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  Electrical storage device heater for vehicleUSPTO Application #: 20060016793Title: Electrical storage device heater for vehicle Abstract: A heater system for an electrical storage device, such as a high voltage traction battery, is connectable to an external AC power source maintain a proper temperature of the battery as long as the system remains connected to the external power source. The battery temperature can be maintained at a level that ensures that the vehicle will start even in extremely cold climates. The heater system includes a heater disposed within the battery itself. Other system components, such as an AC/DC converter and a control module, may be connected to the battery heater system outside of the battery, allowing the battery heater system to act as a modular component that can be easily included in or excluded from a vehicle as an option, either alone or in a package with an engine block heater. The battery heater system is designed so that it can be connected along with the engine block heater to the AC power source using a single common connector. (end of abstract)
Agent: Carlson, Gaskey & Olds, P.C. - Birmingham, MI, US Inventors: Douglas Zhu, Jacob Mathews, Pax Maguire, Patrick Padgett USPTO Applicaton #: 20060016793 - Class: 219205000 (USPTO) Related Patent Categories: Electric Heating, Heating Devices, Combined With Diverse-type Art Device, Vehicle Or Vehicle Component, Motor Or Engine The Patent Description & Claims data below is from USPTO Patent Application 20060016793. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD OF THE INVENTION [0001] The present invention relates generally to thermal controls for an electrical storage device in a vehicle. More particularly, the present invention relates to a system and method for heating the electrical storage device. BACKGROUND OF THE INVENTION [0002] Electric and hybrid electric vehicles have become increasingly popular to meet the demand for fuel-efficient, environmentally-friendly transportation. Such vehicles often include an electrical storage device, such as a high-voltage traction battery, for powering an electric motor to drive the vehicle, either alone or in conjunction with an internal combustion engine, fuel cell engine, or other prime mover. [0003] Currently available electric and hybrid electric vehicles tend to operate more effectively in moderate and warm climates and less effectively in extremely cold climates. This is because high voltage traction batteries tend to lose power as battery cell temperature drops (e.g., below approx. 20.degree. C.). This power decrease results in reduced vehicle performance, fuel economy and drivability. At extremely low temperatures, the traction battery may have insufficient power to even start the vehicle. [0004] Maintaining a proper battery temperature is desirable to ensure optimal vehicle performance in many different climates. Sustaining the battery temperature at a desired level can be challenging because the battery temperature can be affected by many factors, such as the battery condition, the battery cell temperature, the battery charge condition when the vehicle is turned off, and the ambient temperature. Self-powered battery heaters are able to maintain a minimum battery temperature level only for short time periods because the amount of power available for heating is limited by the storage capacity of the battery itself. Thus, self-powered battery heaters are unsuitable when the battery needs to be heated for an extended time period and/or when the battery needs to be warmed to a higher temperature to ensure optimal vehicle performance. [0005] As such, there is a need for a system that can maintain a battery temperature to a level that ensures reliable starting of an electric or hybrid vehicle. There is also a need for a system that can maintain a proper battery temperature in a controlled manner to ensure optimum vehicle performance. SUMMARY OF THE INVENTION [0006] The invention is generally directed to a battery heater system that can be connected to an external power source outside a high-voltage vehicle battery to maintain a proper temperature of the high-voltage battery as long as the system remains connected to the external power source. The external power source can be, for example, a separate low-voltage battery or a power source outside the vehicle itself. The battery temperature can be maintained at a level that ensures optimal battery performance as well as a minimum level that ensures the vehicle will start in any climate. The high-voltage battery itself can be any appropriate vehicle battery, such as a high voltage traction battery. [0007] In one embodiment, the system includes a battery heater, such as a heater containing thermoelectric heater elements, disposed within the battery system itself. Other heater system components, such as a converter and a controller, may be connected to the heater either inside or outside the battery system. Keeping other system components outside the battery system allows the battery heater system to act as a modular component that can be easily included as a part of the battery itself or as part of an optional vehicle heating package. Moreover, placing the converter and/or the controller outside the battery allows the battery heater system to be easily omitted from vehicles operating in climates that do not require battery heating. [0008] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 is a block diagram illustrating a battery heater system according to one embodiment of the invention; [0010] FIG. 2 is a block diagram illustrating a battery heater system according to another embodiment of the invention; [0011] FIG. 3 is a block diagram illustrating an example of the battery heater system in conjunction with an engine block heater; and [0012] FIG. 4 is a flow diagram illustrating a method for controlling the battery heater according to one embodiment of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0013] FIG. 