CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 62/688,893, filed on June 22, 2018, the entire contents of which are incorporated by reference herein in their entirety and for all purposes. This application is related to U.S. Patent Application No. 15/379,070, filed on December 14, 2016; U.S. Patent Application No. 15/379,193, filed on December 14, 2016; and International Application No.

PCT/US2016/066985, filed on December 15, 2016; each of which claims priority to U.S. Provisional Patent Application Nos. 62/269,420 and 62/331,756, the entire disclosures of each of which are incorporated by reference herein in their entirety and for all purposes.

BACKGROUND

Field of the Invention

[0002] The field relates generally to circuit breakers, and an electrical system incorporating such circuit breakers.

Description of the Related Art

[0003] In various types of electrical devices, circuit elements such as batteries, which may comprise one or more cells, or other components may experience faults which negatively affect the operation or reliability of the larger electrical device. For example, the circuit elements can become overheated and/or may experience overcurrent faults in which excessive electrical current passes through the circuit element. Such overtemperature and/or overcurrent faults may reduce the functionality, reliability, lifetime, and/or safety of the device. Accordingly, there remains a continuing need for an apparatus that protects the larger electrical device when circuit elements (such as batteries) experience overtemperature and/or overcurrent faults during operation.

SUMMARY

[0004] In one embodiment, an electrical breaker responsive to a fault condition for one or more battery cells is disclosed. The breaker can comprise a first terminal configured to electrically connect to a battery management system, a second terminal configured to electrically connect to a first discharge resistor, and a third terminal. A second discharge resistor can be electrically connected to the third terminal, the second discharge resistor configured to electrically connect to a first electrode of a battery cell of the one or more battery cells, the third terminal disposed between the first terminal and the second discharge resistor. A thermally-activated switch can be disposed between the first terminal and the second and third terminals. The switch can have a first operating condition in which the first terminal is electrically connected to the second terminal, and the switch can have a second condition in which the first terminal is electrically connected to the third terminal.

[0005] In another embodiment, an electrical breaker is disclosed. The breaker can comprise a first terminal configured to electrically connect to a first electrode of a battery cell, a second terminal configured to electrically connect to a battery management system, and a thermally-activated switch disposed between the first terminal and the second terminal. A resistor can be in parallel with the switch and configured to electrically connect to the battery management system. The switch can have a first operating condition in which the first terminal is disconnected from the second terminal, and a second operating condition in which the first terminal is electrically connected to the second terminal. During a connection phase when an electrical connection between the electrical breaker and the battery cell is made, the switch can be in the first operating condition and a first electrical current can pass through the resistor to the battery management system. During an operational phase the switch can be in the second operating condition and a second electrical current can pass through the switch to the battery management system, the first electrical current greater than the second electrical current.

[0006] In another embodiment, a fuse is disclosed. The fuse can comprise an electrical breaker comprising a first terminal electrically connected to a first pin, a second terminal, a third terminal, a thermally-activated switch between the first terminal and the second and third terminals, and a resistor electrically connected to the third terminal and thermally coupled with the switch. A transistor can be electrically connected to the resistor and the third terminal. When the transistor is in a first state, current does not flow through the transistor and the breaker, and the first terminal is electrically connected to the third terminal. When the transistor is in a second state, current flows through the transistor and the resistor, the switch being configured to disconnect from the third terminal and connect to the second terminal when a temperature of the resistor exceeds a predetermined threshold.

[0007] In another embodiment, an electrical breaker responsive to a fault condition is disclosed. The breaker can comprise a first terminal, a second terminal, a third terminal, and a thermally-activated switch disposed between the first terminal and the second and third terminals. A resistor can be provided in parallel with the switch and in electrical communication with the second terminal. A thyristor can be provided in parallel with the switch and in series with the resistor.

[0008] In another embodiment, an electrical breaker responsive to a fault condition is disclosed. The breaker can comprise a first terminal, a second terminal, and a third terminal configured to connect to an electrical bypass pathway to bypass an electrical component. The breaker can comprise a thermally-activated switch disposed between the first terminal and the second and third terminals, wherein the switch has a normal operating condition in which the first terminal is electrically connected to the second terminal, and the switch has a fault condition in which the first terminal is electrically connected to the third terminal, such that in a fault condition, at least a majority of the current flows between the first terminal and the third terminal. The switch can be configured such that, after the switch moves from the normal operating condition to the fault condition, the switch does not automatically move back to the normal operating condition.

[0009] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Specific implementations of the invention will now be described with reference to the following drawings, which are provided by way of example, and not limitation.

[0011] Figure 1A is a schematic circuit diagram of an electrical system in a normal operating condition, according to one embodiment. [0012] Figure 1B is a schematic circuit diagram of the system shown in Figure 1A in a fault condition.

[0013] Figure 2A is a schematic side sectional view of an electrical breaker used in the embodiment of Figures 1A-1B in a normal operating condition, according to one embodiment.

[0014] Figure 2B is a schematic circuit diagram of the breaker shown in Figure 2A.

[0015] Figure 3A is a schematic side sectional view of the electrical breaker of Figure 2A in a fault condition.

[0016] Figure 3B is a schematic circuit diagram of the breaker shown in Figure 3A.

[0017] Figure 4 is a graph that shows the current and temperature at which exemplary switches trip from a normal operating condition to a fault condition, according to various embodiments.

[0018] Figure 5 is a schematic graph that shows the relationship between temperature and resistance of an exemplary positive temperature coefficient (PTC) resistor, according to various embodiments.

[0019] Figure 6A is a schematic circuit diagram of an electrical system in a normal operating condition, according to another embodiment.

[0020] Figure 6B is a schematic circuit diagram of the system shown in Figure 6A in a fault condition.

[0021] Figure 6C is a schematic circuit diagram of a non-resettable breaker in a normal operating condition and that can be used in conjunction with the embodiments of Figures 6A-6B, according to various embodiments.

[0022] Figure 6D is a schematic circuit diagram of the non-resettable breaker of Figure 6C in a fault condition.

[0023] Figure 7 is a schematic circuit diagram of an electrical system, which can be used to simulate the performance of the system, according to yet another embodiment.

[0024] Figure 8A is a schematic top, front, and right perspective view of a battery housing incorporating a circuit breaker, according to one embodiment. [0025] Figure 8B is a schematic, bottom, rear, and left perspective view of the battery housing shown in Figure 8A.

[0026] Figure 9A is a schematic top, front, and right perspective view of the battery housing shown in Figures 8A-8B, with first and second battery cells disposed in the housing.

[0027] Figure 9B is a schematic, bottom, rear, and left perspective view of the battery housing and battery cells of Figure 9A.

[0028] Figure 10A is a schematic top plan view of the battery housing and battery cells shown in Figures 9A-9B.

[0029] Figure 10B is a schematic bottom plan view of the battery housing and battery cells shown in Figures 9A-9B and 10A.

[0030] Figure 11A is a schematic top, rear, and right perspective cross-sectional view of the battery housing and battery cells, with the cross-section taken along the battery terminal and the first cell contact.

[0031] Figure 11B is a schematic top, rear, and right perspective cross-sectional view of the battery housing and battery cells, with the cross-section taken along the second cell contact.

[0032] Figure 12 is a rear and right perspective view of a string of modular battery housings connected together, according to various embodiments.

[0033] Figure 13 A is a schematic circuit diagram of a string of battery housings connected in series, according to various embodiments.

[0034] Figure 13B is a schematic circuit diagram of battery housings with two battery housings connected in parallel, according to various embodiments.

[0035] Figure 14 is a schematic system diagram of a battery pack comprising a string of cells connected in series with one another and with a buck-boost converter.

[0036] Figure 15A is a schematic system diagram showing an electrical device in accordance with various embodiments.

[0037] Figure 15B is a schematic system diagram showing an electrical device in accordance with another embodiment. [0038] Figure 16 is a schematic system diagram of an electrical device incorporating a breaker for managing overcurrent conditions during hot swapping of a battery cell, according to various embodiments.

[0039] Figure 17 is a schematic system diagram of a fuse device that can incorporate various embodiments of the breakers disclosed herein.

[0040] Figure 18A is a schematic circuit diagram of a breaker that incorporates a thyristor in series with a resistor, shown in a normal operating condition, according to various embodiments.

[0041] Figure 18B is a circuit diagram of the breaker of Figure 18 A, shown in a fault condition.

DETAILED DESCRIPTION

I. EXAMPLES OF THREE- TERMINAL BREAKERS

[0042] Various embodiments disclosed herein relate to an electromechanical three-terminal breaker for protecting electrical devices from overheating and/or from excessive electrical current. Electrical devices and systems may have numerous circuit elements which can experience fault conditions ( e.g ., overtemperature and/or overcurrent faults) that can negatively affect the performance or reliability of the entire system. For example, many devices rely on a plurality of batteries or battery cells (whether connected in series, parallel or combinations thereof) to provide power to the electrical system. The batteries are often rechargeable, which enables the user to reuse the battery after discharge instead of purchasing a new battery. For example, mobile electronic devices (such as smartphones, tablet computing devices, laptop computers, etc.) utilize high energy capacity rechargeable batteries (e.g., lithium-ion batteries) to provide power to the electronic device for high performance computing over several hours of operation. Electric bicycles, electric vehicles and hybrid vehicles also rely on high energy capacity batteries to provide sufficient power for operating the vehicle at long driving ranges. Solar power generation systems often use batteries to store energy generated by the solar cells. Skilled artisans will appreciate that there is a continuing demand for reliable and long-lasting batteries for numerous types of electrical systems and devices. [0043] One problem with such battery-powered systems is that one or more battery cells may experience excessive temperatures (overtemperature fault condition) and/or excessive currents (overcurrent fault condition) that can negatively affect the performance, reliability, and/or safety of the entire electrical system. For example, in systems utilizing lithium-ion batteries ( e.g ., lithium polymer or other types of lithium-ion batteries), cells can experience thermal runaway if a cell becomes sufficiently hot so as to cause the lithium in solution to convert to a solid and short out the lithium layers in the cell. In such situations, the battery can become short circuited and can cause excessive current to flow in the cell, causing the temperature of the cell to rise even more. In some cases, the excessive temperatures can cause the overheated cell to degrade or disrupt the operation of the larger electrical system.

[0044] Some types of electromechanical circuit breakers can address overtemperature and/or overcurrent fault conditions by connecting a bimetal switch with a positive temperature coefficient (PTC) resistor, for example, in parallel. A PTC resistor is a resistor in which the resistance increases with increasing temperature, in contrast to conventional resistive materials. In some breakers, if excessive current flows through a particular circuit element, for example a battery, the temperature of the bimetal switch and the PTC resistor increases. At a threshold temperature, the bimetal switch may trip into an inverted position, causing the switch to open. Thus, in a fault condition for such breakers, the open switch may halt or significantly reduce the flow of electrical current through the circuit element to relieve the circuit element of the fault condition. However, in some arrangements, it may be undesirable to stop or significantly reduce the flow of electrical current through the entire circuit. For example, if the circuit element is in series with other circuit elements, then opening the switch of an existing state of the art breaker may cause the flow of electrical current through the other circuit elements to be stopped or be significantly reduced.

