Power supply device and components thereof

Abstract

A battery module comprising: a plurality of battery cells held in a respective plurality of battery receptacles; a plurality of inter-cell connectors interconnecting the plurality of battery cells; a battery tray comprising the plurality of battery receptacles; and a power interface facilitating power input and power output; wherein the inter-cell connectors are configured as heat spreading members extending through the first plurality of battery receptacles to interconnect the respective plurality of battery cells.

Description

Technical Field

[0001] The present invention relates to power supply equipment, and more particularly to mobile power supply equipment and components thereof. Background Technology

[0002] Mobile devices are increasingly powered by electricity, which is considered a green or relatively green energy source. The amount of electrical energy available to power mobile devices, such as electric vehicles, is typically limited and depends on the energy stored in the device. The situation can become problematic when stored energy is depleted and the mobile device is far from a charging station. Mobile power supply devices capable of supplying energy to mobile devices powered by stored electrical energy would be useful and desirable. Summary of the Invention

[0003] A power supply device is disclosed, comprising an energy storage source, a power interface, and electronic circuitry configured to control the operation of the device. The energy storage source can be charged to store electrical energy and can be discharged to release the stored energy. The device can be configured as a power station (e.g., a mobile power station) for supplying power to a load (e.g., an electric vehicle).

[0004] The device, abbreviated as MOBO-I, includes a main housing, wheels that support the main housing to provide mobility, and a battery assembly and electronic circuit assembly housed in the main housing. The battery assembly includes multiple battery modules connected in series and / or in parallel. Each battery module includes a module housing, an assembly of battery cells connected in series and / or in parallel, and a ventilation device for moving air into and / or out of the battery module. Attached Figure Description

[0005] The disclosure of this invention is described by way of example with reference to the accompanying drawings, wherein,

[0006] Figure 1A and Figure 1B These are the front and rear perspective views of an exemplary power supply device.

[0007] Figure 1C yes Figure 1A Bottom view of the device,

[0008] Figure 1D and Figure 1E These are the front view and front perspective view of the device, with the front panel removed.

[0009] Figure 1F This is a perspective view showing the chassis of the equipment, on which the drive unit is mounted.

[0010] Figure 2A This is a schematic block diagram showing a device connected to an external power source.

[0011] Figure 2B This is a schematic block diagram showing a device connected to an external load.

[0012] Figure 3A and Figure 3B This is a perspective view of an exemplary battery module.

[0013] Figure 3C yes Figure 3A A longitudinal section view of the power supply equipment taken along the main longitudinal axis L-L'.

[0014] Figure 3D This is a schematic diagram illustrating an exemplary compartment layout of the power module.

[0015] Figure 3E and Figure 3F yes Figure 3A An exposed view of an alternative exemplary battery construction for a battery module, wherein the upper module housing has been removed.

[0016] Figure 4 This is an exploded view showing exemplary main components of a power module.

[0017] Figure 5A This is an exposed perspective view of the battery module.

[0018] Figure 5B This is a perspective view of an exemplary substrate showing thermally conductive tracks.

[0019] Figure 6A and Figure 6B These are, respectively, a perspective view and a front view of an exemplary battery row connector including an array of exemplary battery row connectors.

[0020] Figure 6C yes Figure 6A An enlarged view of the circular portion (A) of the battery bank connector.

[0021] Figure 7 This illustrates the interconnection of two rows of batteries via an exemplary inter-row connector.

[0022] Figure 8A and Figure 8B This is a perspective view of an exemplary battery tray for a power supply device.

[0023] Figure 8C yes Figure 8A A top view of the battery tray.

[0024] Figure 8D and Figure 8E This is an enlarged view of the circular parts (B, C) of the battery tray.

[0025] Figure 9 It shows how to... Figure 8A The combined battery tray is formed by the latching of two battery trays.

[0026] Figure 9A yes Figure 9 An enlarged view of the circular portion (D) of the combined battery tray, showing the interface between the two battery trays. Detailed Implementation

[0027] An exemplary power supply device 1000 includes a main housing on which an energy storage source, a power interface, and electronic circuitry for controlling the operation of the device are mounted. The device 1000 is movable and includes a main housing 1100 supported on a plurality of wheels, such as... Figure 1A and Figure 1B As shown. The wheels are mounted on the chassis 1120, which is the base of the main housing, as... Figure 1C As shown.

[0028] A battery assembly comprising multiple battery modules constitutes an exemplary energy storage source for device 1000. The battery assembly includes, exemplary, multiple (four) battery modules 1200A, 1200B, 1200C, and 1200D, as shown below. Figure 1D and Figure 1E As shown.

[0029] Electronic circuits include power circuits, communication circuits, and control circuits. Power circuits include power input circuits and power output circuits. The power input circuit may include a first power converter, which may be an AC-DC converter, and the power output circuit may include a second power converter, which may be a DC-DC converter. The AC-DC converter may be configured to convert AC mains power into DC power for internal device operation, such as charging a battery pack. The DC-DC converter may be configured to convert a battery voltage component into another DC voltage for output. The DC output voltage may be higher or lower than the battery pack voltage. Power circuits may be configured as: a power input module including a power input port, a power output port, and an AC-DC converter interconnecting the power input port and the power output port; and a power output module including a power input port, a power output port, and a DC-DC converter interconnecting the power input port and the power output port.

[0030] The communication circuit may include internal communication circuitry to facilitate data communication within the device, and external communication circuitry to facilitate data communication between the device and the external world (such as other compatible power supply equipment). The communication circuit may include a data communication front end and may be configured as a communication module or multiple modules.

[0031] The control circuitry is configured to control the operation of the device and includes a battery management system (“BMS”) configured to control battery operations, including battery charging and discharging. The control circuitry may be configured as one or more control modules. The battery management system is configured to monitor parameters of the battery assembly and the individual battery modules within the battery assembly. Parameters may include electrical parameters such as charge rate, discharge rate, state of charge (SoC), loop current, and / or state of health (SoH); and / or physical parameters including temperature, humidity, and / or the internal pressure of the battery modules.

[0032] The main housing 1100 includes a top portion having a top panel 1102, a bottom portion having a bottom panel 1104, and a peripheral wall 1106 interconnecting the top and bottom portions. The top panel, bottom panel, and peripheral wall cooperate to form a cabinet with internal compartments in which components of the equipment (including electronic circuitry and battery packs) are housed. An exemplary main housing is organized into multiple shelves, compartments, and / or receptacles for housing a battery module 1200, a power module 1300, a control module 1400, and a communication module. The peripheral wall may include multiple side panels. One or more of the side panels may be removable to allow access to the interior of the main housing containing the modules for maintenance. The main housing may include a rigid rack frame on which the top panel and peripheral wall are mounted. The rack frame may include slotted vertical posts for mounting (e.g., removably mounting) the modules.

[0033] The main housing may include vents to allow heat exchange between the device and its surrounding environment via air exchange (e.g., forced air exchange). By allowing air to pass through the vents and exchange between the device and its surrounding environment, the internal temperature of the device can be regulated by the heat exchange of air flowing into or out of the main housing to maintain optimal or preferred thermal conditions. In an exemplary embodiment, as in this embodiment, vents in the form of vent grilles are formed on the peripheral wall to allow heat exchange via airflow through the peripheral wall. In an exemplary embodiment, vents are formed on the rear panel of the main housing, such as... Figure 1B As shown.

[0034] The exemplary device includes an exemplary plurality (four) of battery modules arranged to form a stack of battery modules, such as Figure 1EAs shown. The battery module is housed in a battery compartment surrounded by peripheral walls and located above the chassis. The power module, control module, and communication module are housed in a compartment located above the battery compartment because they are lighter (compared to the battery module) and to make them more easily accessible to the user and / or operator. The exemplary battery modules have identical (including substantially identical, to avoid ambiguity) specifications, including rated voltage, rated power, and external dimensions, and are arranged in a vertically aligned manner.

[0035] The exemplary device has a tower shape factor whose height is significantly greater than its base dimension, which can be the width or length of the bottom portion of the main shell, thus limiting the energy storage per unit base area of ​​the main shell cross-sectional area. The term "significantly greater than" as used herein means at least 20% greater, including at least 30%, 40%, 50%, 60%, 80%, 100%, 150%, and 200% or more.

