 gr . LiFe 0.95 Mg 0.05 PO 4 1 .times. 6.941 gr . mol Li 156.18
gr . mol LiFe 0.95 Mg 0.05 PO 4 = 0.493 grams of equivalent Li
##EQU00005##
[0129] For a 1700 mAhr 18650 cell containing
Li.sub.3V.sub.2(PO.sub.4).sub.3 cathode active material, where the
Li.sub.3V.sub.2(PO.sub.4).sub.3 material has a specific capacity of
150 mAhr/gr when cycled at a C/5 rate, the cathode is loaded with
11.34 gr. of the Li.sub.3V.sub.2(PO.sub.4).sub.3 material, the
equivalent lithium content is:
11.34 gr . Li 3 V 2 ( PO 4 ) 3 1 .times. 6.941 gr . mol Li 407.61
gr . mol Li 3 V 2 ( PO 4 ) 3 .times. 3 Li = 0.579 grams of
equivalent Li ##EQU00006##
[0130] In one embodiment, individual ones of devices 62 may have an
equivalent lithium content defined by the number of cells coupled
in parallel with one another to form the respective device 62. In
one implementation, devices 62 may individually have an equivalent
lithium content of at least 3 grams or more in examples where the
respective devices 62 individually have a capacity of approximately
10 Ahr or more (e.g., 3.451 grams for at least seven
parallel-coupled 1400 mAhr cells or 3.474 grams for at least six
parallel-coupled 1700 mAhr cells to form a respective device 62).
Devices 62 individually having other quantities of equivalent
lithium content may be provided in configurations using devices 62
of increased capacities. For example, in exemplary configurations
described herein, individual ones of devices 62 including
thirty-five 1400 mAhr cells coupled in parallel have an equivalent
lithium content of approximately 17 grams while thirty-five 1700
mAhr cells yield an equivalent lithium content of approximately
20.265 grams. Other configurations of devices 62 having other
values (more or less) of equivalent lithium content are
possible.
[0131] As described above, a plurality of the above-mentioned cells
may be coupled in parallel to form a device 62. Devices 62 using
the above-described exemplary cells may provide a capacity in
excess of 10 Ahr. In other embodiments, such as the above-described
exemplary configurations, devices 62 of additional capacity may be
utilized. For example, a capacity of approximately 50 Ahr per
device 62 is obtained by thirty-five of the above-mentioned 1400
mAhr cells coupled in parallel to form the device 62. A capacity of
approximately 60 Ahr per device 62 is obtained by thirty-five of
the above-mentioned 1700 mAhr cells coupled in parallel to form the
device 62. Devices 62 of other equivalent lithium content,
capacities and/or using other cells are possible in other
embodiments.
[0132] In some configurations, the above-described lithium
Saphion.RTM. cells for devices 62 may be subjected to increased
temperatures compared with conventional designs without
experiencing thermal runaway conditions. For example,
configurations of 18650 format lithium Saphion.RTM. cells as
described above and available from Valence Technology, Inc. have
been exposed to temperatures of 220 degrees C. for two hours or
more during tests without experiencing thermal runaway conditions.
During, tests, the 18650 format lithium Saphion.RTM. cells
experienced thermal runaway conditions at temperatures of 230
degrees C. or greater. This enhanced resistance to thermal runaway
may be compared with conventional designs including lithium cobalt
18650 format cells which were observed to experience thermal
runaway after exposure to temperatures of 150 degrees C. for less
than two hours and lithium manganese 18650 format cells which were
observed to experience thermal runaway after exposure to
temperatures of 180 degrees C. for less than two hours.
[0133] A communications bus 64 is configured to communicate status
information of one or more of devices 62 to control circuitry 46.
For example, voltage, state of charge, capacity, current or
information regarding other electrical characteristics of devices
62 may be communicated using bus 64. Also, state of health (e.g.,
capacity) of individual devices 62 may be monitored by control
circuitry 46 by counting charge/discharge cycles, temperature
exposure, and/or other means.