[0045] To address the effects of overtemperature and/or overcurrent faults in circuit elements while maintaining connectivity with other circuit elements in the system, the embodiments disclosed herein provide a three-terminal breaker which allows current to flow through the circuit element during a normal operating condition, but which bypasses or shunts most (or all) of the current around the problematic circuit element during a fault condition. For example, the breaker can include a first terminal, a second terminal, and a third terminal which can connect to corresponding terminals of the larger electrical system. The breaker can also include a thermally-activated mechanical switch disposed between the first terminal and the second and third terminals. The switch can have a normal operating condition in which the first terminal is electrically connected to the second terminal. The switch can have a fault condition in which the first terminal is electrically connected through a resistor to the second terminal and directly to the third terminal. In some embodiments, the switch can comprise a bimetal element, such as but not limited to a dome-shaped bimetal disc, which can be activated to move the switch from the normal condition to the fault condition, and vice versa. In some embodiments, a positive temperature coefficient (PTC) resistor can be provided between the first terminal and one of the second and third terminals.

[0046] Figure 1A is a schematic circuit diagram of an electrical system 1 in a normal operating condition, according to one embodiment. The electrical system 1 can include a load L and a plurality of battery cells 2a-2e connected in series. It will be understood that the polarity of the series of battery cells may be the opposite of that shown in Figure 1A, as is the case in all of the figures disclosed herein. The cells 2a- 2e can comprise any suitable type of battery cell that provides sufficient power to the load L. For example, in some embodiments, the battery cells 2a- 2e can comprise lithium-ion or lithium polymer battery cells. The load L can comprise any suitable type of electrical load, such as components of a mobile device (such as a smartphone, tablet computing device, laptop computer, etc.), components of a vehicle (such as a hybrid or electric vehicle), components of an electrical energy storage system or any other suitable electrical or electronic system. In some embodiments, the battery cells 2a- 2e may be used for energy storage in a solar power generation and storage system. It should be appreciated that, although the battery cells 2a- 2e are connected in series in the embodiment shown in Figure 1A, in other arrangements the cells can also be connected in parallel or combinations thereof. Furthermore, although five battery cells 2a-2e are illustrated in Figure 1A, it should be appreciated that any suitable number of cells may be used.

[0047] In Figure 1A, an electrical breaker 3 is connected to battery cell 2c to protect the circuit from a fault condition. The breaker 3 can comprise a switch 4 connected with a positive temperature coefficient (PTC) resistor 5. In the embodiment of Figure 1A, for example, the switch 4 is connected in parallel with the PTC resistor, but in other embodiments, the PTC resistor may be connected in other configurations. In the illustrated embodiment, the switch 4 is a thermally-activated mechanical switch, in particular a bimetal element. As explained herein, a PTC resistor 5 can comprise a resistive element with a resistance that increases with increasing temperature. The PTC resistor 5 can be any suitable type of PTC resistor, including a ceramic PTC resistor or a polymeric PTC resistor. Although the breaker 3 is shown as providing protection for the circuit from a fault condition, it should be appreciated that each cell 2a- 2e (or any combination thereof) may be connected to its own breaker to provide fault protection. As explained below in connection with Figure 1A, for example, a bypass circuit 6 can be routed around the cell 2c to divert all or most of the current away from the cell 2c in a fault condition.

[0048] The system 1 shown in Figure 1A is illustrated in a normal operating condition, in which the switch 4 electrically connects a first terminal Tl, which can be considered an input terminal, with a second terminal T2, which can be considered a first or primary output terminal. As shown in Figure 1A, the first terminal Tl is disposed between the switch 4 and the adjacent battery cell 2d. The second terminal T2 is disposed between the switch 4 and the cell 2c which is to be protected from a fault condition. In the illustrated embodiment, the PTC resistor 5 is in parallel with the switch 4 electrically connecting the first terminal Tl with the second terminal T2. During normal operation of the electrical system 1, if each cell 2a- 2e supplies a voltage V to the system, then the cells 2a-2e connected in series collectively supply a voltage of 5*F to the load L.

[0049] The battery cells 2a-2e can supply a first current h to the load L. Within the breaker 3, because the PTC resistor 5 is in parallel with the switch 4, a second current h can flow through the switch 4 and a third current h can flow through the PTC resistor 5, where h = h + h- The resistance Rs of the switch 4 may be significantly smaller than the resistance RPTC of the PTC resistor 5 during normal operation of the system 1. For example, during normal operating conditions, the resistance RPTC of the PTC resistor 5 may be in a range of 1 ohm to 20 ohms, and the resistance Rs of the switch 4 may be in a range of 1 milliohm to 10 milliohms. Accordingly, the relatively low resistance Rs of the switch 4 causes most of the current to flow through the switch 4 without passing through the PTC resistor 5. In some embodiments, for example, during normal operation the second current h that flows through the switch 4 and bypasses the PTC resistor may be more than 100 times, more than 1000 times, or more than 10,000 times the third current h that flows through the PTC resistor 5. Advantageously, therefore, the relatively low resistance Rs of the switch 4 may not reduce the electrical performance of the larger electrical system 1 during normal operating conditions.

[0050] Figure 1B is a schematic circuit diagram of the system 1 shown in Figure 1A in a fault condition. Unless otherwise noted, the reference numerals shown in Figure 1B represent the same components as those shown in Figure 1A. As explained above, in a fault condition, the cell 2c may experience excessive temperatures and/or current. If the temperature and/or current passing through cell 2c exceed a predetermined temperature and/or current, the switch 4 can move from the normal condition shown in Figure 1A to the fault condition shown in Figure 1B. For example, as explained below in connection with Figures 2A-3B, in the fault condition the switch 4 can move from the second terminal T2 to a third terminal T3. As shown in Figure 1B, the third terminal T3 can provide electrical connection to the bypass circuit 6 that bypasses the cell 2c. Thus, in the fault condition, the switch 4 can bypass the cell 2c (which experiences an overtemperature and/or overcurrent fault) to provide electrical connection between the first terminal Tl and the cell 2b adjacent to cell 2c. In the fault condition, most of the current bypasses the cell 2c undergoing an overtemperature and/or overcurrent fault so as to prevent further increases in temperature of and/or current through the cell 2c.

[0051] Figure 2A is a schematic side sectional view of an electrical breaker 3 that can be used in the embodiment of Figures 1A-1B in a normal operating condition, according to one embodiment. Figure 2B is a schematic circuit diagram of the breaker 3 shown in Figure 2A. Figure 3A is a schematic side sectional view of the electrical breaker 3 of Figure 2A in a fault condition. Figure 3B is a schematic circuit diagram of the breaker 3 shown in Figure 3A. As shown in Figures 2A and 3A, the breaker 3 can comprise an electromechanical device comprising a housing 10 to which the first terminal Tl, the second terminal T2, and the third terminal T3 are coupled. The housing 10 can comprise a first conductive line 12 electrically connected to the second terminal T2 and to the PTC resistor 5 by way of one or more interconnects 13. The housing can also comprise a second conductive line 14 along a top side of the housing 10 that is electrically connected to the third terminal T3.

[0052] The switch 4 can comprise a movable ( e.g ., pivotable or bendable) conductive arm 8 and a switching element 7. The pivotable arm 8 can electrically connect to the first terminal Tl and to the switching element 7 by contact. For example, in the normal condition shown in Figure 2A, the pivotable arm 8 can electrically contact a central portion of the switching element 7. For example, in Figure 2A, the pivotable arm 8 is shown in a normal condition in which a contact 15 on a distal end portion of the pivotable arm 8 contacts and is electrically connected to the first conductive line 12 and the second terminal T2. In Figure 3 A, the pivotable arm 8 is shown in a fault condition in which another contact 16 contacts and is electrically connected to the second conductive line 14 and the third terminal T3. In the fault condition, the pivotable arm 8 can also electrically contact the switching element 7 at opposing end portions of the switching element 7.

[0053] The pivotable arm 8 can move from the normal condition to the fault condition by engaging with the switching element 7 and the PTC resistor 5. For example, the switching element 7 can comprise an electromechanical or thermomechanical switching element, particularly a dome-shaped bimetal element, which changes shape in response to temperature changes. During normal operation, as shown in Figures 2A and 2B, the first current h can flow along the pivotable arm 8. Most of the current h passes through the second terminal T2, the first conductive line 12, and the pivotable arm 8 without passing through the PTC resistor 5. However, a small trickle current I 3 (shown in dashed lines) passes from the second terminal T2 and the first conductive line 12 to the pivotable arm 8 through the PTC resistor 5 and the switching element 7. As explained above, during normal operation, the current that bypasses the PTC resistor 5 may be much greater than the trickle current I3 through the PTC resistor 5.

[0054] If the temperature and/or current through the breaker 3 exceeds predetermined values, then the breaker 3 can move from the normal operating condition shown in Figures 2A-2B to the fault condition shown in Figures 3A-3B. For example, if the temperature of the switching element 7 exceeds a particular temperature threshold, which can be selected and tuned in the manufacturing process, then the switching element 7 can switch from the downwardly-curving shape of Figure 2A to the upwardly-curving shape of Figure 3A. The PTC resistor 5 can also increase the temperature of the switching element 7, as excessive currents cause corresponding increases in temperature of the PTC resistor 5 and the switching element 7, which contacts the PTC resistor 5. When the switching element 7 changes shape to the upwardly-curving shape shown in Figure 3 A, the contact 16 on the distal end portion of the pivotable arm 8 contacts and electrically connects to the second conductive line 14 and the third terminal T3 (or directly to the third terminal T3 in other embodiments, not shown). Although the switching element 7 is shown as downwardly- curving in the normal condition and upwardly-curving in the fault condition, it should be appreciated that in other arrangements the breaker may also be configured such that the switching element 7 is in an upwardly-curving shape during normal operating conditions and in a downwardly-curving shape during a fault condition.

[0055] Thus, in a fault condition, the first current h passes to the first terminal Tl along the pivotable arm 8. As the temperature of the PTC resistor 5 increases with the temperature of the cell 2c (Figure 1B), the resistance RPTC of the PTC resistor 5 correspondingly increases. Due to the increasing resistance RPTC of the PTC resistor 5 with increasing temperature, most of the current h passes from the second conductive line 14 and the third terminal T3 to the pivotable arm 8. The second current h bypasses the cell 2c by passing along the bypass circuit 6 shown in Figure 1B. However, a small trickle current h still passes from the first conductive line 12 and the second terminal T2, through PTC resistor 5 and the switching element 7 ( e.g ., at end portions of the switching element 7), to the pivotable arm 8 and the first terminal Tl. As explained in additional detail below with respect to Figure 5, the trickle current I 3 can provide a small amount of current from the cell 2c to enable essential device functionality, because the heat generated by the PTC resistor 5 maintains high temperatures after the initial fault condition to prevent the switch 4 from chattering, i.e., from repeatedly switching between the fault mode and the normal operating mode. The skilled artisan will appreciate that the trickle currents I3 through the PTC resistor 5 can have different magnitudes under normal and fault conditions, and that the magnitude of can change during the advent of a fault condition.

[0056] Figure 4 is a graph that shows the current and temperature at which exemplary switches 4 trip from a normal operating condition to a fault condition, according to various embodiments. In particular, Figure 4 is a plot of current versus temperature for dome-shaped bimetal switches used in Komatsulite™ KCA Series A-Type Breakers, commercially available from Bourns, Inc., of Riverside, California. In particular, Figure 4 plots the current versus temperature for four different versions of the Series A-Type Breakers. In Figure 4, the line represents the temperature and current combination at which the particular breaker trips to the fault condition. Thus, the region below each line indicates a normal condition and the region at the line and above indicates a fault condition. As shown in Figure 4, the switch 4 can trip from the normal operating condition to the fault condition at relatively high temperatures (even at low currents) and/or at relatively high currents (even at low temperatures). For example, the switch 4 can trip from the normal operating condition to the fault condition when the switch 4 reaches a predetermined temperature in a range of 65 °C to 85°C, or more particularly, in a range of 70°C to 80°C, depending upon the design.