[0036] The tower form also allows for higher energy storage density, enabling more energy to be stored per unit volume of the main housing. In the exemplary device, the battery module is configured such that the battery units occupy a substantial portion of the cross-sectional area of ​​the battery compartment. "Substantial portion" as used herein means at least 50%, including 55%, 60%, 65%, 70%, 75%, 80%, or more.

[0037] The exemplary device has an exemplary height of approximately 1 m (988 mm), an exemplary width of approximately 0.5 m (430 mm), an exemplary length of approximately 1 m (900 mm), an exemplary volume of 0.382 CBM, and a derated energy storage capacity of 8.0 kWh (4 modules, 2 kWh each), corresponding to a derated energy storage capacity higher than 16 kWh per cubic meter (CBM).

[0038] The exemplary device's main housing has an internal compartment volume of approximately 0.27 CBM (i.e., less than 0.3 CBM), a dated energy storage capacity of 8 kWh, and a weight of 150 kg, corresponding to a dated energy storage density of 29.6 kWh per CBM internal compartment volume (= 8 / 0.27). A dated energy storage density of over 20 or 25 kWh per CBM internal compartment volume provides a compact power bank to support loads requiring a larger energy supply to operate. By adding additional battery modules, the dated energy storage density can be increased to over 30 or 35 kWh per CBM internal compartment volume. Dated energy, as used herein, refers to the available energy above the minimum voltage of a battery cell or battery module.

[0039] The battery modules can be connected in series and / or in parallel. In an exemplary embodiment, the battery modules are connected in series such that the battery assembly has a nominal voltage rating of 403.2V, which is four times the nominal voltage rating of the battery modules.

[0040] Exemplary devices include a human-machine interface (HMI) to facilitate interaction between a human operator and the machine. The HMI may include a display, such as an LCD display panel or an LCD touch panel, and optionally include manual control devices, such as joysticks. In an exemplary embodiment, the LCD touch panel may be configured to act as an interface between the user and the machine to enable operational control of the device, including mechanical control of drive mechanisms.

[0041] The device can be configured as a mobile energy source and equipped with wheels to aid mobility. The wheels can be free-running and / or power-driven. See also Figure 1D and Figure 1E The exemplary device's main housing includes a drive compartment in which a drive unit is held. The drive unit includes a drive mechanism 1510 configured to drive a pair of wheels 1520. The drive mechanism may include an electric motor with a motor shaft, a transmission device (such as a gearbox configured to interconnect the motor shaft and the driven wheels), and control electronics for controlling the operation of the electric motor. The control electronics may include a motor drive controller and peripheral circuitry. The driven wheels of the exemplary device are intermediate freewheels located in front of and behind the drive wheels.

[0042] The drive unit optionally includes a power unit dedicated to the drive mechanism. The drive unit may include a drive battery assembly 1530, a DC-DC converter 1540, and an AC-DC converter 1550, such as... Figure 1F As shown. An exemplary drive battery assembly has an exemplary rated voltage of 50V and includes a 14S3P battery cell configuration; an AC-DC converter is designed to convert mains power into DC power to charge the drive battery assembly and has an exemplary rated power of 160W; and a DC-DC converter has an exemplary rated voltage of 12V and an exemplary rated power of 330W for converting the DC power of the drive battery assembly into a 12VDC output for electronic devices associated with the drive mechanism. In an exemplary embodiment, without loss of generality, the drive mechanism may utilize power from a main battery assembly including battery module 1200. The drive compartment is the lowest compartment located below the battery compartment and between the chassis and the main battery assembly. In embodiments without a dedicated power supply for the drive mechanism, without loss of generality, the lowest compartment may serve as the battery compartment.

[0043] The equipment can be driven to move under manual and / or automatic control. Automatic control can be local or remote. For ease of manual control, the drive control device 1560 is mounted on the main housing, for example, on the top panel. Figure 1E As shown.

[0044] The drive control device 1560 can be configured as a drive lever, which acts as a user interface for controlling the movement of the device. An exemplary drive lever projects upward from the top panel of the main housing and is electrically connected to the electronic control circuitry of the drive mechanism. The drive lever can have multiple predetermined discrete operating positions to correspond to multiple modes. These modes may include, for example, a recharge / parked mode, during which the wheels are locked; a movement mode, during which the wheels are released and not locked; a charging mode, during which the device outputs stored electrical energy to an external load; and an OFF mode, during which the device is displayed as powered off. In an exemplary embodiment, a touch panel can be configured as the drive control device. The drive control device is designed to be external to the main housing to allow manual control by the user from outside the device. The drive control device can be configured at a height such that a user of average height can operate the drive control device to drive the device to move while standing or walking next to the mobile device. For example, the drive control device can be located at a height between 1 m and 1.6 m above the supporting ground.

[0045] The control circuitry of the exemplary device is housed in a top housing and further includes an EMS (“Energy Management System”) module, a charging standard module, a data front-end module, and a general control module. The top housing, as used herein, is the housing closest to the top panel of the main housing. The charging standard module may include a CHAdeMo manager module, a CCSCombo manager module, and a GB module. The charging standard module may be a separate module or an integrated management module configured to work with systems conforming to multiple currently popular charging standards without loss of generality. In an exemplary embodiment, the housing is parallel and the modules are substantially horizontal when the device is placed on a level surface.

[0046] See Figure 2AThe input of the AC-DC converter is connected to a power source. The output of the AC-DC converter is connected to the input of the DC-DC converter via a first switchable link. The output of the battery assembly is connected to the input of the DC-DC converter via a second switchable link, and the output of the DC-DC converter is connected to the battery assembly via a third switchable link. The first switchable link includes a first power switch SW1 operable to open or close the first switchable link. The second switchable link includes a second power switch SW2 operable to open or close the second switchable link. The third switchable link includes a third power switch SW3 operable to open or close the third switchable link. Each of the first, second, and third power switches can be operated by electronic control circuitry to be in an on or off state.

[0047] The device can operate in multiple modes, including standby mode and power output mode.

[0048] In standby mode, the battery pack may be charged or not charged depending on its stored energy level. When the BMS determines that the battery pack has a good energy level, the BMS controller will operate in non-charging mode and will not charge the battery pack. When the BMS determines that the battery pack does not have a good energy level, the BMS controller will operate in charging mode to charge the battery pack. A good stored energy level can be determined by referring to the stored energy level or voltage of the battery pack and can be set according to application requirements. In power output mode, power will be delivered from the device to an external load.

[0049] During charging mode, the device is connected to an external power source, allowing the battery pack to be charged. When the device is connected to an external power source (e.g., AC mains), the AC-DC converter operates to output DC power with a DC voltage. This DC power is a rectified version of the AC mains power and may not have a sufficiently high voltage to charge the battery pack. To provide a sufficiently high charging voltage, the output of the AC-DC converter is connected to the input of the DC-DC converter to supply DC power to the DC-DC converter. The DC-DC converter upconverts the DC power input to output a DC power output with a sufficiently high voltage suitable for charging the battery pack. The BMS is configured to monitor the charging of the battery pack by the DC power output and will stop charging when the battery pack has reached its maximum voltage or falls below one percentage point below its maximum voltage for extended operating life.

[0050] When in charging mode, switches SW1 and SW3 are closed, allowing input power to flow from the power source to the AC-DC converter, then to the DC-DC converter, and finally to the battery pack. The BMS is configured to periodically monitor the battery pack's condition and repeatedly acquire and store battery parameter readings. Before charging of the battery pack begins, the BMS retrieves data, for example, from onboard data storage on the device. The retrieved data may include voltage information for the battery module and battery pack, including maximum and minimum voltages, the battery charging scheme, and some or all of the stored battery parameters, to determine the appropriate charging scheme, thereby promoting safe charging and longer battery life. The BMS controller is configured to follow a predetermined charging mode, which depends on the battery type.

[0051] When in non-charging mode, the BMS controller can stop the operation of the AC-DC converter or disconnect SW1 to cut off the first switchable link.

[0052] When in power output mode, the BMS controller will operate to close SW2 and open SW3, allowing battery energy to flow from the battery pack to the DC-DC converter, and then to the load connected to the device's output, such as... Figure 2B As shown. When in power output mode, SW1 can be opened or closed. When SW1 is closed, if the device is still connected to an external power source, the output power will include power from the external power source.

[0053] When in output mode, the exemplary battery assembly can output a maximum current of 100A, but the actual current can be controlled, for example, through an agreement between the EMS controller and the pairing controller.