[0134] Although not shown in FIG. 2B, sensing circuitry may be
coupled with respective electrochemical devices 62 and
communications bus 64 to provide information to processor 50
regarding status of electrical or other characteristics of devices
62. Further, balance circuitry may be provided coupled with
respective devices 62 to provide uniform voltages of devices 62
during charging of devices 62. Additional exemplary circuitry for
additional aspects of the disclosure including the sensing and
balancing circuitry are provided in FIGS. 3-6.
[0135] One or more temperature sensors 66 are provided to monitor
temperatures of the respective battery assembly 20. In one
embodiment, four temperature sensors 66 are positioned within
housing 24 of assembly 20 to provide temperature information
regarding the operation of the devices 62 or other circuitry of
assembly 20.
[0136] Current measurement sensor 68 is configured to provide
information regarding current flowing into or out of storage
circuitry 60. In the depicted exemplary embodiment, current
measurement sensor 68 is positioned adjacent to a power bus
conductor intermediate the switching device 52 and the negative
node of the storage circuitry 60.
[0137] In addition, exemplary operations of power supply 54 are
described below with respect to the exemplary embodiment of FIGS.
3-6. Other configurations of assembly 20 and the components thereof
apart from the exemplary embodiments of FIGS. 3-6 are possible in
other embodiments.
[0138] The above-described AC voltage may be used to distribute
power to cell voltage sensing circuitry (e.g., shown in FIG. 5A-5P
in one embodiment). By distributing power to the sensing circuitry
as an AC voltage, it is possible to power the individual ones of
the sixteen circuits (e.g., associated with respective ones of the
devices 62) through DC blocking capacitors with the same AC signal
even if the circuits are at different DC potentials. Accordingly,
the sensing circuitry does not draw current directly from devices
62 such that the remaining load upon storage circuitry 60 may be
reduced when the power supply 54 is off in one embodiment.
[0139] The +75 Vdc electrical energy described above from the power
supply 54 may be utilized to charge an electrolytic capacitor C38
of FIG. 3W that is used for energy storage for a coil driver of
switching device 52 (e.g., an exemplary coil driver includes Q24,
Q25, Q27, Q28 of FIG. 3). Through utilization of voltage from power
supply 54, it is further possible to use the same type of switching
device 52 for different battery voltages (e.g., 8-16 devices
62).
[0140] Power supply 54 normally draws power from storage circuitry
60 (e.g., through a diode D22 on FIG. 3X in one embodiment). If the
voltage of storage circuitry 60 drops below a set level (e.g.,
determined by comparator U6 of FIG. 6X), then power supply 54 is
turned off by control circuitry 46 wherein the only draw upon the
storage circuitry 60 is comparator U6. Also, switching device 52
may be opened. The set level may correspond to a minimal threshold
voltage wherein battery assembly 20 provides operational electrical
energy for use by electrical entity 14 or other load.
[0141] As mentioned above, the switching device 52 may be opened if
the voltage of storage circuitry 60 drops below a threshold to
avoid or reduce additional discharge of storage circuitry 60.
Control circuitry 46 of assembly 20 may detect the presence of
charging energy and close switching device 52 to enable charging of
storage circuitry 60 in one embodiment. For example, in one
embodiment, an output voltage of charge circuitry 30 is provided to
an input of power supply 54 through diode D21 of FIG. 3X according
to one exemplary embodiment. The charge energy of a sufficient
voltage (e.g., greater than the threshold of comparator U6) while
result in enablement of power supply 54 and control circuitry 46.
Further, while switching device 52 remains open, power supply 54
draws current from the charge circuitry 30 and not storage
circuitry 60. Thereafter, processor 48 may go through a start-up
routine and detect that the charge voltage is present on power
terminals 40, 42 and switching device 52 may be closed so charge
current may flow into storage circuitry 60.
[0142] In one embodiment, processor 48 may sense available charge
voltage (e.g., using U11A and U9D of respective FIGS. 3V and 3M in
the described embodiment). Processor 48 may measure the two analog
signals and with switching device 52 open, determine if there is
charge voltage upon terminals 40, 42, if there is only a load and
no charge voltage, or if there is nothing attached to the power
terminals 40, 42.
[0143] As mentioned above, individual ones of assemblies 20 may be
selectively provided into a sleep mode of operation wherein power
consumption of the respective battery assembly 20 is reduced
compared with higher modes of operation. While in sleep mode, the
average current drawn from storage circuitry 60 is reduced to
reduce the chances of control circuitry 46 completely discharging
storage circuitry 60 (e.g., while in storage, energy from source 36
is absent, or otherwise not used for extended periods of time).