[0057] The use of the PTC resistor 5 can provide various advantages in some embodiments. As explained herein, the PTC resistor 5 can enable the switch 4 and breaker 3 to operate in a stable manner, such that the breaker 3 does not chatter at a high rate between the normal condition and the fault condition by maintaining an elevated temperature after an initial fault condition. Furthermore, the reduction in the temperature of PTC resistor 5 can assist in resetting the breaker 3 from the fault condition to the normal operating condition under some circumstances.

[0058] Figure 5 is a schematic graph that shows the relationship between temperature and resistance of an exemplary PTC resistor, according to various embodiments. For example, as shown in Figure 5, at temperatures below a predetermined fault temperature Tf, the resistance RPTC of the PTC resistor 5 can be at a relatively low level (but can be higher than the resistance Rs of the switch 4). As the temperature of the PTC resistor 5 reaches the predetermined fault temperature Tf, the resistance RPTC can increase significantly with increasing temperature. In the breaker 3 of Figures 1A-3B, the increasing temperature of the PTC resistor 5 can further increase the temperature of the switching element 7 that contacts the PTC resistor 5. Thus, the increasing temperature of the PTC resistor 5 can accelerate or otherwise assist in causing the switching element 7 to change shape and trip to the fault condition shown in Figures 3A-3B.

[0059] The correspondingly high resistance RPTC of the PTC resistor 5 can cause most of the current to pass along the pivotable arm 8, while maintaining a trickle current h through the PTC resistor 5. If the temperature of the bypassed cell 2c decreases (for example, due to the reduced current passing through the bypassed cell 2c), the PTC resistor 5 may still have high resistance RPTC due to hysteresis and the fact that the resistance RPTC of the PTC resistor 5 increases with the higher temperature causing the fault, and thus generates its own heat to maintain the switching element ( e.g ., bimetal element) in the fault condition longer than it would in the absence of the PTC element. That is, even though the temperature of the PTC resistor 5 decreases by a significant amount, the PTC resistor 5 maintains the high resistance RPTC levels caused by the fault condition, until the temperature drops below a reset temperature T _r .

[0060] Advantageously, the hysteresis shown in Figure 5 can prevent the breaker 3 from operating in a chatter mode. In a chatter mode, without the hysteresis shown in Figure 5, as the temperature decreases (even slightly), the temperature of the bimetallic switching element 7 would decrease and switch back into the normal operating condition prematurely. The increasing current of the operating condition would again increase the temperature of the switching element 7 past the fault temperature 7/, and the breaker might repeatedly switch from normal operating condition to fault condition, and back again. Such a chattering mode is undesirable and can lead to instability in the larger electrical system 1.

[0061] The hysteresis shown in Figure 5 therefore allows the PTC resistor 5 to maintain a high resistance, and a correspondingly relatively high temperature, which can maintain the switching element 7 in the fault condition until the temperature drops to the reset temperature T _r . Moreover, the small trickle current through the PTC resistor may help to maintain the temperatures sufficiently high so as to prevent chattering. Once the temperature of the breaker 3 drops below the reset temperature TV, the resistance of the PTC resistor 5 can drop back to the resistance RPTC of the normal operating condition. In various embodiments, the fault temperature 7/ can be in a range of 65 °C to 85 °C, or more particularly, in a range of 70 °C to 80 °C. In various embodiments, the reset temperature T _r can be in a range of 30 °C to 60 °C, or more particularly in a range of 40 °C to 55 °C.

[0062] Thus, the breaker 3 of Figures 1A-3B can advantageously employ a PTC resistor 5 connected with the switch 4 (for example, in parallel) to maintain stable operating and fault conditions. The breaker 3 of Figures 1A-3B can advantageously be resettable in some arrangements, such that the breaker 3 can return to the normal operating condition if the fault condition subsides (for example, by a sufficient decrease in current and/or temperature). Furthermore, as explained herein, the breaker 3 can stably move to the fault condition and back to the normal operating condition without chattering.

[0063] Figure 6A is a schematic circuit diagram of an electrical system 1 in a normal operating condition, according to another embodiment. Figure 6B is a schematic circuit diagram of the system 1 shown in Figure 6A in a fault condition. Unless otherwise noted, the components of Figures 6A-6B represent the same or generally similar features as those shown and described in connection with Figures 1A-3B. For example, as with the embodiment of Figures 1A-1B, a breaker 3 can be provided to bypass current around a particular battery cell 2c. Unlike the embodiment of Figures 1A-3B, however, in the embodiment of Figures 6A-6B, the breaker 3 may be non-resettable. Thus, in the embodiment of Figures 6A-6B, once the switch 4 trips from the normal operating condition to the fault condition, the switch 4 does not automatically reset back to the normal operation condition. The breaker 3 may therefore act as a non-resettable switch that diverts current around the cell 2c which experiences a fault condition. A battery management system can detect the drop in voltage across the bypassed cell 2c, and can trigger an alert to the user that the cell 2c is not operating properly and has been shunted out of the circuit. The user can respond to the alert by replacing or fixing the cell 2c, and can manually reset or replace the breaker 3.

[0064] In the embodiment of Figures 6A-6B, the breaker 3 may not include a PTC resistor, such as the PTC resistor 5 shown in Figures 1A-3B. In such arrangements, the switch 4 may include a bimetal switching element (similar to switching element 7) which changes shape ( e.g ., inverts) as the temperature of the breaker 3 rises. Once the breaker reaches the fault condition, the switch 4 can trip to connect to the third terminal T3 to bypass the cell 2c. In a non-resettable breaker 3, the switching element can be shaped such that a drop in temperature does not cause the switching element to revert back to the normal operating condition.

[0065] In still other arrangements, a non-resettable breaker 3 may include a PTC resistor similar to that shown in Figures 1A-3B, but the shape of the switch 4 (and associated switching elements) may be selected so as to prevent the switch 4 from reverting to the normal condition after tripping to the fault condition. In such arrangements, the PTC resistor can act to heat up the bimetal switching element more rapidly so as to trigger the fault condition. As explained above, the PTC resistor may also allow a small trickle current to flow through the cell 2c so as to enable critical device functionality.

[0066] Thus, in various embodiments, the breaker 3 may be resettable such that the switch 4 can move back and forth between a normal operating condition and a fault condition in a stable, chatter-less manner. In some embodiments, the breaker 3 may be non- resettable such that the switch 4 does not automatically move back to the normal operating condition after tripping into the fault condition.

[0067] Figure 6C is a schematic circuit diagram of a non-resettable breaker 3 in a normal operating condition and that can be used in conjunction with the embodiments of Figures 6A-6B, according to various embodiments. Figure 6D is a schematic circuit diagram of the non-resettable breaker 3 of Figure 6C in a fault condition. Figures 6C-6D illustrate one example by which the breaker 3 may be made in a manner that is not automatically resettable, e.g., non-resettable or manually resettable by a user. For example, in the normal operating condition shown in Figure 6C, the switch 4 can electrically connect the first terminal Tl with the second terminal T2. In various embodiments, the switch 4 can comprise a bimetallic element as explained above. In other embodiments, the switch 4 can comprise other types of switches. As shown in Figure 6C, a mechanical spring 55 can be mechanically connected to the end of the switch 4 which connects to either T2 or T3. In the normal operating configuration of Figure 6C, the spring 55 can be in compression such that mechanical potential energy is stored in the spring 55 during the normal operating condition. [0068] As explained above, if the temperature of the switch 4 (which may comprise a bimetallic switching element, such as a dome- shaped element) exceeds a threshold, the switch 4 can flip or reverse so as to connect the first terminal Tl with the second terminal T3 in the fault condition which is shown in Figure 6D. Although not shown, an additional resistor may be provided along the pathway of Figure 6C so as to increase the heating effect on the switch 4. When the switch 4 moves to the third terminal T3 shown in Figure 6C, the spring 55 may move to the relaxed or expanded configuration, in which the spring 55 resists forces that tend to move the switch back to the second terminal T2. In such a manner, the spring 55 can prevent the switch 4 from moving back to the second terminal T2 due to the hysteresis properties of the switch 4, such that the switch 4 is not automatically resettable. In some embodiments, the breaker 3 can be non-resettable, such that the breaker can comprise a one-time use fuse. In other embodiments, however, the breaker 3 can be manually resettable, in which the user can manually reset the switch 4 to connect to the second terminal T2, for example, by pressing a button that re-compresses the spring 44 to the configuration shown in Figure 6C.

[0069] Figure 7 is a schematic circuit diagram of an electrical system 1, according to yet another embodiment. In some arrangements, the system 1 shown in Figure 7 can be used to model the performance of the systems utilizing the embodiments disclosed in Figures 1A-6B. In other arrangements, the system 1 can be physically implemented ( e.g ., using discrete electrical components and/or integrated circuit/device technology) to effectively act as a three-terminal breaker as described herein. Unless otherwise noted, the components of Figure 7 represent the same or generally similar features as those shown and described in connection with Figures 1A-6B. For example, the system 1 can include a plurality of battery cells BT1, BT2, and BT3 connected in series. A breaker 3 can be electrically connected to a particular cell BT2 that is to be protected from a fault condition. As with the embodiments of Figures 1A-3B, the breaker 3 can comprise a switch 4 connected with a PTC resistor 5. In Figure 7, the switch 4 may be in parallel with the PTC resistor 5, but in other embodiments, the PTC resistor 5 may be placed elsewhere. As the temperature of the switch 4 and/or the PTC resistor 5 increases, the resistance RPTC of the PTC resistor 5 correspondingly increases. Furthermore, the increasing temperature of the switch 4 and/or the PTC resistor 5 can cause the switch 4 to open when the temperature and/or current exceeds a predetermined threshold.

[0070] Unlike in the embodiment of Figures 1A-3B, however, in the embodiment of Figure 7, the switch 4 may not directly contact the third terminal T3. By contrast, the bypass circuit 6 which bypasses the cell 2c may comprise a relay 20 which is normally open during normal operating conditions. During a fault condition, a sensing circuit 30 (which can also comprise a current- sensing resistor, a magnetic current resistor, and/or a temperature sensing thermistor) can detect the voltage drop across the breaker 3 when the switch 4 trips to the fault condition. The sensing circuit 30 can send a signal to the relay 20 to close the relay 20 and divert the current around the protected cell 2c. Thus, in the embodiment of Figure 7, instead of causing the switch 4 to connect to the third terminal T3 directly, the sensing circuit 30 can detect the fault condition based on a voltage drop across the breaker 3 and can cause the relay 20 to connect to the third terminal T3 while the switch 4 remains open.

Example

[0071] An automated test for system 1 shown in Figure 7 has been developed which utilizes a dedicated test board and an external holder for three 3.6 Vdc Li-ion cells (corresponding to BT1, BT2, and BT3) at 2.5Ah. The test board can include three resistance temperature detector (RTD) temperature sensors, connected in Kelvin mode, the individual battery cells BT1, BT2, BT3 in the external holder, an external load, and a breaker 3 to be connected via screw-type terminal blocks. The breaker 3 used in this example test was the Komatsulite™ model NR82CBO, manufactured by Bourns, Inc., of Riverside, California. Terminal blocks may also be used to connect an external resistance measurement instrument in Kelvin fashion for measuring the RTDs, and three other screw terminals can be used for grounding of shields on the RTDs.