[0054] When the power supply is connected to an external power source in charging mode, the power from the external power source can also be provided to the DC-DC converter as supplementary charging power by closing both switches SW1 and SW2. The first switchable link may include a diode or other unidirectional device that limits the flow of current in one direction (i.e., from the AC-DC converter to the DC-DC converter) without limiting the flow in the opposite direction.

[0055] Modern mobile devices operate using different power supply systems and voltage ratings, and these devices are typically intelligent devices with a smart central controller that has a communication front end configured to communicate and exchange data with a paired controller, such as an EMS controller on the power supply device.

[0056] The controller of the power supply equipment is configured to communicate and exchange data with a paired controller, such as the central controller of an electric vehicle.

[0057] When a load is connected to the charging coupler, the EMS controller establishes a data connection with the onboard controller on the mobile device and identifies the correct protocol for communication. After successfully exchanging data, the EMS controller learns from its paired controller the charging standard, charging schemes such as charging current and voltage, SoC (State of Charge), and other useful data for charging the onboard energy storage device, which is typically a battery component. Once the charging data and standard are determined, the EMS controller will operate to charge the onboard energy storage device of the mobile device.

[0058] In an exemplary embodiment, the external power supply is a 220V single-phase 13A, 50Hz AC power supply, such as... Figure 6A As shown. The battery pack has a maximum voltage of 403.2V and a minimum voltage of 200V. The second energy converter includes two 14kWh DC-DC converters. The DC-DC converters can switch to different output voltages, including the charging voltage of the battery pack and charging voltages conforming to different charging standards such as CHAdeMo, Combo+, and Tesla. The charging coupler may include different charging connectors (or "guns") configured for different charging standards. After detecting the required charging standard and charging voltage, the EMS controller will begin charging according to the requirements of the standard of the connected load.

[0059] The DC-DC converter can be a MIMO (Multiple-Input Multiple-Output) DC-DC converter with multiple switchable inputs and / or multiple switchable outputs. The input and output voltages of the DC-DC converter can be controllable, for example, digitally controlled by an EMS controller. Although multiple power converters are shown in the exemplary embodiments, power converters can be integrated into the MIMO power converter without loss of generality.

[0060] For example, for a 100V battery module, the charging voltage can be set to 114.8V, where it is charged to 80% at a constant current (CC) rate of 11.475A (0.5C), then charged at a constant voltage (CV), and charging ends when the charging current drops to 450mA; or the charging voltage can be set to 117.6V, where it is charged to 90% at a constant current (CC) rate of 11.475A (0.5C), then charged at a constant voltage (CV), and charging ends when the charging current drops to 4.5A.

[0061] For example, for a 50V battery module, the charging voltage can be set to 57.4V, where it is charged to 80% at a constant current (CC) rate of 22.95A (0.5C), then charged at a constant voltage (CV), and charging ends when the charging current drops to 900mA; or the charging voltage can be set to 58.8V, where it is charged to 90% at a constant current (CC) rate of 22.95A (0.5C), then charged at a constant voltage (CV), and charging ends when the charging current drops to 9A.

[0062] In an exemplary embodiment, the power supply equipment may include one or more AC power outputs. To provide AC power output, one or more DC-AC inverters are provided. The exemplary power supply equipment may include 100-120Vac 50Hz output and 200-240Vac 50Hz output.

[0063] An exemplary battery module for the device includes an assembly of battery cells, monitoring and control circuitry, ventilation, and a module housing. The assembly of battery cells typically comprises multiple battery cells, which are connected in series and parallel to meet the voltage and current requirements of the design.

[0064] An exemplary module housing includes a base housing portion and an upper housing portion. The upper housing portion cooperates with the base housing portion to define, along a longitudinal direction defined by a longitudinal axis: a first compartment, which is an electronics compartment housing electronic circuitry configured to control and monitor the local conditions of the battery module; a second compartment, which is a battery compartment housing an assembly of battery cells; and a third compartment, which is a ventilator compartment housing an air movement device. The exemplary air movement device includes a plurality of axial fans. The axial fans are arranged along a direction orthogonal to the longitudinal axis of the module housing, such as... Figure 3E and Figure 3F As shown (where the upper housing portion is removed), and the fan axis is parallel to the longitudinal axis.

[0065] The base housing portion and the upper housing portion cooperate to define an air passage having a first end as an inlet and a second end as an outlet, such that air entering through the inlet will exit through the outlet after traversing the length of the passage. An electronic device compartment is arranged at the inlet end, and a ventilator compartment is arranged at the outlet end.

[0066] The electronic circuitry of a battery module may include sensors, sensing circuits, switching circuits, switching control circuits, control circuits, and peripheral circuits such as a communication front-end. Sensors and sensing circuits include, for example, temperature sensors, temperature sensing circuits, voltage sensors, voltage sensing circuits, current sensors, current sensing circuits, pressure sensors, and pressure sensing circuits. The control circuitry of the battery module is local to the battery module and is referred to as a module management system or group management system (PMS) to distinguish it from a device-wide management system (BMS).

[0067] In an exemplary embodiment, the temperature sensor is placed on or inside the battery module, or more specifically, inside the channel. In an exemplary embodiment, the control circuitry of the battery module is configured such that when the temperature of the battery module reaches a threshold temperature, upon receiving a temperature signal from the sensor, the control circuitry activates an air movement device to remove air out of the channel, thereby removing hot air from the battery module.

[0068] The battery module is mounted such that the ventilator compartment is adjacent to and juxtaposed with the ventilator surface of the main housing.

[0069] The exemplary battery module is assembled from cylindrical battery cells, such as cylindrical battery cells with size code 18650. Currently, rechargeable lithium-ion 18650 cylindrical batteries (e.g., Panasonic™ model UR18650ZM2) are widely used.

[0070] In an exemplary embodiment, the battery cells of the battery module are arranged in an nSmP configuration, where n is the number of cells connected in series and m is the number of cells connected in parallel.

[0071] An exemplary battery module includes an exemplary plurality (252) of 18650 lithium rechargeable cells, each cell having a current rating of 2550mAh and a nominal voltage of 3.6V. 电 The nominal cell voltage range is between 2.5V (minimum cell voltage) and 4.1V (maximum cell voltage), corresponding to a rated energy storage capacity of 2.3kWh and a dated energy storage capacity of 2.0kWh. The exemplary battery cell has an operating temperature range of 0°C to 45°C for charging and an operating temperature range of -20°C to -60°C for discharging.

[0072] In an exemplary embodiment, the battery module is arranged in a 28S9P configuration, such that the battery module has a nominal voltage of 100.8V nV. 电芯标称值 70V (nV) 电芯最小值 ) to 114.8V (nV) 电芯最大值The battery cells are rated for a voltage range between 100A and 14S9P, a maximum discharge current of 100A, and a continuous output rating of 7kW. The battery cells are arranged in two series-connected groups, each group having a 14S9P configuration and held in a cage comprising 14 rows of cells, each row housing nine cells. Figure 3E In one embodiment, the battery housing rows are parallel to the longitudinal axis of the module housing, and the two groups are connected in series.

[0073] In an exemplary embodiment, the battery module is arranged in a 14S18P configuration, such that the battery module has a nominal voltage of 50.4V nV. 电芯标称值 It features a voltage range of 35V to 57.4V, a maximum discharge current of 100A, and a continuous output rating of 3.5kW. The battery cells are arranged in two parallel groups, each with a 14S9P configuration and housed in a chassis comprising 14 rows of nine cells per row. Figure 3F In one embodiment, the battery housing rows are parallel to the longitudinal axis of the module housing, and the two groups are connected in parallel.

[0074] The exemplary battery module has a dated energy storage capacity of 2.0 kWh and a weight of 18.25 kg, corresponding to a dated energy storage density of over 0.1 kWh / kg (2 kWh / 18.25 kg).

[0075] The exemplary battery module has dimensions of 588mm × 315mm × 94mm (length × width × height) and a volume of 0.0174 CBM, corresponding to a dated energy storage density of 115 kWh / CBM. The battery module has a dated energy storage density greater than 100 kWh or 110 kWh per CBM, which is advantageous for roadside assistance or everyday charging.

[0076] An exemplary battery module has an area of ​​0.185 square meters, which corresponds to more than 80% or 90% of the internal cross-sectional area (L×W) of the internal compartment of the main housing.

[0077] In an exemplary embodiment, the control circuit of the battery module is configured to activate the operation of the air movement device to force airflow through the channel when the temperature reaches a threshold temperature of 40°C, and to stop the operation of the air movement device when the temperature drops to 40°C.

