Granted Patent B2

US 12,580,394 · App. 17/463,467 · Granted Mar 17, 2026

Inventors: Glenn Alan Hamblin (Tucson, AZ); Yuriy V. Mikhaylik (Tucson, AZ); Chariclea Scordilis-Kelley (Tucson, AZ); Mark Niedzwiecki (Tucson, AZ); Scott Stewart (Vail, AZ); John Hughes (Tucson, AZ)

Assignee: Sion Power Corporation

H02J7/0025H01M10/441H02J7/0013H02J7/007182B60L58/22H01M2010/4271H01M10/482H02J7/0016H02J7/0019H02J7/0063

Abstract

Claims (98)

1 . A battery management system comprising:

at least one battery comprising two or more strings of cells, each string of cells comprising two or more cells;

a multiplexing switch apparatus connected to each string of cells; and

at least one controller configured to:

use the multiplexing switch apparatus to transition uninterruptedly between discharging of a first string of cells to a load and discharging of a second string of cells to the load while keeping a voltage difference between the first string of cells and the second string of cells below a threshold voltage difference at least during the transition;

transition uninterruptedly between the discharging of the first string of cells and the discharging of the second string of cells in response to a criterion that prompts disconnection of the first string of cells;

in response to the criterion, select the second string of cells for discharging based on the first string of cells and the second string of cells having below the threshold voltage difference;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually are at least twice a charging rate at which the two or more strings of cells are charged in parallel;

transition uninterruptedly between the discharging of the first string of cells at least at the discharging rate and the discharging of the second string of cells at least at the discharging rate; and

select the second string of cells for discharging such that the first string of cells and the second string of cells are discharged at least at the discharging rate.

2 . The battery management system of claim 1 , wherein the threshold voltage difference is such that an in-rush current resulting from the transition is at most 15 amperes.

3 . The battery management system of claim 1 , wherein the threshold voltage difference is at most 8% of a maximum total voltage of the first string or the second string.

4 . The battery management system of claim 1 , wherein the at least one controller is configured to transition to a string of cells having a lowest voltage difference of the two or more strings of cells from the first string at a time of measurement while discharging solely the first string.

5 . The battery management system of claim 1 , wherein the at least one controller is configured to transition to a string of cells having a highest voltage of the two or more strings of cells at a time of measurement while discharging solely the first string.

6 . The battery management system of claim 1 , wherein the at least one controller is configured to transition to a string of cells having a lowest voltage of the two or more strings of cells at a time of measurement while discharging solely the first string.

7 . The battery management system of claim 1 , wherein the at least one controller is configured to transition between discharging of the first string and discharging of the second string when a voltage of the first string decreases to a threshold voltage.

8 . A battery management system comprising:

at least one battery comprising two or more strings of cells, each string of cells comprising two or more cells;

a multiplexing switch apparatus connected to each string of cells; and

at least one controller configured to:

use the multiplexing switch apparatus to perform a transition between discharging of a first string of cells and discharging of a second string of cells while keeping an overall output voltage of the at least one battery within a window, the transition comprising:

while discharging the first string of cells and not discharging the second string of cells, determining to disconnect the first string of cells from discharging;

in response to determining to disconnect the first string of cells from discharging, selecting and connecting the second string of cells such that the overall output voltage of the at least one battery is kept within the window; and

after selecting and connecting the second string of cells, disconnecting the first string of cells from discharging such that the second string of cells is discharging and the first string of cells is not discharging;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually are at least twice a charging rate at which the two or more strings of cells are charged in parallel;

perform the transition between the discharging of the first string of cells at least at the discharging rate and the discharging of the second string of cells at least at the discharging rate while keeping the overall output voltage of the at least one battery within the window; and

select and connect the second string of cells for discharging such that the first string of cells and the second string of cells are discharged at least at the discharging rate.

9 . A battery management system comprising:

at least one battery comprising two or more strings of cells, each string of cells comprising two or more cells;

a multiplexing switch apparatus connected to each string of cells; and

at least one controller configured to use the multiplexing switch apparatus to:

transition between discharging of a first string of cells to a load and discharging of a second string of cells to the load while keeping an in-rush current resulting from the transition below a threshold current at least during the transition;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel; and

transition between the discharging of the first string of cells to the load at least at the discharging rate and the discharging of the second string of cells to the load at least at the discharging rate while keeping the in-rush current resulting from the transition below a threshold current at least during the transition.

10 . A battery management system comprising:

at least one battery comprising two or more strings of cells, each string of cells comprising two or more cells;

a multiplexing switch apparatus connected to each string of cells; and

at least one controller configured to use the multiplexing switch apparatus to:

control a duration of pulse discharge of at least one string of the two or more strings of to decrease non-linearly with an increase in load demand;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel; and

control the duration of pulse discharge to decreases non-linearly with the increase in load demand such that pulse discharge of each of the two or more strings of cells is at least at the discharging rate.