[0072] The test can be implemented to add a high current normally open relay 20 to the breaker 3 so that the breaker 3 acts as if it has a single pole, double throw (SPDT) switching action. A voltage drop across the breaker 3 is monitored. In the example test procedure, a voltage of 0.65 Vdc or more across the breaker 3 caused the relay 20 to close, indicating a tripped-to-open breaker. A voltage of 0.5Vdc or less across the breaker 3 allows the relay 20 to open, indicating a reset breaker. This action allows the relay 20 and the breaker’s contacts to emulate an SPDT switch. When the breaker 3 is closed, or not tripped, the three cells BT1-BT3 are connected in series and may be loaded as desired. A light 240 ohm load on the board can be placed across all the cells BT1-BT3. The externally attached load ( e.g ., up to 10 A), can also be connected across the cells. The breaker 3 can be applied to protect the second or center cell BT2 in the series of three cells. When the breaker 3 opens due to an over-current and/or overheating fault, then the second cell BT2 is bypassed from the series of three cells and becomes shorted across the open breaker to provide energy to heat the PTC resistor 5. This action keeps the breaker 3 open for as long as the second cell BT2 has the charge to keep the PTC resistor 5 warm enough to maintain the breaker 3 in an open state. When the protected cell voltage drops to a level at which the breaker’s PTC resistor 5 cools down enough to allow the breaker 3 to reset, then the breaker 3 resets, and the external relay 20 opens. This action returns the protected cell BT2 into the series of three cells again. The test procedure can be implemented to determine how long, after the breaker 3 is tripped open, the protected cell BT2 can keep the breaker 3 open before the cell BT2 discharges too much to continue doing so.

[0073] Software has also been implemented to conduct the test procedures. The software can be programmed with a user interface on a computer and configured to automatically test the system 1 of Figure 7. If the breaker 3 is tripped, then the software iteratively records the time of the tripped breaker, the voltage of each cell BT1-BT3, the voltage across the breaker 3, the total voltage across the connected cells BT1 and BT3, the current through the PTC resistor 5, the temperature of the protected cell BT2 and the breaker 3, the temperature of the other cells BT1 and BT3, and/or any other suitable data. The program can terminate when any combination of conditions is met, for example: (1) the voltage of any of BT1-BT3 drops to less than 1.10 Vdc, (2) the breaker 3 resets to a closed state (e.g., as indicated by a breaker voltage of less than 0.2 Vdc), (3) the temperature of any of the three cells BT1-BT3 exceeds 85 °C, or (4) the breaker current is less than 5 mA (e.g., due to a failed breaker 3), and/or any other suitable predetermined conditions.

[0074] The test board and system 1 can also be used to charge the battery cells

BT1-BT3. The cells BT1-BT3 can be individually simultaneously charged using three independent charging sources, or the entire string of three battery cells BT1-BT3 can be charged at once with a single charging source using three times the charging voltage of a single cell. In this arrangement, all three cells BT1-BT3 are individually initially charged by applying a constant current ( e.g ., limited to 1 A maximum), with a maximum voltage of 4.10 Vdc. When the voltage across a particular cell has reached 4.10 Vdc and the charging current drops to lOOmA, the charge is considered complete and is terminated.

[0075] In some arrangements, the test board and system 1 can be used to test the charging of the three cells BT1-BT3 with a 12.3 Vdc/ 1 A source at a 0.4C charge rate. For example if the system 1 detects that the software terminated or was interrupted because the breaker 3 has reset, and if the voltage of BT2 is positive, then the software can initiate charging of the three cells BT1-BT3. The charging can be conducted with 1A current at a maximum voltage of 12.3 Vdc across the three cells BT1-BT3. The system 1 can therefore act as a battery management system and can take measurements of the voltages of each cell BT1-BT3, the combined voltage of all three cells, the current in amperes, and the temperature of each cell BT1-BT3. The charging operation can terminate when any combination of the following conditions occurs: (1) the voltage of any one of cells BT1-BT3 exceeds 4.099 Vdc; (2) the current drops to less than 100 mA; and/or the temperature of any of the cells BT1-BT3 exceeds 50 °C.

[0076] Although the embodiments disclosed herein may relate to electrical systems and devices that utilize batteries, it should be appreciated that the breakers 3 disclosed herein can be used with any other suitable type of circuit element. For example, the breakers 3 disclosed herein may be used in any circuit elements that are susceptible to overtemperature and/or overcurrent fault conditions. Furthermore, the breakers 3 disclosed herein may also be used in non-battery power systems, including both direct current (DC) and alternating current (AC) applications.

II. EXAMPLES OF BATTERY HOUSINGS

[0077] In some systems, battery cells are connected together using metal ribbons or other types of electrical interconnects. The ribbons or other interconnects may be spot welded, soldered, or otherwise joined to the positive and negative terminals of the cells. For example, cylindrical lithium ion cells (such as those used in electric bicycles) are typically spot welded to one another in series or parallel using ribbon interconnects. To replace cells with connections that utilize welded joints, solder joints, or other types of metal joining processes, the user breaks the joint, replaces the battery cell, and re-joins the connection to the new battery cell using the desired metal joining process. However, metal joining processes, such as welding, soldering, etc., may require an excessive amount of time, equipment, and/or expertise to form the joint. Moreover, even where the metal joint between two battery cells provides sufficient electrical connectivity, the interconnects and joints may not be adequately housed or packaged in a compact manner. For example, in some arrangements, the interconnects and/or joints may become entangled and/or may flap around if adequate packaging is not provided. In various embodiments, the breaker 3 disclosed herein with respect to Figures 1A-7 may also be welded, soldered, or otherwise joined with the interconnects and/or batteries using suitable metal joining processes. However, as explained above, such metal joining processes may be time-consuming and expensive, and may require specialized expertise. The battery housings disclosed herein can be used in combination with any of the breakers 3 described above in connection with Figures 1A-7.

[0078] Accordingly, various embodiments disclosed herein utilize a modular battery housing that incorporates circuit breakers having the function and/or form disclosed above in connection with Figures 1A-7. The battery housing can comprise a housing body that defines a cavity sized and shaped to receive one or more battery cells. A breaker (which may be similar to or the same as the breakers 3 disclosed with respect to Figures 1A-7) having a switch may be coupled or integrated with the housing body. A first electrical conductor can be disposed at a first end portion of the housing body and electrically connected to the switch. The first electrical conductor can be configured to electrically connect to a first battery cell terminal of the battery. A second electrical conductor can be disposed at a second end portion of the housing body. The second electrical conductor can be configured to electrically connect to a second battery cell terminal of the battery cell to define a first electrical pathway between the first electrical conductor and the second electrical conductor. A bypass conductor can also be coupled with the housing body. The bypass conductor can be electrically connected to the switch and the second electrical conductor to define a second electrical pathway between the switch and the second electrical conductor.

[0079] In a normal condition, the breaker may be configured such that all the current flows along the first electrical pathway through the battery cell between the first and second electrical conductors. In a fault condition (such as an overtemperature and/or overcurrent condition), the breaker may be configured such that a majority (or all) of the current bypasses the battery cell and flows along the second pathway between the switch and the second electrical conductor. In some embodiments, a minority of the current flows through the battery cell in the fault condition. Advantageously, the battery housings disclosed herein can enable the user to simply snap the battery cell inside the cavity of the battery housing, without performing any metal joining processes, such as welding, soldering, etc. Moreover, the battery housing provides a compact structural support for one or more battery cells and provides a modular construction in which multiple battery housings may be connected to one another to provide any number of battery cells in series or parallel. The housing body may comprise insulating walls which can mechanically and electrically separate the conductive components, such as the insulator coated housing of the cells, cell contacts, modular battery terminals, and conductive segments, so as to prevent components of the housing from shorting to one another. The housing body may alternatively or additionally comprise insulating spacer elements, which provide air gaps to mechanically and electrically separate the conductive components, such as the insulator coated housing of the cells, cell contacts, leads, and conductive segments, so as to prevent components of the housing from shorting to one another.

[0080] Figure 8A is a schematic top, front, right perspective view of a battery housing 100, according to one embodiment. Figure 8B is a schematic, bottom, front, left perspective view of the battery housing 100 shown in Figure 8A. The battery housing 100 can comprise a housing body 101 having one or more walls 110 and defining a cavity 102 sized and shaped to receive one or more battery cells (see Figures 9A-9B). The walls 110 of the housing body 101 can comprise an insulating material which serves to define the receptacle for receiving cells, and to electrically separate the conductive materials that are coupled to or formed with the walls 110. For example, the insulating material of the walls 110 may comprise a plastic or polymer material, a ceramic material, etc.

[0081] The housing body 101 can comprise a first end portion 111 (e.g., top) and a second end portion 112 (e.g, bottom) opposite the first end portion 111. A first wall l lOa and a second wall 110b can extend between the first and second end portions 111, 112, and can be spaced apart from one another along the illustrated y-axis by a distance sufficient to receive a width of a battery cell. A third wall 1 lOc and a fourth wall 1 lOd can be disposed at the respective first and second end portions 111, 112, and can be spaced apart from one another along the illustrated z-axis by a distance sufficient to receive a length of the battery cell. As shown in Figures 8A-8B, each of the third and fourth walls l lOc, l lOd may comprise openings 117 through which terminals of the battery cells may be exposed. The cavity 102 may be defined by the first, second, third, and fourth walls HOa-l lOd. In the illustrated embodiment, the cavity 102 can be accessed by way of apertures defined in the z-y plane on both ends (e.g., left and right ends) of the housing 100. In other embodiments, there may be additional walls formed in the z-y plane so as to form a completely enclosed housing. In such embodiments, the cavity 102 may be accessed by providing one or more doors which may be opened and closed when inserting and/or removing the battery cell or battery cells, and/or through openings in the first and second walls 1 lOa, 1 lOb.

[0082] The cavity 102 illustrated in Figures 8A-8B is sized and shaped to receive two battery cells, such as two cylindrical lithium ion battery cells, but it should be appreciated that the cavity 102 may be shaped to receive other types, sizes, shapes or numbers of battery cells. For example, the cavity 102 may instead be sized to receive only one battery cell, or may be sized to receive three battery cells, four battery cells, five battery cells, six battery cells, seven battery cells, eight battery cells, or more than eight battery cells. Further, although the cavity 102 shown in Figures 8A-8B is shown as being shaped to receive elongated cylindrical battery cells, in other arrangements, the cavity 102 may be sized and shaped to receive battery cells having rectangular, square, or polygonal cross-sections, or to receive battery cells having a coin profile (e.g., the height or length of the battery cell is smaller than the width or diameter).

[0083] Advantageously, the housing body 101 and cavity 102 can be sized and shaped such that a battery cell can be snapped into the housing body 101 without requiring any tools to connect the battery cell to the housing 110, e.g., by way of a tool-less connection. For example, in some embodiments, cell contacts which connect to battery cell terminals of the battery cell can be spaced apart by a distance less than the length of the battery cell such that the battery cell can be snapped between the contacts (e.g., the battery cell can be urged between the contacts and can deflect the contacts away from one another). In other embodiments, the length (along the z-axis) and/or the width (along the y-axis) of the housing body 101 may be selected so as to be slightly smaller than the respective length and width dimensions of the battery cell. The housing body 101 may be sufficiently compliant such that the user can urge the slightly larger battery cell (or battery cells) into the cavity 102, causing the housing body 101 to flex to receive the battery cell or battery cells. Once the battery cell or battery cells are in the housing 100, the housing body 101 can relax to secure the battery cell or battery cells within the cavity 102. Such snap-fit connections enable a relatively simple battery cell installation or replacement process, in which the battery cell or battery cells is or are mechanically and electrically connected to the housing 100 by way of the snap- fit connection. Although a snap-fit connection is described herein, it should be appreciated that other tool-less connections between the cell and the housing may be used. Moreover, in some embodiments, the cells may be connected to the cell contacts l05a-l05c using any suitable metal-joining process or material. For example, in some embodiments, the cell contacts l05a-l05d can be connected to the cells using solder, welding, conductive epoxy, etc. Such metal-joining connections may be used to reduce the resistance of the connections and/or to improve the reliability of the battery housing.