[0078] Battery modules are interconnected to form a power bank. A power bank, as used herein, is an energy storage device in which electrical energy can be stored or withdrawn. Unless the context otherwise requires, energy herein refers to electrical energy. Battery modules may be connected in series and / or parallel to form a battery assembly with predetermined rated voltage and current.

[0079] In an exemplary embodiment, the battery cells of the battery module are arranged in multiple cell rows. Each cell row includes multiple battery cells. Adjacent battery cells of the battery module are spaced apart and separated by air gaps. For example, a battery module with an nSmP battery cell configuration can be arranged in an exemplary plurality (n) cell rows or an exemplary plurality (m) cell rows. Adjacent cell rows of the battery module are spaced apart and separated by air gaps.

[0080] Battery cells are held on a battery holder to maintain the battery cells of the battery module in a substantially fixed relative position and a substantially fixed relative spacing. An exemplary holder includes a grid of cell receptacles, each cell receptacle configured to accommodate a single battery cell. The grid of cell receptacles includes multiple rows of receptacles. Each row of receptacles includes multiple cell receptacles and has a row axis. Each cell receptacle (receptacle for short) defines a cell compartment and has a receptacle axis parallel (e.g., coaxial) to the cell axis of the battery cell to be accommodated. The row axis intersects the receptacle axis and defines a row direction, which, in an exemplary embodiment, is orthogonal to the receptacle axis as in this embodiment. Each receptacle has a receptacle width, which is measured along the row direction and includes the receptacle axis as the central axis of the receptacle. Each row of receptacles has a row width equal to the receptacle width multiplied by the number of receptacles constituting the row of receptacles. Each housing has a spacer arrangement configured to maintain the battery cells housed within the housing in a relatively fixed and stable position.

[0081] In an exemplary embodiment, the cell housing includes a peripheral wall on which a plurality of axially extending ribs are formed as exemplary spacers. The ribs of the housing extend axially and project radially toward the axis of the housing. The ribs herein can be continuous or discontinuous. The radial extent of the ribs is configured to maintain an air gap surrounding the battery cell housed within the housing. The ribs and the resulting air gap can have a radial extent of 0.5 mm to 1.5 mm, or a radial extent that is 2.5% to 8.5% of the battery cell diameter. In an exemplary embodiment, the peripheral wall of the housing has a hexagonal cross-sectional shape, and the ribs project from the corners of the hexagons defining the hexagonal cross-sectional shape. In an exemplary embodiment, the peripheral wall of the housing has a wall thickness of about 1 mm, for example, between 0.8 mm and 1.5 mm, or a wall thickness that is 4% to 8.5% of the battery cell diameter. A passage parallel to the direction of the array is formed on the peripheral wall, allowing a portion of the inter-cell connector to pass through the housing, for example, at a height between the top and bottom of the housing. The passageway is offset from and parallel to the row axis and the receiving axis, and traverses or extends through two adjacent receiving rows. In other words, each passageway is shared between two adjacent receiving rows. An exemplary receiving portion includes a first slot and a second slot, which cooperate to define the passageway. Each of the first and second slots is a slot formed on a peripheral wall shared with the adjacent row and parallel to the receiving axis. The first slot is also a slot on a first receiving portion in the adjacent row, and the second slot is also a slot on a second receiving portion in the adjacent row, which is adjacent to the first receiving portion.

[0082] In an exemplary embodiment, the peripheral wall of the receiving portion is shared by three to seven receiving portions. More specifically, the peripheral wall of the receiving portions on the end rows is shared by three or four receiving portions, the peripheral wall of the first or last receiving portion on the middle rows is shared by four or five receiving portions, and the peripheral wall of the middle receiving portion is shared by six receiving portions. The middle receiving portion is a receiving portion that is neither on the end rows nor the first or last receiving portion in a row. The middle row is a row that is neither the first nor the last row. In other words, the peripheral wall of the middle receiving portion is shared by two receiving portion rows immediately adjacent to the middle row containing the middle receiving portion. In an exemplary embodiment, the adjacent receiving portion rows are offset in the row direction such that a portion of the receiving portion of one row is also a portion of the receiving portion of another row. In other words, a portion of the receiving portion is shared by two adjacent receiving portion rows or shared between two adjacent receiving portion rows.

[0083] An exemplary hexagonal-shaped receptacle includes a peripheral wall with six sidewalls, wherein two opposing parallel sidewalls cooperate to define the width of the receptacle. The axis of the receptacle is located midway between the two parallel sidewalls, and the parallel sidewalls defining the two parallel sidewalls are orthogonal to the row axis. In an exemplary embodiment, two adjacent sidewalls of the hexagonal-shaped receptacle that interconnect the parallel sidewalls are shared by two adjacent receptacles in an adjacent row of receptacles. The two adjacent sidewalls join at the vertices of the hexagonal receptacle to form a V-shaped peripheral wall portion, and the vertices of the hexagonal receptacle are also the vertices of the hexagonal receptacles in the adjacent row. More specifically, the vertices are also the ends of the parallel walls of the hexagonal receptacles in the adjacent row.

[0084] An exemplary receiving portion includes a first groove and a second groove that cooperate to define a passage. Each of the first and second grooves is a groove formed on a peripheral wall shared with an adjacent row and parallel to the axis of the receiving portion. The first groove is also a groove on a first receiving portion on the adjacent row, and the second groove is also a groove on a second receiving portion on the adjacent row, which is adjacent to the first receiving portion.

[0085] In an exemplary embodiment, such as this one, adjacent receptacles are offset or displaced in the row direction by half the width of the receptacle. This offset or displacement in the row direction helps improve the compactness of the battery module, thereby increasing battery cell density. Air gaps surrounding each battery cell, defined by multiple insulating ribs, mitigate battery cell heating in high-cell-density environments.

[0086] The housing of the battery module can be formed on one or more battery enclosures. The battery enclosure can be integrally molded from a rigid plastic such as ABS or PC (polycarbonate). Each battery enclosure can have an i,j configuration, including multiple (i) rows of housings, each row of housings including multiple (j) integrally molded housings, where i and j are natural numbers. An exemplary battery module including an exemplary multiple (i×j×k) cells requires k enclosures to assemble. Multiple enclosures can be arranged side-by-side and / or end-to-end connected and connected in series or parallel to form a battery module.

[0087] The exemplary battery enclosure has an exemplary plurality (i = 14) rows, and each row has an exemplary plurality (j = 9) housings. An exemplary battery module consisting of 252 battery cells can be assembled from two battery enclosures.

[0088] When the chassis has an i=n, ​​j=m configuration, the cells in one row can be connected in parallel, and adjacent rows can be connected in series to form an nSmP configuration. In such a configuration, the cell terminal with the first polarity of the battery cell is connected to the first row connector, and the cell terminal with the second polarity opposite to the first polarity of the battery cell is connected to the second row connector.

[0089] The battery cells of this module are interconnected through multiple integrally formed connectors to form an nSmP structure, where n and m are natural numbers.

[0090] An exemplary connector is an inter-row connector configured to connect two battery cell rows in series. The inter-row connector is an integral connector comprising a plurality of integrally formed terminal contacts configured to connect a first set of cell terminals of a first polarity of one row of battery cells to cell terminals of a second polarity of another row of battery cells. The terminal contacts include a first set of contacts configured to connect the cell terminals of the first polarity of one row of battery cells in parallel, and a second set of contacts configured to connect the cell terminals of the second polarity of another row of battery cells in parallel. A plurality (n-1) exemplary inter-row connectors are required to form a set of n battery cell rows.

[0091] An exemplary inter-row connector includes a main portion and a plurality of branch portions engaged with the main portion. The plurality of branch portions include a first set of branch portions configured to connect cell terminals of a first polarity (“first set of cell terminals”) of battery cells in one row, and a second set of branch portions configured to connect cell terminals of a second polarity (“second set of cell terminals”) of battery cells in another row.

[0092] The main section extends along the row direction to interconnect the first and second sets of branch sections. The first set of branch sections is located on one axial side of the main section, and the second set of branch sections is located on the other axial side of the main section, such that the main section lies between the first and second sets of branch sections. The number of branch sections in each set of branch sections (i.e., the first or second set of branch sections) is equal to the number of cells in one row or "another" row. In the case of m cells in a row, the set of branch sections used to connect to that row typically has m branch sections.