[0144] Different triggering events may be utilized to provide
assembly 20 into the sleep mode of operation. For example, if it is
known that assembly 20 will not be used for an extended period of
time and/or there is an absence of electrical energy from source 36
(e.g., in storage or coupled to a system not being used) a user may
provide assembly 20 into the sleep mode. In one embodiment, a user
may use a sleep indication to place assembly 20 into sleep mode.
One exemplary user sleep indication comprises a user-operable
switch including a short circuit plug which is placed into
communications interface 44 while the assembly 20 is desired to be
in sleep mode. The above-described user sleep indication or other
mechanisms (e.g., other hardware or other mechanism) may be
utilized by a user to place assembly 20 into sleep mode. Processor
48 may sense the presence of the exemplary plug coupled with the
communications interface 44 (e.g., J7, J8 of FIG. 3Y) and implement
a shut down procedure to place assembly 20 into the sleep mode.
Further, communications may be disabled if the above-described user
sleep indication is coupled with interface 44 in one embodiment.
The user sleep indication reduces the self discharge rate of
storage circuitry 60 in one embodiment. When normal use is desired,
the plug may be removed.
[0145] In another embodiment, additional or alternative stimulus or
triggering events may be utilized to provide assembly 20 into sleep
mode. For example, in one embodiment, control circuitry 46 may be
configured to initiate sleep mode responsive to switching device 52
being changed from a closed state to an open state, monitoring of
an electrical characteristic of one or more devices 62 of storage
circuitry 60 (e.g., state of charge and/or voltage indicating a low
remaining capacity, etc.), or other triggering event. In one
embodiment, if switching device 52 is closed when sleep is
initiated responsive to a monitored electrical characteristic or
other condition, control circuitry 46 may switch device 52 to an
open state to isolate storage circuitry 60 from electrical entity
14.
[0146] During the sleep mode of operation, draws upon storage
circuitry 60 are reduced or minimized. For example, power supply 54
and at least a portion of control circuitry 46 (e.g., processors
48, 50) may be powered down. Further, switching device 52 may be
opened if in a closed state when sleep mode of operation is
initiated as mentioned above.
[0147] According to one embodiment, power supply 54 when started
remains on unless an undervoltage condition of storage circuitry 60
is detected by comparator U6 or processor 48 provides a signal to
shut down power supply 54. In one sleep implementation, processor
48 may issue a control signal to shut down power supply 54 and
enter the sleep mode of operation. In the example of FIGS. 3-6,
processor 48 may provide a shutdown signal (e.g., GOSLEEP) to an
optoisolator U4 of FIG. 6Z which will reset a wakeup timer U3 of
FIG. 6Y. Thereafter, Q14 and Q19 will both turn off which shuts off
Q11 causing the power supply 54 to shut off (e.g., Q11, Q14, and
Q19 are shown in FIGS. 6T, 6R and 6FF respectively). In this
example, Q11 may disconnect the bias voltage to a buckregulator
control circuit U2 of FIG. 6T which shuts down power supply 54 in
one embodiment (e.g., power supply 54 is off if Q11 does not have a
gate voltage).
[0148] Exemplary shut down signals originating from processor 48
may be generated responsive to a received external communication,
an undervoltage or other electrical condition of circuitry 60 or
one of devices 62, presence of the user sleep indication, opening
of switching device 52 or other desired stimulus or triggering
event.
[0149] In one embodiment, at plural moments in time during sleep
mode, control circuitry 46 may monitor to determine whether
assembly should remain in sleep mode or enter a higher level or
mode of operation. For example, control circuitry 46 may perform
relatively fast measurements to determine the status of assembly 20
and depending on the results, decide if it should return to sleep
mode or enter a higher mode of operation wherein electrical energy
is consumed at a rate larger than while in sleep mode. Control
circuitry 46 may also monitor for the presence of the
above-described user sleep indication and return to sleep mode if
present.
[0150] According to the presently described exemplary
configuration, wakeup timer U3 of FIG. 6Y of control circuitry 46
is provided to define the above-mentioned plural moments of time.