[0084] The battery housing 100 can also include a first modular battery terminal l04a and a second modular battery terminal l04b, each configured to electrically communicate with an external component, such as another modularly connected battery housing, an electrical load, etc. The housing 100 can also include a plurality of electrical conductors configured to direct current along various electrical pathways, as explained in detail in connection with Figures 9A-12. For example, the housing 100 can comprise a first conductive segment l07a, a second conductive segment l07b, a third conductive segment l07c, a fourth conductive segment l07d, a fifth conductive segment l07e, and a sixth conductive segment 107T A first cell contact l05a can be configured to contact a first battery cell terminal of a first cell, and a second cell contact l05b can be configured to contact a second battery cell terminal of a second cell. Similarly, a third cell contact l05c can be configured to contact a second battery cell terminal of the first cell, and a fourth cell contact l05d can be configured to contact a first battery cell terminal of the second cell. The housing 100 can also include a first bypass conductor l06a and a second bypass conductor l06b. In addition, a first breaker 3 a can be connected to the first conductive segment l07a, the second conductive segment l07b, and the first bypass conductor l06a. A second breaker 3b can be connected to the third conductive segment l07c, the fourth conductive segment l07d, and the second bypass conductor l06b.

[0085] As explained herein, the battery housing 100 (which may receive a single cell or multiple cells) and conductors can define various electrical pathways for the flow of current through the housing 100 and the one or more cell(s) disposed in the housing 100. The battery housing 100 can include a three-terminal breaker (e.g., the breakers 3a, 3b) integrated with the battery housing 100. As explained above in connection with Figures 1A-7, the breakers 3a, 3b can have a normal operating condition and a fault condition. The breakers 3a, 3b can enter the fault condition when the cell(s) are subjected to overtemperature and/or overcurrent situations. The battery housing 100 can define a primary current pathway through the cell when the breaker is in the normal operating condition. The battery housing 100 can define a bypass current pathway configured to bypass the cell when the circuit breaker is in the fault condition. For example, in the normal operating condition, the first terminal Tl of the breaker 3 a, 3b can be connected to the second terminal T2 such that current flows through the switch connecting Tl to T2, and through the cell along the primary current pathway. In the fault condition, the first terminal Tl can move to be connected to the third terminal T3 of the breaker 3a, 3b. In the fault condition, a minority of the current (e.g., a small trickle current) can flow along the primary current pathway and a majority of the current can flow along the bypass current pathway. In some arrangements, a PTC resistor is provided in the breaker 3a, 3b. As explained above, the breaker 3a, 3b can comprise a bimetal switch which can move from the second terminal T2 to the third terminal T3 when the cell is in the fault condition. The breaker 3a, 3b can be positioned at any suitable location in the battery housing to detect a fault condition (e.g., an overtemperature and/or overcurrent situation) and to cause the current to bypass the cell when in the fault condition.

[0086] Although the electrical conductors illustrated herein may be described as corresponding to separate conductive segments or contacts, it should be appreciated that the conductive segments or contacts may instead be formed from fewer conductive segments (. e.g ., the conductor may be continuous). For example, although the first conductive segment l07a is illustrated as being separate from the modular battery terminal l04a, in other embodiments, the modular battery terminal l04a may be directly connected to the breaker 3a without an intervening segment, or the modular battery terminal l04a may be connected to the breaker 3a by way of a continuous conductive material. Similarly, even though the second conductive segment l07b is illustrated as being separate from the first cell contact 105 a, it should be appreciated that the breaker 3 a may be directly connected with the cell contact l05a without an intervening segment, or the cell contact l05a may comprise a continuous conductive material between the breaker 3a and the cell. Similarly, the breaker 3b may be directly connected through a cell contact to the cell without intervening segments l07c and l07d. And, the bypass conductors l06a, l06b may be connected directly from breakers 3 a, 3b to the cell contacts l05a, l05b without intervening segments (or by way of a continuous conductive material). A skilled artisan would appreciate that various types of electrical routing arrangements may be suitable for use with the embodiments disclosed herein.

[0087] The electrical conductors (e.g., the conductive segments l07a-l07f, the cell contacts l05a-l05d, the modular battery terminals l04a-l04b, and the bypass conductors l06a, l06b) can be coupled to or formed with the housing body 101. For example, in some embodiments, the housing body 101 can be formed using a suitable process, such as injection molding, three-dimensional (3D) printing, etc. The conductors can be connected to recesses sized and shaped to receive the conductors, or the housing body 101 can be molded around the desired conductors. In some embodiments, adhesives may be used to connect the conductors to the housing body 101. In other embodiments, the entire battery housing 100 (e.g., including the insulating housing body 101 and the conductors) may be manufactured using a 3D printing process capable of simultaneously defining insulating and conductive structures in a single monolithic body.

[0088] In addition, as shown in Figures 8A-8B, a first connector l35a can be coupled to or formed with the second cell contact l05b. A second connector 135b can be coupled to or formed with the third cell contact l05c. The first and second connectors l35a, l35b can comprise conductive tabs or lugs which are configured to electrically connect to a battery management system (BMS). For example, in some embodiments, the second and third cell contacts l05b, l05c can electrically connect the negative terminals of battery cells with the first and second connectors l35a, l35b, respectively. The BMS (see Figures 13A- 13B) can monitor the voltage of each battery cell and can notify the user ( e.g ., with an alarm or other indicator) if the voltage of the cells rises or drops to unacceptable levels. For example, in some embodiments, the BMS can determine if one or more battery cells has been bypassed due to, e.g., the switch being in a fault condition. Such a notification can alert the user that the battery cells should be replaced.

[0089] Figure 9A is a schematic top, front, right perspective view of the battery housing 100 shown in Figures 8A-8B, with a first cell H4a and a second cell H4b disposed in the housing 100. Figure 9B is a schematic, bottom, front, left perspective view of the battery housing 100 and cells H4a, H4b of Figure 9A. Figure 10A is a schematic top plan view of the battery housing 100 and cells H4a, H4b shown in Figures 9A-9B. Figure 10B is a schematic bottom plan view of the battery housing 100 and cells H4a, H4b shown in Figures 9A-10A. Figure 11A is a schematic top, rear, right perspective cross-sectional view of the battery housing 100 and cells H4a, H4b, with the cross-section taken through the modular battery terminals l04a, l04b and the first cell contact l05a. Figure 11B is a schematic top, rear, right perspective cross-sectional view of the battery housing 100 and cells H4a, H4b, with the cross-section taken through the second cell contact l05b.

[0090] The first and second cells 114a, 114b shown in Figures 9A-11B are cylindrical battery cells (e.g., lithium ion battery cells), although as explained above, the battery cells can comprise any suitable shape or profile, and any suitable type of battery cell. Moreover, as explained above, although two cells 114a, 114b are shown, more or fewer battery cells may be disposed in the housing 100. For example, in some embodiments, the battery housing 100 can be sized and shaped to receive a single cell. Multiple housings with one or more cells can be connected together in a modular arrangement. In the arrangement of Figures 9A-9B, each cell H4a, H4b comprises a first battery cell terminal H3a (e.g., a positive terminal) and a second battery cell terminal H3b (e.g., a negative terminal). The cells H4a, H4b may be disposed in the housing 101 such that the first battery cell terminal H3a of the first cell H4a is at or near the first end portion 111 and the second battery cell terminal H3b of the first cell H4a is disposed at or near the second end portion 112. The first battery cell terminal 1 l3a of the second cell 1 l4b may be disposed at or near the second end portion 112 adjacent the second battery cell terminal H3b of the first cell H4a. The second battery cell terminal 1 l3b of the second cell 1 l4b may be disposed at or near the first end portion 111 adjacent the first battery cell terminal 113a of the first cell 1 l4a.

[0091] Figures 9A-9B illustrate various electrical pathways P1-P7 defined by the battery housing 100. In the illustrated embodiment, the arrows for the pathways P1-P7 illustrate the direction of electron flow (assuming that first battery cell terminal H3a is a positive terminal), which the skilled artisan will understand is opposite the direction of the conventional definition for electrical current. Thus, to envision current flow in the example provided, the direction of all arrowheads can be reversed. In other embodiments, the electrons may flow opposite the direction illustrated, depending on the polarity of the cells 114a, 114b relative to the housing 100.

[0092] A first pathway PI (Figures 9 A and 10A) can be defined between the first modular battery terminal 104a and the breaker 3 a, which may comprise a switch similar to those disclosed throughout this disclosure. The first modular battery terminal 104a can be configured to provide electrical communication with an external component, such as another battery housing, an electrical load, etc. The first modular battery terminal 104a can be disposed on an exterior surface of the housing body 101, e.g., disposed on the exterior surface of the first wall 110a. In other embodiments, however, the first modular battery terminal l04a may be disposed on other surfaces of the housing 100 and may comprise other shapes and profiles. For example, in other embodiments, the modular battery terminal l04a may extend outwardly from the housing body 101 to facilitate electrical connection to the external component. Current can flow between the first modular battery terminal 104a and the first breaker 3 a along the first conductive segment 107a. As explained above, in some embodiments, the first segment 107a can be a separate piece of conductive material that is joined to the modular battery terminal 104a and the breaker 3a. In other embodiments, the first pathway Pl is defined between the modular battery terminal l04a and the breaker 3 a along a continuous piece of conductive material. [0093] One end of the first segment l07a can be electrically connected to a first terminal of the breaker 3a, such as the first terminal Tl described and illustrated in connection with Figures 1A-3B and 6A-7. For example, the segment l07a can be welded or soldered to the first terminal Tl, or can be electrically connected in other ways. The second conductive segment l07b can electrically connect to the breaker 3 a and the first cell contact l05a. For example, one end of the second segment l07b can electrically connect to the second terminal T2 of the breaker 3, and the other end of the second segment l07b can electrically connect to the first cell contact l05a. As explained above, in some embodiments, the second segment l07b can comprise a separate piece of conductive material from the breaker 3a and the cell contact l05a. In other embodiments, the second terminal T2 of the breaker 3a and the first cell contact l05a can comprise a continuous piece of conductive material. As one example, as shown in Figure 11 A, the second segment l07b can be bent so as to extend through an aperture of the first cell contact 105a to secure the second segment 107a to the cell contact l05a and to provide electrical connectivity to the first terminal 113a of the first cell H4a. The first bypass conductor l06a can be electrically connected to the third terminal T3 of breaker 3a and the third cell contact l05c, which is connected to the third conductive segment l07c (see Figures 9A, 9B, 10A, and 10B). For example, the first bypass conductor l06a can be connected to the third terminal T3 of the breaker 3 a to provide a bypass path around the cell H4a. The bypass conductor l06a can be adhered to or formed with the housing body 101.

[0094] As explained above in connection with Figures 1A-7, the breaker 3 a can comprise a switch having a normal condition and a fault condition. In the normal condition, as explained above in connection with Figures 1A-7, the first terminal Tl of the breaker 3a may be connected to the second terminal T2 (see Figure 10A). In such an arrangement, where the operating current and/or temperature are within normal ranges, current is allowed to flow along the second electrical pathway P2 through the first cell H4a. For example, in the normal condition, electrons may flow along the pathway P2 from the breaker 3 a (Figure 9 A) along the second segment 107b and the first cell contact 105a, through the first battery cell terminal 113a into the cell 114a, and through the second battery cell terminal 113b (Figure 9B) and into the cell contact l05c and the third conductive segment l07c at the second end portion 112 of the housing 100.