1 is a block diagram illustrating components of a battery heater system 100 according to one embodiment of the invention. Generally, the invention is directed to a vehicle battery heater system 100 that is powered by an external power source e.g., a 120V AC power source outside the vehicle or a supplemental low-voltage or accessory battery on-board the vehicle) outside a high-voltage battery system 102 or other electrical storage device. The battery system 102 includes one or more battery cells 103. By using an external power source that is separate from the high-voltage battery system 102 to operate the heater system 100, the invention can keep the battery system 102 warm and regulate the temperature of the battery system 102 reliably when the vehicle is exposed to a cold environment. [0014] As shown in FIG. 1, the battery heater system 100 includes a heater 104 for warming the battery cells 103. The heater 104 itself may have any configuration known and appreciated in the art that is appropriate for regulating the temperature of the battery cells 103. In one embodiment, a plurality of resistive or other thermoelectric heater elements disposed in the battery system 102 act as the heater 104. The heater 104 is coupled to the battery cells 103. The battery cells 103 themselves can be, for example, nickel metal hydride cells, lithium-ion cells, lead acid cells, or any equivalent electric energy storage device. Although the description below focuses on battery cells, the heater system may apply to other electrical storage devices, such as ultra-capacitors, without departing from the scope of the invention. [0015] The heater system 100 also includes a converter 108. In the example shown in FIG. 1, the converter 108 is an AC/DC converter that converts an AC voltage output from an external AC power source 110 to a lower level DC voltage output. The AC power source 110 can be, for example, power from a wall outlet in a garage. A connector 112, such as a conventional three-pronged plug, connects the battery heater system 100 to the AC power source 110. The output of the AC/DC converter 108 or a suitable control signal may also be sent to a controller 114 that controls operation of the heater 104 via one or more switches 116, such as relays, mechanical switches, field effect transistors, etc. In one embodiment, the controller 114 also receives signals indicating a battery temperature, a key on/off condition (e.g., whether a key is in the vehicle ignition), and an AC/DC active signal as inputs and controls operation of the switch 116 based on these inputs. [0016] Alternatively, the controller 114 may be powered by, for example, a separate low-voltage battery 120 or other alternative power source. The low-voltage battery 120 may be, for example, a conventional accessory battery having a nominal voltage output of approximately 10V-15V. If the controller 114 is powered by the low-voltage battery 120, the controller 114 can monitor the temperature of the battery system 102 even when the battery heater system 100 is not connected to the AC power source 110. The controller 114 preferably draws a very small current during operation (e.g., on the order of less than 1 mA). Moreover, by intermittently placing the controller 114 into a sleep mode where it draws minimal current, as will be described in greater below, the controller 114 avoids draining the low-voltage battery 120. The components of the heater system 100 may be connected together via any connection structure, such as an electrical harness (not shown). [0017] In the example shown in FIG. 1, the controller 114 and the switches 116 are disposed in the battery system 102, while the AC/DC converter 108 may be placed at any location in the vehicle outside the battery system 102. The AC/DC converter 108 tends to be an expensive component; by placing the AC/DC converter 108 outside of the battery system 102, the battery heater system 100 can be marketed as a separate component as part of a vehicle heating package and can be omitted in vehicles that do not require cold weather assistance. Note that other components in the system (e.g., the controller 114 and/or the switch 116) may be placed outside the battery system 102 as well, if desired, to further enhance modularity by placing these components only in vehicles that require it. FIG. 2 illustrates another embodiment of the battery heater system 100 where both the AC/DC converter 108 and the controller 114 are disposed outside the battery system 102. [0018] Moreover, by placing the AC/DC converter 108 outside the battery system 102 (e.g., near a vehicle engine), only low voltage DC electrical lines, as opposed to high voltage AC lines, need to be passed through a passenger compartment of the vehicle, eliminating possible safety concerns. Keeping the AC/DC converter 108 separate from the battery system 102 makes UL certification simpler because certification is needed only for the AC/DC converter 108, as opposed to the entire battery system 102 if the AC/DC converter 108 were included within the battery system 102. [0019] Connecting the battery heater system 100 to the AC power source 110 allows the battery system 102 to be heated for an unlimited time period as long as the connection lasts. This creates a distinct advantage over self-powered battery heaters, which can heat the battery only for a finite time period. Also, the unlimited nature of the AC power source 110 allows the battery system 102 to be heated to a higher temperature without risking power supply drainage, making it possible to maintain the battery temperature to a level that allows the vehicle to start. In another embodiment, the temperature level may be selected to ensure optimum battery performance. Continue reading... Full patent description for Electrical storage device heater for vehicle Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Electrical storage device heater for vehicle patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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