11 . A battery pack comprising:

at least one battery comprising three or more strings of cells, each string of cells comprising two or more cells; and

an integrated switching control system comprising at least one switch connected to each of the three or more strings of cells,

wherein the integrated switching control system is configured to:

control the at least one switch to:

discharge, to a load, a first string of the three or more strings of cells having a first voltage at a time of measurement while discharging the first string and not a second string of cells and not a third string of cells of the three or more strings of cells;

then transition uninterruptedly to discharge, to the load, the first string of cells and the second string of cells having a second voltage that is closest to the first voltage at the time of measurement and not the third string of cells; and

then transition uninterruptedly to discharge, to the load, the second string of cells and not the first string of cells and not the third string of cells;

discharge each of the three or more strings of cells individually and to charge each of the three or more strings of cells in parallel such that a discharging rate at which the three or more strings of cells are discharged individually is at least twice a charging rate at which the three or more strings of cells are charged in parallel; and

transition uninterruptedly from discharging the first string at least at the discharging rate and not the second string and not the third string to discharging the first string and the second string and not the third string, and transition uninterruptedly from discharging the first string and the second string and not the third string to discharging the second string at least at the discharging rate and not the first string and not the third string, such that the first string of cells and the second string of cells are discharged at least at the discharging rate.

12 . A battery management method comprising:

using a multiplexing switch apparatus, which is connected to two or more strings of cells of at least one battery, to transition uninterruptedly between discharging of a first string of cells to a load and discharging of a second string of cells to the load while keeping a voltage difference between the first string and the second string below a threshold voltage difference at least during the transition,

wherein transitioning uninterruptedly between the discharging of the first string of cells and the discharging of the second string of cells is in response to a criterion that prompts disconnection of the first string of cells,

wherein the multiplexing switch apparatus is configured to:

in response to the criterion, select the second string of cells for discharging based on the first string of cells and the second string of cells having below the threshold voltage difference;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel;

transition uninterruptedly between the discharging of the first string of cells at least at the discharging rate and the discharging of the second string of cells at least at the discharging rate; and

select the second string of cells for discharging such that the first string of cells and the second string of cells are discharged at least at the discharging rate, and

wherein each string of cells comprises two or more cells.

13 . A battery management method comprising:

using a multiplexing switch apparatus, which is connected to two or more strings of cells of at least one battery, to:

perform a transition between discharging of a first string of cells and discharging of a second string of cells while keeping an overall output voltage of the at least one battery within a window, the transition comprising:

while discharging the first string of cells and not discharging the second string of cells, determining to disconnect the first string of cells from discharging;

in response to determining to disconnect the first string of cells from discharging, selecting and connecting the second string of cells such that the overall output voltage of the at least one battery is kept within the window; and

after selecting and connecting the second string of cells, disconnecting the first string of cells from discharging such that the second string of cells is discharging and the first string of cells is not discharging;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel,

perform the transition between the discharging of the first string of cells at least at the discharging rate and the discharging of the second string of cells at least at the discharging rate while keeping the overall output voltage of the at least one battery within the window, and

select and connect the second string of cells for discharging such that the first string of cells and the second string of cells are discharged at least at the discharging rate,

wherein each string of cells comprises two or more cells.

14 . A battery management method comprising:

using a multiplexing switch apparatus, which is connected to two or more strings of cells of at least one battery, to:

transition between discharging of a first string of cells to a load and discharging of a second string of cells to the load while keeping an in-rush current resulting from the transition below a threshold current at least during the transition;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel, and

transition between the discharging of the first string of cells to the load at least at the discharging rate and the discharging of the second string of cells to the load at least at the discharging rate while keeping the in-rush current resulting from the transition below a threshold current at least during the transition,

wherein each string of cells comprises two or more cells.

15 . A battery management system comprising:

at least one battery comprising two or more strings of cells, each string of cells comprising two or more cells;

a multiplexing switch apparatus connected to each string of cells; and

at least one controller configured to use the multiplexing switch apparatus to;

selectively discharge the two or more strings of cells and to transition between discharging of a first string of cells to discharging of a second string of cells while keeping an in-rush current resulting from the transition below a threshold current at least during the transition;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel, and

transition between the discharging of the first string of cells at least at the discharging rate and the discharging of the second string of cells at least at the discharging rate while keeping the in-rush current resulting from the transition below a threshold current at least during the transition,

wherein the multiplexing switch apparatus does not comprise a balance rail.

16 . A battery pack comprising:

at least one battery comprising two or more strings of cells, each string of cells comprising two or more cells; and

an integrated switching control system comprising at least one switch connected to each string of cells without including a balance rail,

wherein the integrated switching control system is configured to:

control the at least one switch to discharge the two or more strings of cells and to transition between discharging of a first string of cells to discharging of a second string of cells while keeping an in-rush current resulting from the transition below a threshold current at least during the transition;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel, and

transition between the discharging of the first string of cells at least at the discharging rate and the discharging of the second string of cells at least at the discharging rate while keeping the in-rush current resulting from the transition below a threshold current at least during the transition.

17 . A battery management method comprising:

using a multiplexing switch apparatus, which is connected to two or more strings of cells of at least one battery, to:

selectively discharge each string of cells and to transition between discharging of a first string of cells to discharging of a second string of cells while keeping an in-rush current resulting from the transition below a threshold current at least during the transition;

discharge each of the two or more strings of cells individually and to charge each of the two or more strings of cells in parallel such that a discharging rate at which the two or more strings of cells are discharged individually is at least twice a charging rate at which the two or more strings of cells are charged in parallel, and

transition between the discharging of the first string of cells at least at the discharging rate and the discharging of the second string of cells at least at the discharging rate while keeping the in-rush current resulting from the transition below a threshold current at least during the transition,

wherein each string of cells comprises two or more cells, and

wherein the multiplexing switch apparatus does not comprise a balance rail.

Assignments (1)

Continuity (2)

References Cited (400)