[0093] Each branch portion includes a cell contact terminal and a finger portion. The finger portion includes a first end that serves as a proximal end engaging with the main portion, and a second end that serves as a distal end engaging with the cell contact terminal. The cell contact terminal is configured to make physical and electrical contact (typically permanent contact) with the cell terminal and has a contact surface area comparable to the exposed area of ​​the cell terminal. The cell contact terminal protrudes away from the finger portion and extends at an angle to the finger portion to reach the cell terminal for contact. In an exemplary embodiment, as in this embodiment, the cell contact terminal is at 90° to its finger portion. Without loss of generality, the cell contact terminal can be soldered to the cell terminal by spot welding or other bonding techniques.

[0094] The main portion of an exemplary inter-row connector includes an elongated row conductor that extends along the row direction and through a passageway of the cell row. A first plurality of finger-like portions constituting a first set of branch portions protrude away from the main portion and extend toward a first axial end of a first receiving portion to reach a first set of cell terminals. A second plurality of finger-like portions constituting a second set of branch portions protrude away from the main portion and extend toward a second axial end of the first receiving portion to reach a second set of cell terminals. The aforementioned first and second plurality of portions are typically an equal number, but may be unequal. The finger-like portions of the first set of branch portions may protrude at a first angle to the row conductor, such that the plurality of finger-like portions constituting the first set of branch portions cooperate to form a grid of finger-like portions extending toward the first set of cell terminals. The finger-like portions of the second set of branch portions may protrude at a second angle to the row conductor, such that the plurality of finger-like portions constituting the second set of branch portions cooperate to form a grid of finger-like portions extending toward the second set of cell terminals. In an exemplary embodiment, as in this embodiment, both the first and second angles are equal to 90°, such that the finger-like portions are orthogonal to the row direction.

[0095] The finger-like portions of the first group of branches can protrude at the same angle relative to the conductor array, making the finger-like portions parallel or substantially parallel.

[0096] The finger-like portions of the second set of branches can protrude at the same angle relative to the conductor array, making the finger-like portions parallel or substantially parallel.

[0097] The finger-shaped portion has a main surface that is parallel to the row direction and parallel to the axis of the receiving portion.

[0098] In an exemplary embodiment, the finger-like portions belonging to the same group of branch sections are at the same angle relative to the conductor array, such that there is an air gap between two adjacent finger-like portions in the same group. The cell contact terminals of the first group of branch sections protrude in a first direction, and the cell contact terminals of the second group of branch sections protrude in a second direction opposite to the first direction.

[0099] The cell contact terminals of the first branch section are at a first axial level, and the cell contact terminals of the second branch section are at a second axial level. The cell contact terminals of the first branch section and the cell contact terminals of the second branch section are separated by an axial distance equal to the axial length of the battery cell.

[0100] The cell contact terminals of the first and second branch sections are used to make contact with cell terminals of opposite polarity on adjacent cell arrays. Unless the context otherwise requires, contact in this document refers to both electrical and physical contact.

[0101] The inter-row connector is installed such that the row conductor is accommodated in a passage defined by a first cell row and a second cell row adjacent to the first row, such that the finger portion of the first set of branch portions is located in a first accommodating portion, which is one or any accommodating portion in the first row, and the finger portion of the second set of branch portions is located in a second accommodating portion, which is one or any accommodating portion in the second row adjacent to the first accommodating portion.

[0102] The finger-like portions of the first set of branch portions of the inter-row connector are located within the receiving portion of the first cell row and extend axially to reach the first axial end of the receiving portion, where a first cell terminal of the first battery cell with a first polarity is positioned. The finger-like portions of the second set of branch portions of the inter-row connector are located within the receiving portion of the second cell row and extend axially to reach the second axial end of the receiving portion, where a second cell terminal of the second battery cell with a second polarity is positioned.

[0103] In an exemplary embodiment, the plurality of finger-like portions include a first set of finger-like portions configured to connect to cell terminals of a first polarity of a row of battery cells, and a second set of finger-like portions configured to connect to cell terminals of a second polarity of another row of battery cells. The first set of finger-like portions protrudes in a first axial direction, and the second set of finger-like portions protrudes in a second axial direction opposite to the first axial direction.

[0104] In an exemplary embodiment, the busbar conductor is a metal strip having a main surface parallel to the axial direction, and the finger-like portions are substantially coplanar with the metal strip, such that the busbar conductor and the finger-like portions cooperate to define a planar portion. In an exemplary embodiment, the main surface of the finger-like portions is parallel to or coplanar with one or more main surfaces of the busbar conductor. The busbar connector is received within a passage and has a thickness equivalent to or less than the width of the passage, the width of which is measured in a direction orthogonal to the busbar direction and the axis of the receiving portion. In an exemplary embodiment, as in this embodiment, the passage has a width of approximately 1 mm, and may be in the range of 0.8 mm to 1.2 mm.

[0105] The width of the busbar conductor is slightly smaller than the length of the slot defining the passage. An exemplary busbar conductor has a thickness between 0.1 mm and 0.2 mm, and may have a thickness range between 0.1 mm and 0.6 mm. An exemplary busbar conductor has a width of approximately 0.8 mm, and may have a width range between 0.5 cm and 1.5 cm. An exemplary finger-like portion has a width of approximately 0.7 mm, and may have a width range between 0.5 cm and 1 cm. The finger-like portions are distributed along the busbar direction and arranged in the form of a grid or mesh of finger-like portions.

[0106] An exemplary row connector, or at least a row of conductors and finger-like portions, is integrally formed from a single metal sheet (e.g., a copper sheet, a copper alloy sheet, or a steel sheet).

[0107] The conductors and finger portions cooperate to define the middle portion of the inter-row connector. The middle portion of the exemplary inter-row connector has a fishbone-like structure and defines a grid of spaced-apart finger portions. The middle portion has a sheet-like shape factor and a small thickness configured for assembly in a narrow inter-row space between adjacent cell rows.

[0108] An exemplary intermediate portion defines a connector network comprising laterally extending row conductors and axially extending finger portions, with adjacent finger portions separated by air gaps to define inter-digital spacing. The connector network defines a grid of connector portions that define the intermediate portion of the inter-row connectors. The intermediate portion extends axially and has an axial range comparable to the axial range of the battery cells of the battery module. In an exemplary embodiment where the battery cell is a cylindrical battery having a battery axis as a cylindrical axis and battery terminals with opposite polarities at opposite axial ends on the battery body, the intermediate portion has an axial range comparable to or greater than the axial length of the battery body or battery cell, the axial length being parallel to the battery axis and / or the receiving portion axis.

[0109] The networked structure of the middle section (including the integrated network of row connectors and spaced-apart finger portions) is due to the parallel connection of the finger portions, which defines the row connectors with very low row-to-row resistance, even though the middle section has an axial range comparable to the axial length of the battery cell.

[0110] Very low inter-row resistance, which is the series resistance between a pair of adjacent and contiguous cell rows, is highly advantageous. For example, the terminals of cells of the same polarity belonging to adjacent or contiguous cell rows can be at the same axial level, and it is not necessary to invert some cell rows relative to others in order to shorten the length of the inter-row connector. This will enhance the reliability and durability of the cell rows, as well as provide other advantages.

[0111] The very low inter-row resistance of the intermediate section also translates to very low thermal resistance. This very low thermal resistance means that heat from the battery cells can be efficiently transferred from the cells to the intermediate section used for heat dissipation. The intermediate section, constructed in a grid pattern, acts as a heat sink and effective heat fin for rapid heat dissipation, mitigating the risk of overheating. In other words, the exemplary intermediate section forms a heat sink partition within a narrow inter-row space. This construction of the intermediate section improves the compactness of the battery module and enhances its reliability and durability.

[0112] See Figures 3A to 5AThe battery module 1220 includes a battery assembly 100, management circuitry 300, and a main module housing 200, wherein the battery assembly 100 and management circuitry 300 are housed within the main module housing. The battery assembly 100 includes a plurality of batteries 102, which are typically rechargeable batteries organized into multiple battery packs.

[0113] The housing 200 includes multiple compartments, such as a main compartment and a fan compartment, as... Figures 3A to 3F As shown. The main compartment is divided into: a battery compartment 106, which houses the battery assembly 100; a circuit compartment 104, which houses the management circuitry; an air compartment 400; and functional compartments, which may be useful or beneficial. A fan compartment 500 is formed at the longitudinal end of the housing 200, and an air movement structure (air supply structure) is installed inside the fan compartment.