[0095] The third cell contact l05c may serve to convey electrons from the second terminal H3b of the first cell H4a to the third conductive segment l07c. Advantageously, each of the first cell contact l05a and the third cell contact l05c may be sized so as to contact the respective terminals H3a, H3b of the battery cells without using a metal joining operation, such as welding, soldering, etc. Instead, as explained above, electrical contact between the cell contacts l05a, l05c and the cell H4a may be provided by a snap-fit connection in which the cell 114a is urged between the cell contact l05a and the cell contact l05c. It should be appreciated that, although the cell contacts l05a, l05c are illustrated as disk- shaped pieces of conductive material, in other embodiments, the cell contacts l05a, l05c can comprise elongated pieces of conductive material. Moreover, although the cell H4a may be mechanically and electrically connected to the housing 100 by a simple snap-fit connection, in some embodiments, the user may additionally or alternatively conduct a joining procedure (such as welding, soldering, etc.) to connect the terminals H3a, H3b to the cell contacts l05a, l05c, particularly for rechargeable batteries.

[0096] Thus, during normal operation of the larger system, current flows (in the opposite direction to the illustrated arrows) along the second pathway P2, i.e., through the cell H4a. However, as explained above, in some instances, the cell H4a may become overheated or too much current may flow through the cell 114a. As explained above in connection with Figures 1 A-7, if the temperature and/or current flowing through the cell 114a exceeds various predetermined values, then the breaker 3a may enter a fault condition in which the switch 5 in the breaker moves to connect the first terminal T1 of the breaker 3 a with the third terminal T3. In such a fault condition, a minority of the current may still flow between the first terminal T1 and the second terminal T2, and through the cell 114a along the second pathway P2. However, a majority (or all) of the current is shunted or bypassed around the cell 114a along the third pathway P3, which extends between the third terminal T3 of the breaker 3a and the third cell contact 105c. Shunting most or all the current around the cell 114a can prevent the cell 114a from being damaged and can extend the life of the cell 114a. Moreover, in the fault condition, the cell 114a can be bypassed without disrupting the flow of current to the second cell H4b and the larger electrical system. Advantageously, the arrangement shown in Figures 9A-9B can utilize a shorter electrical pathway P2 to and from the cell H4a in normal operation, and a longer bypass pathway P3 through the bypass conductor l06a in a fault condition. The longer bypass pathway P3 may have a higher resistance than the pathway P2 through the cell H4a. The relatively low resistance provided during normal operation can beneficially reduce the loss of power to heat generation.

[0097] As shown in Figure 10B, the first bypass conductor l06a can contact the third cell contact l05c, which provides electrical communication between the first bypass conductor l06a and the third conductive segment l07c. The third conductive segment l07c can define a fourth electrical pathway P4 between the junction of the second and third pathways P2, P3 and the second breaker 3b. For example, in a normal condition, current can flow along the second pathway P2 through the cell 1 l4a and along the fourth pathway P4 and the third segment l07c to the second breaker 3b. In a fault condition, most or all of the current (I 2 in Figure 1B) can flow along the third pathway P3 and the first bypass conductor l06a to the third cell contact l05c and third segment l07c, and a minority of the current (I3 in Figure 1B) can flow along the second pathway P2 to the third cell contact l05c and third segment l07c. The combined current (/ _/ in Figure 1B) can flow along the third segment 107c and the fourth pathway P4 to the breaker 3b.

[0098] As with the first breaker 3 a, the second breaker 3b has a normal operating condition and a fault condition. In a normal condition, the third segment l07c is connected to the first terminal Tl of the breaker 3b, which is in turn connected to the second terminal T2 of the breaker 3b. The second terminal T2 of the breaker 3b can be connected with the fourth conductive segment l07d, the fourth cell contact l05d, and the first battery cell terminal H3a of the second cell H4b (see Figure 10B). Thus, in the normal condition, the current flows through the breaker 3b along a fifth pathway P5 through the second cell 114b between the fourth cell contact 105d and the second cell contact 105b (see Figure 9B).

[0099] In a fault condition (such as an overtemperature and/or overcurrent fault), the switch of the breaker 3b can move to connect the first terminal Tl with the third terminal T3, which can be connected with a first end of the second bypass conductor l06b. As with the first breaker 3a, if the second cell H4b is in a fault condition, a majority of the current flows through the bypass conductor l06b along a sixth electrical pathway P6, and a minority of the current flows through the cell H4b along the fifth electrical pathway P5. As noted previously, the arrowheads in the drawings illustrate the direction of electron flow (assuming H3a is positive and H3b is negative), such that the current flows in the opposite direction to the illustrated arrowheads.

[0100] As shown in Figures 9A, 10A, and 11B, a second end of the second bypass conductor 106b can be connected to the fifth electrical segment 107e. In addition, the second cell contact l05b can be connected to the fifth electrical segment l07e. Current flowing along the fifth and/or sixth pathways P5, P6 can flow along a seventh electrical pathway P7 through the fifth segment 107e and the sixth segment 107f to the second modular battery terminal 104b. The second modular battery terminal 104b can be formed on an exterior surface of the housing 100, e.g., on the exterior surface of the second wall 110b. The second modular battery terminal 104b can be configured to provide electrical communication with another external component, such as another battery housing or an electrical load. As shown in Figures 11A-11B, a channel 116 can be defined along a portion of the housing walls 110 and can be sized and shaped to receive the sixth segment 107f.

[0101] Figure 12 is a rear right perspective view of a battery pack comprising a string 120 of battery housings 100A-100D connected together, according to various embodiments. Advantageously, the battery housing 100 shown in Figures 9A-11B can provide a modular platform by which numerous battery housings can be electrically and mechanically connected together. The use of numerous battery housings connected together in a modular arrangement can beneficially enable the use of high voltage power supplies for high power applications, such as automotive applications (cells for electric vehicles such as cars, scooters or bicycles), computing applications (laptop computers, mobile smartphones, tablets, etc.), medical devices, etc. Moreover, by incorporating one or more breakers 3 into each housing 100A-100D, the battery pack can continue to deliver current for device operation even if one or more of the battery cells is bypassed due to a fault condition, and the user can replace a defective battery cell by simply removing the battery cell from the battery housing and snapping in a replacement battery cell, without disrupting the supply of current to the electrical load. [0102] As shown in Figure 12, the first modular battery contact l04a of the first housing 100A can electrically connect to the second modular battery contact l04b of the second housing 100B, the first modular battery contact l04a of the second housing 100B can electrically connect to the second modular battery contact l04b of the third housing 100C, and the first modular battery contact l04a of the third housing 100C can electrically connect to the second modular battery contact l04a of the fourth housing 100D. The connection between the respective first and second modular battery contact l04a, l04b of adjacent housings can be made without the use of metal joining processes. For example, in some embodiments, the modular battery contacts l04a, l04b of adjacent housings can snap together to provide electrical and mechanical connection between adjacent housings. In some embodiments, the modular battery contacts l04a, l04b of adjacent battery housings can interlock in a sliding connection to provide electrical and mechanical connection between adjacent housings. In some embodiments, the user may elect to weld or solder the modular battery contacts l04a, l04b of adjacent housings together. In various embodiments, the housing body 101 of each housing 100A-100D can comprise various mechanical locking features to provide mechanical engagement between adjacent battery housings. Although four housings 100A-100D are illustrated in Figure 12, it should be appreciated that any suitable number of battery housings can be connected to one another. When the string 120 is assembled, the outermost electrical modular battery contacts ( e.g ., the second modular battery contact l04b of the housing 100A and the first modular battery contact l04a of the housing 100D in Figure 12) can electrically connect to the desired electrical load (e.g., motor) to provide power thereto.

[0103] Figure 13 A is a schematic circuit diagram of a battery pack comprising a string 120 of battery housings 100A-100C connected in series, according to various embodiments. Unless otherwise noted, reference numerals shown in Figure 13A represent the same or similar components as those shown in Figures 1A-12. As explained herein, multiple battery housings 100A-100C can be connected together in series. Connecting the housings 100A-100C together in series can advantageously increase the total amount of electrical energy available for supplying to the electrical load. For example, three housings 100A-100C are shown in Figure 13A, with each housing 100A-100C comprising two cells 114a, 114b. If each cell 1 l4a, 1 l4b has a voltage of V, then the string 120 of six battery cells connected in series as shown supplies a voltage of 6V. The modularity of the housing enables the use of numerous batteries for applications with high power requirements. If one of the battery cells fails, then the associated breaker 3a, 3b can advantageously route the majority of the current around the failed battery cell to provide power to the larger system. The snap-fit connection of the housings 100A-100C enables the user to easily remove and replace the failed battery cell. Moreover, as shown in Figure 13A, the battery management system (BMS) can connect to respective first and second connectors 135a, 135b which are electrically coupled with selected terminals ( e.g ., negative terminals) of the battery cells. As explained herein, the BMS can monitor the voltage of each battery cell and can alert the user if the voltage of a particular cell rises or falls to undesirable levels. For example, in some embodiments, the BMS can determine if one or more battery cells has been bypassed due to, e.g., the switch being in a fault condition.

[0104] Figure 13B is a schematic circuit diagram of a battery pack comprising a group 122 of battery housings 100A-100B connected in parallel, according to various embodiments. Unless otherwise noted, reference numerals shown in Figure 13B represent the same or similar components as those shown in Figures 1A-12. Unlike the embodiment of Figure 13A, in Figure 13B, two battery housings 100A and 100B are connected in parallel. If one of the battery cells from the first housing 100A fails (e.g., cell H4a), then the breaker 3a can bypass the cell H4a and supply current to the second cell H4b and the larger electrical system. In addition, as with Figure 13 A, the BMS can electrically connect to respective first and second connectors 135a, 135b to monitor the voltage of each battery cell, as explained above.

[0105] One challenge with the arrangement shown in Figure 13B is that, if one cell fails and is bypassed by the breaker, then the resulting arrangement would include one cell in parallel with two cells. The resulting imbalance in voltage across the two strings may damage the cell which remains operational, and/or may reduce the performance of the larger electrical system. In some embodiments, such a voltage imbalance may be addressed by providing a diode (e.g., a Schottky-type diode) in each parallel string to prevent reverse biasing through the cells. In some embodiments, the potential voltage imbalance may be addressed by providing a transistor in each string ( e.g ., a p-channel MOSFET), which can act similar to a diode to prevent or reduce reverse biasing through the cells.

[0106] Figure 14 is a schematic system diagram of a battery pack comprising a string 120 of cells H4a-l l4e connected in series with one another and with a buck-boost converter 130. The cells H4a-l l4e can be coupled with any of the battery housings 100 disclosed herein, or can be connected together in any other suitable manner. The buck-boost converter 130 can comprise a DC-to-DC conversion structure which maintains the output voltage of the string 120 within an acceptable voltage range. For example, if one of the cells H4a-l l4e is bypassed from the string by the breaker, then the overall voltage of the string 120 would drop by an amount equal to the voltage supplied by the bypassed cell. The buck- boost converter 130 can advantageously maintain the output of the string 120 within a desired voltage range. For example, as shown in Figure 14, if each cell H4a-l l4e supplies a voltage of 3.6V, then the string 120 would normally supply 18V total. If one of the cells is bypassed, then the supplied voltage would drop to 14.4V total. The buck-boost converter 130 can maintain the total output of the string 120 at 18V, even if one or more cells is bypassed.