In one embodiment, the wakeup timer defines the moments in time
according to a period (e.g., 1 minute). The wakeup timer may
control application of the gate voltage to Q11 via Q14 to power-up
power supply 54 and processors 48 and/or 50 of control circuitry
46.
[0151] Further, user switch 56 may be configured to manually start
power supply 54 according to another described aspect. For example,
user switch 56 (e.g., SW1 which is shown in FIG. 6EE in the
presently described example) causes Q19 of FIG. 6FF to turn on and
an indication signal may be sent to processor 48 through. Q17, Q1,
and Q26 of FIGS. 6Z, 6C, 3CC, respectively, permitting processor 48
to detect activation of user switch 56 and taking desired
action.
[0152] A shutdown signal from processor 48 may shut down power
supply 54 even if user switch 56 is depressed or otherwise
activated by a user. However, once processor 48 loses power, the
shutdown signal is released and power supply 54 starts responsive
to activation of switch 56 or after the time delay of the wakeup
timer. U3 in the presently-described embodiment.
[0153] In one sleep embodiment described above, assembly 20 may be
considered to be partially awake inasmuch as control circuitry 46
may monitor operations and wakeup assembly 20 if appropriate. In
other embodiments, a third operational mode may be provided wherein
the assembly 20 may be considered to be entirely off and no energy
is consumed by assembly 20.
[0154] According to one embodiment, individual battery assemblies
20 may be configured to provide electrical energy having different
electrical characteristics, for example, corresponding to the
associated respective electrical entity 14 (e.g., different
voltages for use when installed in different applications or for
use with different loads utilizing electrical energy of different
voltages). Individual assemblies 20 may have different numbers of
electrochemical devices 62 coupled in series to provide different
voltages. Accordingly, undervoltage comparator U6 may be set for
different threshold levels utilizing J2 shown on FIG. 61 of the
presently described embodiment. In the described embodiment, a
jumper may be soldered to the desired position of J2 for use with
8-16 devices 62 coupled in series in the described exemplary
embodiment. The exemplary power supply 54 also has a wide input
voltage range.
[0155] An exemplary arrangement of power supply 54 includes a
plurality of power stages coupled in series. For example, power
supply 54 may include a buckregulator to drop voltage from storage
circuitry 60 to about 8 Vdc and an unregulated pushpull converter
to provide isolation and one or more different output voltages.
[0156] The buckregulator utilized in the exemplary embodiment of
FIGS. 3-6 includes U2, Q12, D10 and L3 of FIGS. 6T, 6U, 6M, and 6U,
respectively and may be referred to as a low side buckregulator
which provides advantages over a high side buckregulator inasmuch
as the gate drive signal may be direct with no isolation and
current sensing is simplified.
[0157] An exemplary pushpull converter includes U7, U5, Q7, Q10 and
T1 of respective FIGS. 6HH, 6BB, 6DD, 6O, and 6G. An input
capacitor may be omitted from the pushpull converter and input
current may be fed using L3 of FIG. 6U and the circuit may be
referred to as a current fed pushpull converter. The exemplary
pushpull converter is less sensitive to flux imbalance of the
transformer T1, currents in the converter are well controlled,
additional outputs with good crossregulation may be added if
desired, and output inductors may or may not be used.
[0158] As mentioned above, voltage regulation may be performed by
the buckregulator. The feedback voltage may be sensed at the output
of the buckregulator by level shifting circuitry including Q6, R15
and R27 of respective FIGS. 6L, 6D, and 6T. The voltage across
resistor R15 is converted into a current by Q6 and the current is
converted back to a voltage by R27 which is connected to the signal
ground of control circuit U2.
[0159] During power up, the buckregulator draws bias current
through Q5 of FIG. 6D which is connected as a constant current
series regulator with voltage limiting provided by D8 and D11 of
FIG. 6K. When the buckregulator is started, the bias current is
provided through C4, D3 and D12 of FIGS. 6M, 6M and 6K,
respectively, and Q5 is shut off by Q9 of FIG. 6K to limit power
dissipation.
[0160] Precision series regulators of power supply 54 may be
utilized to provide desired voltages for use by the respective
assembly 20. The precision series regulators are shown for example
in FIGS. 3A and 3B.