[0114] The housing 200 may be formed from metal components, robust plastic components, or a combination of metal and robust plastic components. The housing may include multiple housing portions. For example, the housing may include a main compartment housing portion and a fan compartment housing portion. The main compartment housing may be divided into multiple functional compartments.

[0115] The housing includes a first housing portion (referred to as the "first portion"), a second housing portion (referred to as the "second portion"), and a circumferential housing portion (referred to as the "circumferential portion") interconnecting the first portion and the second portion. The first portion is located at a first axial end and has an inwardly facing main surface ("first main surface"). The second portion is located at a second axial end and has an inwardly facing main surface ("second main surface"), the second main surface having an orientation opposite to that of the first main surface. An exemplary housing 200 includes a top portion 202 as an exemplary first portion, a bottom portion 204 as an exemplary second portion, and a circumferential portion 206 interconnecting the top portion and the bottom portion, these portions cooperating to define a main compartment housing. The circumferential portion extends in an axial direction Z between the bottom portion and the top portion to surround and define the main compartment. The circumferential portion has a first end (a first longitudinal end 210 in this example) and a second end (a second longitudinal end 220 in this example). The first longitudinal end 210 and the second longitudinal end 220 define the first longitudinal end and the second longitudinal end of the main compartment, respectively.

[0116] The first longitudinal end 210 and the second longitudinal end 220 are opposite longitudinal ends of the housing 200 and are located on the main longitudinal axis L-L' of the housing, which is also the longitudinal axis of the main compartment and defines the main longitudinal direction Y of the device. The axial direction Z of the circumferential portion defines the main axial direction of the device orthogonal to the main longitudinal direction L.

[0117] The fan compartment housing portion is a longitudinal housing portion that protrudes away from the main compartment and extends along the main longitudinal axis L-L' to define the fan compartment.

[0118] The circuit compartment is located on the first longitudinal end 210 of the housing, the fan compartment is located on the second longitudinal end 220 of the housing, and the battery compartment is located between the circuit compartment and the fan compartment.

[0119] A plurality of peripheral devices are arranged on the front panel at the first longitudinal end 210 of the housing. The peripheral devices may include input, output and control interfaces, including power input, power output, data interface and user interface.

[0120] The device is constructed as a power module, which can operate as an independent power source or as a modular component of multiple power modules forming a larger-scale power source.

[0121] The management circuitry includes battery management circuitry and peripheral circuitry. Battery management circuitry may include battery charging control circuitry, battery discharging control circuitry, battery condition monitoring circuitry, battery safety control circuitry, and / or other useful circuitry. Peripheral circuitry may include metering circuitry, telecommunications circuitry including a data communication front-end, switch control circuitry, remote sensing circuitry, and other useful circuitry.

[0122] The exemplary housing 200 includes a first housing portion and a second housing portion, which cooperate to form a housing. The exemplary first housing portion is an upper housing portion 230 that includes a top portion and a circumferential portion, and the exemplary second housing portion is a lower housing portion 240 that includes a bottom portion.

[0123] In exemplary embodiments, such as this embodiment, the upper housing portion 230 is shaped and configured to define a battery compartment and is formed of an insulating material such as a rigid engineering plastic. The exemplary upper housing portion is integrally formed of a robust engineering plastic material such as ABS, and the battery compartment is a closed compartment except where the vent 232 is provided. In some embodiments, the upper housing portion may be made of a thermally conductive material, such as steel, aluminum, or other metal. The upper housing includes a circumferential flange that complements a circumferential flange on the lower housing portion to facilitate rapid assembly.

[0124] An exemplary lower housing portion 240 is formed as a metal housing portion. The metal housing portion includes a metal plate portion 242, a fan panel 244 at a longitudinal end, and a circumferential flange 246 extending along the side of the metal housing portion. The metal plate portion defines a bottom portion of the housing and a base plate 208 of the housing. The fan panel extends orthogonally to the metal plate portion and defines a plurality of fan holes that are aligned with a fan mounted on a fan mounting frame formed in the upper housing portion to allow air to pass through the fan mounted in a fan compartment.

[0125] The portion of the metal housing 242 that forms the bottom of the housing is a stainless steel plate, which cooperates with the upper housing 230 to form the main compartment and the fan compartment which is adjacent to and in fluid communication with the air compartment.

[0126] The battery assembly 100 is mounted on the housing and held between the top portion of the housing and the air compartment.

[0127] Battery assembly 100 includes a plurality of electrically interconnected cells. The cells of the battery assembly can be interconnected to form a plurality of cells connected in parallel and / or a plurality of cells connected in series. The battery assembly can be arranged as a battery ensemble or multiple battery ensembles, and each battery ensemble is referred to as a battery group. A battery group may include a plurality of cells connected in parallel and / or a plurality of cells connected in series. The cells of the battery assembly are electrically connected to each other via a plurality of inter-cell connectors. The plurality of inter-cell connectors may be connected in series to form inter-ensemble connectors, thereby connecting adjacent pairs of battery ensembles.

[0128] The battery assembly can be arranged as one battery module or multiple battery modules. Each battery module includes multiple battery packs connected in parallel and / or multiple battery packs connected in series.

[0129] An exemplary battery module includes a first module portion and a second module portion. The first module portion has a first module surface defining a first module end, and the second module portion has a second module surface defining a second module end. The exemplary battery module has a top portion as the exemplary first module portion and a top surface as the exemplary first module surface defining a top tip portion that is an exemplary first end portion of the battery module. The exemplary battery module has a bottom portion as the exemplary second module surface and a bottom surface as the exemplary second module surface defining a bottom end portion of the battery module, and a circumferential portion extending axially between the top tip portion and the bottom end portion. The top tip portion and the bottom end portion are opposite axial ends of the battery module. The axial direction of the exemplary battery module is parallel to the battery axis of the battery module's battery. The axial direction of the exemplary battery module is parallel to the main axial direction of the exemplary housing, but in some embodiments it may be at an angle to or orthogonal to the main axial direction of the housing.

[0130] The battery module includes a plurality of first battery terminal contact tabs 112 distributed on a first portion of the battery module to form an exposed first module surface, and a plurality of second battery terminal contact tabs 114 correspondingly distributed on a second portion of the battery module to form an exposed second module surface. The first battery terminal contact tabs are physically connected to the first battery terminals of the battery, for example, by spot welding or laser welding. The first battery terminals of the battery have a first polarity and a safety vent formed at or near the first battery terminal. The first battery terminal contact tabs 112 have slits or holes and are exposed to a discharge chamber located between the first portion of the battery module and the housing. The battery is held such that its safety vent is close to and not obstructed by the first module surface, allowing hot gas emissions from the battery to move freely from the first battery terminals to the first module surface and subsequently to a vent 232 on the housing. In conventional batteries, the safety vent is typically formed near the positive terminal of the battery, in which case the first battery terminal is the positive terminal and the second battery terminal is the negative terminal. With the safety vent near the negative battery terminal, without loss of generality, the first battery terminal will be the negative terminal and the second battery terminal will be the positive terminal.

[0131] The second battery terminal contact tab 114 is physically connected to the second battery terminal of the battery, for example, by spot welding or laser welding. The second battery terminal has a second polarity opposite to that of the first battery terminal. If the first battery terminal is the positive terminal, the second battery terminal is the negative terminal, and vice versa. The second module surface is an exposed module surface to facilitate physical and thermal connection with a heat exchange device.

[0132] The circumferential portion of the battery module includes a circumferential wall that surrounds the battery of the battery module. The circumferential wall includes circumferential surfaces extending in an axial direction to define a first portion and a second portion of the battery module.

[0133] A battery module is mounted on a housing such that a first surface of the battery module is close to a first portion of the housing and away from a second portion of the housing, and a second surface of the battery module is close to the second portion of the housing and away from the first portion of the housing. An exemplary battery module is mounted on an exemplary housing such that a top surface of the battery module is close to a top portion of the housing and away from a bottom portion of the housing, and a bottom surface of the battery module is close to a bottom portion of the housing and away from a top portion of the housing.