[0107] As explained herein, when one or more cells is bypassed by the breaker due to a fault condition, the bypassed cell does not interrupt the current supplied to the other cells and the electrical load. When the overcurrent and/or overtemperature fault condition subsides, the breaker can reset and return to the normal operational condition, as explained above in connection with Figures 1A-7. Moreover, the user can easily remove and replace the bypassed and damaged cell with a new cell using a simple snap-fit connection that provides electrical and mechanical connection of the new cell with the housing. In various embodiments, an electrical battery monitoring system can be provided which determines whether a cell is bypassed during use. The battery monitoring system can send a signal to the user to alert the user that one or more cells should be replaced. To facilitate the use of a battery monitoring or management system (BMS), terminals or contact points can be incorporated into the modular battery housing which facilitate the connection of the BMS to a point in the circuit between each of the cells. The use of the breakers disclosed herein can be integrated into the housing for a battery or battery pack to automatically monitor overtemperature and/or overcurrent fault conditions can beneficially reduce the costs for providing breakers at the housing level, rather than within the battery cells themselves. Eliminating breakers for each cell can reduce the overall costs of the system while increasing safety of the system relative to omitting breakers. Moreover, utilizing the breakers disclosed herein can also reduce the need for costly thermal management systems, such as liquid cooling systems. In some embodiments, one or more heating elements, for example PPTC elements, may be incorporated into the housing to improve the performance of the battery, especially in cold environments.

III. EXAMPLES OF ADDITIONAL CIRCUIT BREAKERS

[0108] Additional embodiments disclosed herein relate to circuit breakers that can be integrated into various types of electrical circuits, including, e.g., battery cell monitoring circuits. As explained above, the embodiments disclosed herein can be useful in providing overcurrent and/or overtemperature protection for high capacity and/or high voltage battery packs for systems such as electric cars, electric bicycles, or any other suitable system. In some embodiments, the circuit breakers can comprise switches similar to switches disclosed above. In some embodiments, the breaker can comprise a three-terminal switch, similar to the three-terminal switches described above. In other embodiments, the breaker can comprise a two-terminal switch. In various embodiments, the breaker can comprise a positive temperature coefficient (PTC) resistor configured to assist in moving the breaker from a first condition (e.g., a normal operating condition) to a second condition (e.g., a fault condition), or vice versa.

A. Circuit Breakers for Cell Balancing

[0109] Various embodiments disclosed herein can be used for cell balancing to improve the capacity of a battery pack with multiple cells (e.g., provided in series or in parallel). For example, different battery cells within a battery pack may have different respective states of charge (SOC), which can negatively affect the battery pack’s capacity and lifespan. In some embodiments, therefore, the cell with the smallest SOC may limit the ability to charge and/or operate the other cells in the battery pack. Some circuits employ active balancing techniques, in which an integrated circuit chip can be configured to transfer electrical energy from cells with a high SOC to other cells with a lower SOC. For example, in various implementations, a battery management system (BMS) can comprise integrated circuitry comprising one or more direct current-to-direct current (DC-to-DC) converters, which can regulate the voltage to be applied to the cells with the lower SOC. Various embodiments disclosed herein may beneficially simplify the design of the BMS and/or provide back-up protection (e.g., redundancy) in the event that the BMS fails or is inactive.

[0110] Figure 15A is a schematic system diagram showing an electrical device 200 in accordance with various embodiments. The device 200 can comprise a plurality of battery cells 202a, 202b in electrical communication with a battery management system 240. Although only two cells 202a, 202b are shown in Figure 15 A, it should be appreciated that any suitable number of battery cells may be used in the electrical circuit 200. As explained herein, the battery management system 240 can be configured for active balancing of the cells in the battery pack. The device 200 also includes a transistor 241 (which may comprise a metal oxide semiconductor field effect transistor, or MOSFET, such as an n-channel MOSFET), which can be controlled by the battery management system 240. The transistor 241 can include any suitable type of transistor, including, e.g., an insulated gate bipolar transistor (IGBTs), MOSFETs, bipolar junction transistors (BJTs), etc. Figure 15A illustrates the device 200 in a balancing configuration in which the battery management system 240 has detected a fault condition for the cell 202a (e.g., that the cell 202a may be overcharged relative to other cells). In Figure 15 A, the battery management system 240, upon detection of a fault condition, can place the transistor 241 in an ON position so as to transfer energy to another cell (e.g., cell 202b) in the battery pack. The battery pack can continue charging after bypassing the cell 202a. In the OFF position, no current may pass through the transistor 241, such that the current passes through the battery cell 202a in a normal operating condition.

[0111] In the fault condition, electrical current can be transferred through the transistor 241 along a bypass pathway Po. In some embodiments, the amount of current along the bypass pathway Po may be higher than desired, for example, if the current along the bypass pathway Po were to cause overcurrent or overtemperature conditions in other cells, or if the transistor 241 and/or battery management system 240 were to be damaged or otherwise inactive. Accordingly, in the embodiment of Figure 15 A, a breaker 203 can be connected in series with the transistor 241 (for example, with a drain of an n-channel MOSFET transistor). The breaker 203 can comprise a switch 204. The switch 204 can comprise any of the switches 4 disclosed herein. For example, in some embodiments, the switch 204 can comprise a thermally-activated mechanical switch, such as a bimetal element ( e.g ., a dome shaped bimetal element), as described herein. In other embodiments, other types of switches may be suitable. As above, the switch 204 can comprise a first terminal Tl, a second terminal T2, and a third terminal T3. Furthermore, in various embodiments, the switch 204 can be resettable. In other embodiments, the switch 204 may not be resettable, or may be manually resettable.

[0112] First and second discharge resistors 205a, 205b can be provided in parallel, as shown in Figure 15 A. In a first condition, the first terminal Tl can be connected to the second terminal T2, which is illustrated in Figure 15 A. In the first condition shown in Figure 15 A, when the transistor 241 is placed in the ON state, current may flow along a first pathway Pi through terminals Tl and T2, through the second discharge resistor 205b, and to another cell (e.g., cell 202b) of the battery pack. If the current flowing along the first pathway Pi exceeds a particular current and/or temperature threshold, then the switch 204 (e.g., a bimetallic dome switching element) may flip so as to electrically connect the first terminal Tl with the third terminal T3. In a second condition (e.g., a fault condition), the current can flow along a second pathway P ₂ through the first discharge resistor 205a and to another cell (e.g., cell 202b) in the battery pack.

[0113] The first and second discharge resistors 205a, 205b can comprise any suitable type of resistor. In some embodiments, for example, one or both discharge resistors 205a, 205b can comprise positive temperatures coefficient (PTC) resistors. In various embodiments, one or both of the resistors 205a, 205b can comprise a variable-resistance resistor, such that the user can select the desired resistance for either pathway Pi, P ₂ . In some embodiments, one of the resistors 205a, 205b can comprise a PTC resistor, and the other resistor 205b may not be a PTC resistor, or vice versa. In such an embodiment, if the amount of current passing through the second resistor 205b along the first pathway Pi is excessive, the switch 204 can switch so as to transfer the current through the first resistor 205a (e.g., a PTC resistor). In such an embodiment, the inrush of current through the first resistor 205a (in this example, a PTC resistor) may raise the temperature of the first resistor 205a and, accordingly, its resistance, which can reduce the current along the second pathway P ₂ . The resistance of the first resistor 205a can be the same as or different from ( e.g ., higher than) the resistance of the second resistor 205b.

[0114] Beneficially, the embodiment of Figure 15A can provide redundancy or back-up circuitry such that, if excessive current passes through the bypass pathway Po and the transistor 241, the breaker 203 can provide a passive backup circuit that further reduces the current passing into the subsequent battery cell (e.g., cell 202b). Although the cells 202a, 202b are shown in Figure 15 A, each cell of the battery pack can have its own associated bypass pathway. Furthermore, the transistors 241 of Figure 15A may be selected to have a large current capacity to accommodate the relatively large inrushes of current that may occur when the cell 202a is to be bypassed. The embodiment of Figure 15A can advantageously enable the user of the device 200 to use smaller transistors 241, e.g., transistors that may handle lower amounts of electrical current. Thus, the embodiment of Figure 15A can simplify battery management circuits and provide redundant overcurrent protection, such as reducing the size of the transistors 241 and providing balancing protection if the transistor 241 and/or the battery management system 240 is damaged or inactive.

[0115] Figure 15B is a schematic system diagram showing an electrical device 200 in accordance with another embodiment. Unless otherwise noted, the components of Figure 15B may be the same as or generally similar to like-numbered components of Figure 15 A. For example, as with Figure 15 A, the device 200 can comprise a battery management system 240, a transistor 241 (which can comprise any suitable type of transistor, as explained above) in communication with the battery management system 240, a battery cell 202a, and a breaker 203 in electrical communication with the transistor 241. The breaker 203 of Figure 15B may operate in a generally similar manner as the breaker 203 of Figure 15 A.

[0116] Unlike the embodiment of Figure 15 A, however, in the embodiment of Figure 15B, an additional breaker 243 may be provided in parallel with the battery cell 202a, disposed electrically between the battery cell 202a and the breaker 203. For example, in some arrangements, the battery management system 240 and/or the transistor 241 may malfunction, or otherwise be inactive. In such cases, the breaker 203 may not regulate the current through the pathways Pi, P ₂ , e.g., if the transistor 241 blocks current to the breaker 203. Beneficially, the breaker 243 may act as an additional level redundancy in case the battery management system 240 and/or the transistor 241 malfunctions.

[0117] In some embodiments, the breaker 243 can comprise a switch 242, which can comprise an electrically- or thermally-activated mechanical switch ( e.g ., a bimetallic element, such as a dome-shaped bimetallic element), and a third discharge resistor 205c in series with the switch 242. In various embodiments, the switch 242 can be thermally connected with the cell 202. The breaker 243 can be thermally coupled or bonded to the cell 202a, so as to provide passive cell balancing in the event the cell 202a exceeds a temperature threshold. The switch 242 may be a normally-open switch, such that the switch 242 is open during a normal operating condition. The switch 242 is illustrated in a closed, fault condition in Figure 15B. Furthermore, in various embodiments, the switch 242 can be resettable. In other embodiments, the switch 242 may not be resettable, or may be manually resettable. The third discharge resistor 205c can comprise any suitable type of resistor, including a PTC resistor. Beneficially, the third discharge resistor 205c can limit the current passing through the breaker 243 when the switch 242 is closed, e.g., when the first terminal Tl is connected to the second terminal T2. In various embodiments, the third discharge resistor 205c can comprise a variable resistor, such that the user can select the value of the load for the application under consideration.

[0118] The switch 242 can comprise a first terminal Tl and a second terminal T2. During a normal operating condition of the battery pack (and/or the battery management system 240 during a fault condition of the cell 202a), the transistor 241 may be OFF (so as to block current from passing to the breaker 203), and the switch 242 may be open, such that current can pass through the battery cell 202a. If the battery management system 240 detects an overcurrent or overtemperature condition, then the battery management system 240 can switch the transistor 241 to ON, and the breaker 203 can operate as described above in connection with Figure 15 A. If, however, the battery management system 240 and/or the transistor 241 malfunction (such that no current passes through the transistor 241), then the temperature of the switch 242 may rise due to the overcurrent state of the cell 202a, flipping the switch 242 from the open state to the closed state shown in Figure 15B, such that the first terminal Tl is electrically connected to the second terminal T2. The current / may pass along a pathway P3 through Tl and T2, through the third discharge resistor 205c, and to another cell (not shown), as illustrated in Figure 15B. The breaker 243 shown in Figure 15B can therefore provide a separate redundant bypass pathway around the cell 202a in a fault condition, even in cases in which the battery management system 240 and/or the transistor 241 malfunctions. Beneficially, the breaker 243 of Figure 15B can operate independently of the battery management system 240 and the transistor 241 to provide redundant circuit protection.