[0161] Processor 48 (U10 of FIG. 3J in the described example) may
measure a voltage of circuitry 60 using U9C of FIG. 3N. U9A and U9B
of respective FIGS. 3M and 3L provide an exemplary way of measuring
smaller variations in voltage of circuitry 60 and can performed
with higher gain and variable offset. Current of circuitry 60 may
be sensed using sensor 68 (U14 of FIG. 3EE in the described
example) which comprises a hall effect sensor which measures the
magnetic field close to a busbar which carries the current of
assembly 20. The output signal is proportional to the current of
circuitry 60 and can be measured by processor 48 and/or processor
50.
[0162] Communications interface 44 may include an external serial
communications port using U13 of FIG. 3AA which is an isolated
RS485 transceiver. The transceiver uses T2 of FIG. 3AA to provide
isolated voltage for the communications port. An overload on the
isolated voltage supply (pins 14 and 11 on U13) causes U13 to
indicate an error signal on pin 27 which may be read by processor
48 corresponding to the user initiated sleep mode control and which
provides the overload in the described embodiment.
[0163] Processors U10 and U22 (corresponding to processors 48, 50
of FIGS. 3J and 4M) may be located on separate circuit boards
within housing 24 of assembly 20 and internal communication may be
implemented between processors 48, 50 using an I.sup.2C interface
in one embodiment. In one embodiment, processor 50 uses 5 Volts and
processor 48 uses 3.3 Volts, and accordingly, a level shifter of
Q21 and Q22 of FIG. 3H may be used.
[0164] Two hardwired signals EMERGENCY and SECOND DEFENSE may be
communicated to processor 48 from an external circuit board. The
EMERGENCY signal may be used by processor 50 to quickly inform
processor 48 to open switching device 52 inasmuch as the exemplary
I.sup.2C communication may have delays.
[0165] The SECOND DEFENSE signal comes from an analog portion of
control circuitry 46 including U21, U25, U26, and U28 of FIGS. 4C,
4AA, 4CC, 4EE, respectively, and also measuring cell voltage
signals from diodes D65-D82 of FIGS. 4R-4DD and comparators U27 of
FIG. 4Y, which may also be referred to as backup circuitry. The
analog circuitry provides a backup in case processor 50 is too slow
in detecting or reacting to a situation wherein switching device 52
should be opened immediately (e.g., triggering events such as
rapidly falling cell voltage caused by discharge current, rapidly
rising cell voltage caused by overcharge or overtemperature, etc.).
Accordingly, processor 50 may utilize additional time compared with
the analog control signal SECOND DEFENSE to provide a proper
control signal to processor 48 to open switching device 52
responsive to the same detected triggering event. The portion of
control circuitry 46 providing the backup circuitry may detect
undervoltage, overvoltage, and/or overtemperature in the devices 62
or other triggering events or stimulus, and activate an alarm
(i.e., SECOND DEFENSE) signal if these abnormal conditions occur in
one or more devices 62 or other circuitry to inform processor 48
(and independent of processor 50) to open switching device 52 in
less time than if processor 50 were to formulate an appropriate
alarm signal for processor 48 for the same triggering event in one
embodiment.
[0166] Signals from voltage measurement circuits of devices 62
comprising operational amplifiers U1-U18 of FIGS. 5A-5P convert
cell voltages into current signals which may be sent to the inputs
of analog multiplexers U20 and U23 of FIGS. 4B and 4L,
respectively. Input resistors at the multiplexers convert the
current signals back into voltage signals referenced to the ground
pin of the microcontroller analog-to-digital converter. J7 of FIG.
4P provides an additional four inputs from temperature sensors 66.
Processor 50 may measure the signals from the multiplexers and
control balance circuitry including transistors Q31-Q46 of FIGS.
4D-4S that will turn on balancing loads to balance voltages of
devices 62. Balancing may be performed during charging operations
when the battery assembly may be close to full charge.
[0167] In compliance with the statute, the invention has been
described in language more or less specific as to structural and
methodical features. It is to be understood, however, that the
invention is not limited to the specific features shown and
described, since the means herein disclosed comprise preferred
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.
* * * * *