[0134] The battery module is maintained at an axial height relative to a first surface of the housing such that an axial gap is maintained between the first surface of the battery module and the first surface of the housing. This axial gap defines a discharge chamber, allowing gaseous emissions from the battery module to exit the module through vents 232 on the first surface of the housing after traveling through the discharge chamber. This axial gap is chosen to be relatively small to facilitate effective monitoring of extreme battery conditions. For exemplary battery structures, the axial gap distance can be approximately between 0.2 cm and 2 cm, which is between 3% and 30% of the axial range of the battery module for 18650 batteries. Typically, based on experience, the axial range is chosen to be equal to or greater than 3%, 5%, 7%, 9%, and 11% of the axial range of the battery module and less than 20%, 25%, and 30% of the axial range of the battery module.

[0135] The vents are in fluid communication with the discharge chamber, and the number of vents is significantly less than the number of cells in the battery pack. An exemplary battery pack has more than 250 cells but only four vents. Each vent is equipped with a thermal sensor, which is connected to a temperature monitoring circuit of the battery management circuitry to monitor the temperature of the gaseous emissions from the battery pack. To prevent the temperature of the hot gaseous emissions from the cells of the battery pack from dropping significantly before reaching the thermal sensor, the discharge chamber (or more specifically, the top portion of the housing) is thermally insulated from the surrounding environment to facilitate accurate temperature monitoring. In this example, the surface of the first module is close to and faces the top plate of the housing, multiple vents are distributed on the top portion of the housing, and the battery module is maintained at an axial height below the top plate of the housing such that an axial gap is maintained between the top surface of the battery module and the top plate of the housing. In some embodiments, the surface of the first module is close to and faces the bottom plate of the housing, multiple vents are distributed on the bottom portion of the housing, and the battery module is maintained at an axial height above the bottom plate of the housing such that an axial gap is maintained between the bottom surface of the battery module and the bottom plate of the housing. The use of terms such as up and down, top and bottom, above and below is for ease of reference in how the module is constructed during use, and is not intended to be restrictive. For example, a module may be constructed such that the battery axis defining the module axis is horizontal or at an angle to the vertical direction, and without loss of generality, the terms up and down, top and bottom, above and below should be interpreted accordingly and with necessary modifications.

[0136] An exemplary battery assembly includes two battery modules 101A and 101B, which are mounted side-by-side and adjacent to each other to achieve maximum compactness. When compactness is not required, the battery modules can be mounted spaced apart. The exemplary battery modules are mounted such that the top surfaces of each battery module, as components, are aligned at the same axial height and face the top plate of the housing, the bottom surfaces of each battery module are aligned at the same axial height and face the bottom portion of the housing, and the circumferential portions are laterally aligned, resulting in a generally rectangular outline for the battery assembly.

[0137] The battery assembly 100 includes a substrate 120 mounted on the bottom end of each battery module (or, in the case of a battery assembly having a single battery module), to form the bottom end of the battery module. The substrate 120 divides a portion of the housing into an upper portion defining a battery compartment and a lower portion defining an air compartment. The substrate is fastened to a circumferential flange of the housing to form a substantially hermetically sealed battery compartment except at vent holes. The circumferential flange extends along the inner circumference of the housing and projects inward to form a sealing flange, thereby forming a substantially hermetically sealed battery compartment when engaged with the substrate and fasteners distributed along the circumferential flange. The substrate is in physical and thermal contact with battery terminal tabs on the bottom end of the battery module, but is electrically insulated from the battery terminal tabs.

[0138] The battery assembly is mounted on the housing and held at an axial height above the bottom plate of the housing. The bottom plate of the housing is an inward-facing surface located on the bottom portion of the housing.

[0139] The axial height of the battery assembly above the bottom plate of the housing defines the axial range of the air compartment. The axial range of the air compartment is greater than the axial length of the discharge chamber by, for example, 25%, 30%, 35%, 40%, or more.

[0140] The substrate 120 forms the bottom end of the battery module and has a main surface that faces away from the battery module and forms the bottom surface of the battery assembly. An air chamber is defined between the bottom surface of the substrate and the bottom plate of the housing.

[0141] The battery assembly 100 includes a heat exchange structure that facilitates heat exchange between the battery assembly and air within an air compartment or with ambient air. The heat exchange structure includes a heat exchange device thermally connected to the battery module and having a heat exchange surface that is thermally exposed to the air compartment, or, in embodiments where the housing does not have an air compartment, thermally exposed to ambient air for heat exchange with it.

[0142] An exemplary heat exchange device in this example includes a thermally conductive plate having a thermal contact surface 122 and a heat exchange surface 124. The thermal contact surface 122 is thermally connected to the battery terminals of a battery assembly via a heat transfer network. The heat exchange surface 124 is exposed to air, such as air in an air chamber or, in the absence of an air chamber, to ambient air. The thermal contact surface and the heat exchange surface are opposite main surfaces of the thermally conductive plate.

[0143] The substrate 120 of the exemplary battery assembly is a thermally conductive plate, which serves as a heat exchange device in this example. To establish an efficient thermal connection between the battery terminals and the substrate, battery contact tabs exposed on the bottom portion of the battery module are bonded to the upper surface of the substrate via an electrically insulating thermally conductive medium (such as thermally conductive adhesive or preferably a flexible thermally conductive sheet or thermally conductive strip 130), such that the substrate and the battery contact tabs are maintained thermally connected but electrically isolated from each other. For operations where the heat exchange structure is intended to prevent overheating of the battery in the battery assembly, the upper surface of the substrate is used to collect heat from the battery in the battery assembly and is therefore a heat-collecting surface, while the lower surface of the substrate is a heat-dissipating surface for dissipating heat into the air chamber. For operations where the heat exchange structure preheats the battery in the battery assembly to its operating temperature range, the operation is reversed, such that the lower surface of the substrate becomes a heat-collecting surface to collect heat from the air chamber, and the upper surface of the substrate becomes a heat-dissipating surface for dissipating heat into the battery.

[0144] The air compartment is an air chamber that is in fluid communication with the fan compartment at one longitudinal end and with ambient air at the other longitudinal end away from the fan compartment. This allows ambient air to be freely drawn into the air compartment for heat exchange. The circuit compartment has a lower surface 250 that is substantially flush with the substrate to form an air passage between the first longitudinal end of the housing and the inlet of the air compartment.

[0145] In an exemplary embodiment, such as this one, substrate 120 is physically and thermally attached to battery contact tabs on the bottom surface of the battery module to ensure good thermal contact and good thermal connection between the battery module and the substrate. Exemplary substrate 120 is a metal plate having a plurality of contact tracks 126. The contact tracks are integral parts of the metal plate, and adjacent contact tracks are isolated and insulated. Each track is thermally connected to a row of batteries via a thermal connector strip 130 of a corresponding shape. The exemplary substrate is formed from a composite substrate having a composite structure similar to that of a composite board used to form a printed circuit board, except that the substrate has an insulating layer formed on a metal substrate instead of a metal layer formed on an insulating substrate. The exemplary substrate has an aluminum plate substrate and an electrically insulating coating on that plate substrate. The contact tracks can be formed by mask imprinting and etching, such that after the insulating layer on top is removed by the mask, the contact tracks remain and appear as printed metal tracks on a metal substrate. The thermal contact tracks are mutually isolated and insulated. Adjacent contact tracks are separated and / or surrounded by insulating tracks forming insulating gaps. Each track is elongated and has a serrated profile on each of its long sides to follow the serrated profile of the battery compartments forming the battery receptacle row. The exemplary serrated profile on the long side of the exemplary contact track is symmetrical about the longitudinal axis of the contact track, which is also the central axis of the contact track. The substrate serves as a heat sink to absorb heat accumulated or developed in the battery assembly and as a heat sink to dissipate heat into the air compartments. To improve heat dissipation rate, heat dissipation protrusions, such as fins or distributed protrusions, can be formed on the bottom surface of the substrate. The bottom surface of the substrate is the heat exchange surface of the substrate exposed to the air compartments and in thermal contact with the air or ambient air inside the air compartments. When the heat exchange surface is arranged to dissipate heat from the battery compartments, the heat exchange surface will serve as a heat dissipation surface.

[0146] The metal plate forming the bottom part of the casing also helps to improve the heat dissipation rate.

[0147] Exemplary thermal connector strips can be resilient thermal connectors, such as those made of non-silicone thermal interface materials. The F-CO™ series, available from Furukawa Electric Corporation, is an example of a thermally conductive medium suitable for this purpose.