B. Circuit Breakers for Battery Cell Hot Swapping

[0119] Various embodiments disclosed herein can also be used for managing overcurrent and/or overtemperature conditions when battery cells are hot swapped, e.g., when replacing battery cells during operation of the device (e.g., without shutting down the device). Figure 16 is a schematic system diagram of an electrical device 300 incorporating a breaker 303 for managing overcurrent conditions during hot swapping of a battery cell 302, according to various embodiments. Unless otherwise noted, the components of Figure 16 may be the same as or generally similar to like-numbered components of Figures 15A-15B, with the reference numerals incremented by 100 relative the reference numerals of Figures 15A-15B.

[0120] For example, the electrical device 300 can comprise a battery pack comprising a plurality of battery cells in series to supply power to an electrical system, such as an electric automobile, an electric bicycle, an electric power tool, etc. Only one cell 302 is shown in Figure 16, but as explained above, any suitable number of battery cells can be provided. A battery management system 340 can be configured to manage the state of charge of the cells of the battery pack. Furthermore, cell balancing circuitry 344 can be connected to the battery management system 340 for balancing the charge of the cell 302.

[0121] In various situations, the battery cell 302 may be electrically connected to the device 300 while the system is on or activated. For example, during manufacture of the device 300, the battery cell 300 may be inserted into the device, and the device components can be activated (e.g., during a connection phase of the device). When the device is activated during manufacturing or assembly, there may be a sudden inrush of initial current Io along the wiring that leads to the battery management system 340 and the balancing circuitry 344. Similarly, if the cell 302 were to be replaced or swapped during operation of the device 300, there may likewise be a rush of current Io into the balancing circuitry 344 and battery management system 340. Such inrushes of current may damage the balancing circuitry 344, the battery management system 340, and/or other components of the device 300.

[0122] Accordingly, in the embodiment of Figure 16, the breaker 303 can be provided to protect against the initial inrushes of current that may occur during hot swapping of a battery cell 302. The breaker 303 can comprise a normally open switch 304 in parallel with a resistor 305, along the electrical pathway between the cell 302 and the battery management system 340 and balancing circuitry 344. As with the embodiments above, the switch 304 can comprise a thermally- or electrically-activated mechanical switch, for example a bimetallic element, such as a dome-shaped bimetallic element that can flip positions when the temperature of the element exceeds a predetermined threshold. The resistor 305 can comprise any suitable type of resistor. In some embodiments, the resistor 305 may not comprise a PTC resistor. In other embodiments, the resistor 305 may comprise a PTC resistor.

[0123] In the embodiment of Figure 16, the switch 304 is initially in the open configuration, which is shown in Figure 16. When the cell 302 is hot swapped into the device 300 during manufacturing or use, the inrush of current Io may pass through the resistor 305, as shown in Figure 16 ( e.g ., during a connection phase of the cell). The switch 304 ( e.g ., a thermally activated switch) may be thermally connected to the resistor 305 (e.g., may be packaged with and/or contacting the resistor 305) such that, as the current Io passes through the resistor 305, the temperature of the resistor 305 rises. The initial inrush of current Io may therefore be significantly reduced by the resistor 305 so as to lower the current that passes to the battery management system 340 and/or the balancing circuitry 344, mitigating or preventing damage to the battery management system 340 and balancing circuitry 344 during the initial inrush of current Io.

[0124] When the temperature of the switch 304 and/or the resistor 305 (and/or current through the resistor 305) exceeds the predetermined threshold, then the switch 304 can switch to the closed connection such that a first terminal Tl is electrically connected to a second terminal T2, thereby bypassing the resistor 305 (e.g., during an operational configuration). The resistor 305 can be selected to have resistance properties sufficient to reduce the inrush of current Io to levels that do not damage the balancing circuitry 344 and/or the battery management system 340 during the time period of the inrushing current, which may be a relatively short period of time ( e.g ., on the order of milliseconds). Accordingly, when the switch 304 moves to the closed position to connect the first and second terminals Tl, T2, the current passing through the circuit may be at levels that can be accommodated by the balancing circuitry 344 and/or the battery management system 340. The lower current (e.g., after the resistor 305 has sufficiently reduced the inrush current Io) can pass through the closed switch 304 and into the battery management system 340 and/or the balancing circuitry 344.

[0125] In some embodiments, the switch 304 may be nonresettable such that the switch 304 is configured to not automatically move back to the open configuration shown in Figure 16 after it moves to the closed configuration. For example, in some electrical systems (such as electric automobiles or telecommunications system batteries), it may be preferable to prevent the switch 304 from opening again, since the resistor 305 would reduce or block the current provided to the battery management system 340. In such embodiments, for example, the resistor 305 may not comprise a PTC resistor. In some embodiments, the switch 304 may be manually resettable. For example, a button and/or mechanical linkage can be provided on the device 300, such that the user can manually reset the switch 304 to the open position, for example, before replacing the cell 302. In still other embodiments, the resistor 305 can comprise a PTC resistor, which can allow the switch 304 to be automatically resettable for some applications.

[0126] Accordingly, the embodiment disclosed in Figure 16 can beneficially be used to prevent damage to the balancing circuitry 344 and/or the battery management system 340 when the cell 302 is hot swapped. In some embodiments, the switch 304 may be non resettable and may not comprise a PTC resistor 305 in the breaker 303. Such embodiments can also simplify the manufacturing process of the device 300, so as to obviate the need for the manufacturer to manually design solutions for handling inrush currents.

C. Additional Examples of Breakers

[0127] Figures 17-18B illustrate additional examples of breakers or fuses. Figure 17 is a schematic system diagram of a fuse device 400 than can incorporate various embodiments of the breakers disclosed herein. Unless otherwise noted, the components of Figure 17 may be the same as or generally similar to like-numbered components of Figure 16, with the reference numerals incremented by 100 relative the reference numerals of Figure 16. The fuse device 400 can comprise first and second I/O pins pi and pi configured to electrically connect to an external device for overcurrent and/or overtemperature protection, such as a battery pack and/or battery management system. The fuse device 400 can comprise a transistor 441 in electrical communication with a resistor R and a capacitor C that are in parallel, between the second pin pi and the transistor 441. The transistor 441 can comprise any suitable type of transistor, e.g., an n-channel MOSFET transistor such as that shown in Figure 17, or an insulated gate bipolar transistor (IGBTs), MOSFETs, bipolar junction transistors (BJTs), etc. A gate driver circuit 448 can be provided to control the operation of the gate G of the transistor 441. During normal operation of the larger electrical system, the transistor 441 may be placed in the OFF position, for example, by the gate driver circuit 448, such that no electrical current flows through the fuse device 400.

[0128] The fuse device 400 can also comprise a breaker 403. The breaker 403 can comprise a switch 404, which may be an electrically- or thermally activated mechanical switch similar to the switches described herein. As explained above, for example, the switch 404 can comprise a bimetallic element, such as a dome-shaped bimetallic element. The switch 404 can comprise a three-terminal switch in some embodiments with a first terminal Tl, a second terminal T2, and a third terminal T3. In other embodiments, the switch 404 can comprise a two-terminal switch. In various embodiments, an output terminal T _out can be provided to electrically connect to the load L during normal operation of the device. In the illustrated embodiment, the switch 404 can comprise a normally-closed switch in which Tl is electrically connected to T3 during normal operation of the larger electrical device (e.g., when the transistor 441 is OFF). The breaker 403 can also comprise a resistor 405 in series with the third terminal T3. In some embodiments, the resistor 405 may not comprise a PTC resistor. In other embodiments, the resistor 405 may comprise a PTC resistor. In the illustrated embodiment, the third terminal T3 can be electrically connected to the resistor 405 of the breaker 403 and the drain D of the transistor 441. During normal operation, current /„ can pass between the first terminal Tl and the third terminal T3, can connect to the load L by way of the output terminal Tout.

[0129] The transistor 441 can be turned ON by the external electrical device which is connected to the fuse 400, such as a battery management system (not shown). When the transistor 441 is turned ON, for example by a battery management system, current can flow through the fuse device 400, e.g., to bypass portions of the larger external electrical device, such that current flows through the transistor 441, the resistor 405, and the closed switch 404. When the temperature of the resistor 405 exceeds a predetermined threshold, the switch 404 can move to terminal T2, for example, an open or fault configuration. In such arrangements, the fuse 400 can remain open and may be non-resettable (or manually resettable, e.g., by way of a button). In other arrangements, however, the fuse 400 may be automatically or manually resettable. In such embodiments, the fuse 400 can enable the larger electrical device to shut down or have a reduction in operating power when tripped, e.g., a power supply or battery may be bypassed upon tripping.

[0130] Figure 18A is a schematic circuit diagram of a breaker 503 that incorporates a thyristor 556 in series with a resistor 505, shown in a normal operating condition, according to various embodiments. Figure 18B is a circuit diagram of the breaker 503 of Figure 18A, shown in a fault condition. Unless otherwise noted, the components of Figures 18A-18B may be similar to the components illustrated in Figures 1-17, with the reference numerals beginning at 500. As explained above, the switch 504 can comprise a bimetallic switching element, e.g., a dome- shaped switching element in some embodiments. The resistor 505 can comprise any suitable type of resistor. In some embodiments, the resistor 505 can comprise a PTC resistor. In other embodiments, the resistor 505 may not comprise a PTC resistor.

[0131] The thyristor 556 can be any suitable thyristor surge protection device, including, e.g., TISP ^® Thyristor Surge Protectors, manufactured by Bourns, Inc., of Riverside, California. The thyristor 556 shown in Figure 18A (e.g., a normal operating condition) can be configured to be in an open state when the voltage across the thyristor 556 is less than a predetermined voltage threshold. Accordingly, in Figure 18A, the first terminal Tl can connect to the second terminal T2 in the normal condition, and the current h can pass through the switch 504 and the terminals Tl, T2. In Figure 18A, since the thyristor 556 is in an open state, no current may pass through the thyristor 556 or the resistor 505. If the battery cell to which the breaker 503 is connected becomes overcharged, the thyristor 556 can detect the overcharging ( e.g ., based on a voltage exceeding a predetermined threshold) and move to a closed state in which current passes through the thyristor 556 and the resistor 505.

[0132] If the current raises the temperature of the resistor 505 and/or the switch 504 to a sufficiently high temperature, the switch 504 can flip or reverse so as to connect the first terminal Tl with the third terminal T3, as shown in Figure 18B. In Figure 18B, the current h can be split into a second current h pathway along the switch 504 through the first and third terminals Tl, T3, and a third current h pathway through the thyristor 556 and the resistor 505. In some embodiments, as explained above, a majority of the current can pass along the second current pathway, and a minority of the current can pass along the third current h pathway. The breaker 503 can comprise a resettable breaker such that, when the temperature of the resistor 505 drops below another threshold, as explained above, the switch 504 may move back into the normal operating condition to connect the first terminal Tl with the second terminal T2.

[0133] In various embodiments, a two-terminal, normally closed breaker (which may or may not include a PTC resistor) can be used with one of its two terminals in physical and electrical contact with one of a cell’s terminals or electrodes, and the other breaker terminal can be connected to a line or wire that is connected to a BMS line for thermal monitoring. In such a configuration, if the particular cell’s temperature exceeds a trip temperature of the breaker, the BMS thermal monitoring line for that cell can experience an open circuit, which the BMS can be programmed to interpret as that cell having exceeded the trip temperature of its connected breaker. The breaker may be configured to intermittently open and close as it cools down when open and heats up when closed. Beneficially, in this embodiment, the breaker can replace or substitute for a more expensive and potentially larger thermal monitoring device, for example, a PTC.

[0134] Although this invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while several variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.