[0148] In this example, the battery contact tabs forming the top surface of the battery assembly are contact tabs physically bonded to the positive battery terminals of the batteries in the battery assembly, and the battery contact tabs forming the bottom surface of the battery assembly are contact tabs physically bonded to the negative battery terminals of the batteries in the battery assembly. The battery contact tabs can be physically bonded by spot welding, laser welding, or other metal joining techniques.

[0149] The substrate is thermally mounted to the negative battery terminal via battery contact tabs on the bottom surface of the battery module to enhance better heat dissipation from the battery to the substrate by utilizing the larger end surface area of ​​the negative battery terminal of the cylindrical battery (compared to the end surface area of ​​the positive battery terminal). In an exemplary embodiment, the substrate is used as a heat sink or heat dissipation surface.

[0150] In the exemplary module, the top and circumferential portions of the housing cooperate with the substrate to define a battery compartment, and the bottom portion of the housing cooperates with the substrate to define an air compartment. The battery compartment is a closed compartment with a vent as the sole air outlet, so that gaseous emissions from the battery assembly can only exit through the vent located on the top portion of the housing. The air compartment is preferably a closed chamber with an air inlet at one longitudinal end and an air outlet at the other longitudinal end, such that ambient air drawn into the air compartment must travel along the entire span of the air compartment for effective heat exchange.

[0151] An array of electric fans is mounted on a fan compartment housing to form an exemplary air movement structure. The fan array extends transversely to the longitudinal axis and includes an exemplary plurality (three) axial fans, with the fan axes parallel to the longitudinal axis of the housing. The fans are arranged to move air through the axial fans out of the air compartment and to draw ambient air into the air compartment. In an exemplary embodiment, an ambient air inlet is formed on the longitudinal end of the housing remote from the fan compartment, such that the incoming ambient air will traverse the entire length of the substrate before reaching the fan compartment and leaving. In some embodiments, the ambient air inlet may be formed on the side of the housing defining the air compartment.

[0152] During operation of the air-moving structure, air in the fan compartment is drawn out of the fan compartment and exits the module through the fan. As a result, a low-pressure area is formed inside the fan compartment, and due to the pressure difference, air from the air compartment is drawn into the fan compartment. Because air moves from the air compartment to the fan compartment, a low-pressure area is formed inside the air compartment, and ambient air is drawn from outside the module into the air compartment to replenish the air lost from the air compartment.

[0153] The contact between the substrate and the air in the air compartment will result in heat exchange between the substrate and the air in the air compartment, and the movement of air through the air compartment into the surrounding environment will cause the heat in the air residing in the air compartment to be transferred to the outside of the module.

[0154] As the heat-carrying air moves through the air compartment and subsequently out of the module, the air compartment is replenished with re-drawn air at a lower temperature (e.g., at ambient air temperature), and the continuous operation of the heat exchange and removal process implemented by the operation of the air movement structure is expected to rapidly cool the battery assembly to prevent the accumulation of adverse and diffusible heat inside the battery assembly and to prevent catastrophic battery melting.

[0155] The heat exchange device is configured to collect heat from the battery of the battery assembly, more specifically from the interior of the battery. To facilitate heat collection from the battery interior, a heat collection and transfer network (referred to as a heat transfer network) is provided that thermally interconnects the battery electrodes and the heat exchange device. An exemplary heat transfer network includes a heat collection terminal integrally connected to a first battery terminal of the battery. Since the first battery terminal of the battery is always directly engaged with or integrally engaged with the battery electrodes to minimize resistance and is a good conductor of heat and electricity, a heat transfer network having a heat collection terminal well thermally connected to the battery terminals will facilitate the efficient and rapid extraction of heat from the battery interior to dissipate into the surrounding environment when the heat transfer network is thermally connected to the surrounding environment, for example by means of a heat exchange structure.

[0156] An exemplary heat transfer network includes multiple inter-cell connectors for a battery assembly. An exemplary inter-cell connector includes a first battery terminal contact tab 112 (referred to as a "first contact tab"), a second battery terminal contact tab 114 (referred to as a "second contact tab"), and an inter-terminal tab 116 interconnecting the first and second contact tabs. The first contact tab is used to connect to a first terminal of a battery, the second contact tab is used to connect to a second terminal of an adjacent battery, and the inter-terminal tab is an inter-cell connector interconnecting a pair of adjacent batteries.

[0157] An exemplary inter-cell connector includes a first connecting portion 116a, a second connecting portion 116b, and an intermediate connecting portion 116c interconnecting the first and second connecting portions. Each connecting portion is a tab portion having a tab geometry. The tab has a main surface 116d that serves as a flap surface, and the area of ​​the main surface of the tab is significantly larger than the area of ​​the secondary surface 116e (e.g., 5 times, 10 times, 15 times, 20 times, or greater, as a convenient example). The terms tab and flap have the same technical meaning herein and are used interchangeably.

[0158] The first connecting portion (or the first battery cell connector) includes a first metal wing portion that interconnects a first contact tab and an intermediate metal wing portion integrally, and the first contact tab protrudes away from the first metal wing portion along a first protrusion direction. The second connecting portion (or the second battery cell connector) includes a second metal wing portion that interconnects a second contact tab and an intermediate metal wing portion integrally, and the second contact tab protrudes away from the second metal wing portion along a second protrusion direction opposite to the first protrusion direction. The first and second contact tabs are parallel and spaced apart by an axial interval equal to the axial height of one battery connected in the battery. The first metal wing portion and the intermediate metal wing portion are integrally joined and have coplanar main wing surfaces. The second metal wing portion and the intermediate metal wing portion are integrally joined and have coplanar main wing surfaces. The portions are integrally joined or connected if they are welded together or, as a convenient example, formed from a single piece of material.

[0159] In exemplary embodiments such as those described herein, the batteries of a battery module or battery assembly are organized into multiple battery packs, and adjacent pairs of battery packs are interconnected in series via inter-pack connectors.

[0160] In an exemplary embodiment such as this one, the battery module includes multiple battery packs arranged in multiple battery bars. Each battery bar includes multiple batteries connected in parallel, and the battery bars are connected in series.

[0161] A pair of battery rows forming a battery module are interconnected by a battery row connector 110 (referred to as "row connector" or "group connector"). The row connector includes an array of battery row connectors, and the battery row connectors forming the array are distributed along the row direction to form a series of battery row connectors.

[0162] The inter-row connector includes a first connector portion, a second connector portion, and a third connector portion. The first connector includes an array of first contact tabs, the second connector portion includes an array of second contact tabs, and the third connector portion includes an array of inter-terminal tabs. The first contact tabs forming the first contact tab array are distributed along the row direction, and adjacent first contact tabs are separated by air gaps. The second contact tabs forming the second contact tab array are distributed along the row direction, and adjacent second contact tabs are separated by air gaps. The inter-terminal tabs forming the inter-terminal tab array are interconnected at their intermediate connecting portions to form an inter-terminal connector that interconnects the first contact tab array, the second contact tab array, and the inter-terminal tab array. The first tabs and the second tabs project in opposite directions and have contact surfaces orthogonal to the row direction.

[0163] The inter-row connector includes a plurality of first metal wing portions distributed along the row direction to form a row of first metal wing portions, a plurality of second metal wing portions distributed along the row direction to form a row of second metal wing portions, and a plurality of intermediate metal wing portions distributed along the row direction to form a row of intermediate metal wing portions. In this example, the first metal wing portions and the second metal wing portions are respectively a first connecting portion and a second connecting portion.

[0164] An exemplary inter-row connector has a first metal wing portion distributed along the row direction to form a plurality of metal wing portions extending orthogonally to the row direction between an intermediate metal wing portion and a first contact tab.

[0165] The second metal wing portion of the exemplary inter-row connector is distributed along the row direction to form a plurality of metal wing portions extending orthogonally to the row direction between the middle metal wing portion and the second contact tab.

[0166] The first metal wing portion and the second metal wing portion are arranged alternately along the row direction, such that the first metal wing portion is between a pair of adjacent second metal wing portions, and the second metal wing portion is between a pair of adjacent first metal wing portions.

[0167] The adjacent first metal fin portions of the inter-row connector are separated by an interdigital spacing, and the interdigital spacing between immediately adjacent first metal fin portions of the inter-row connector is uniform, wherein the width of the first metal fin portions is uniform. The interdigital spacing of the first metal fin portions of the inter-row connector depends on the width of the second metal fin portion and can be equivalent to or greater than the size of the battery in the row direction.

[0168] The adjacent second metal fin portions of the inter-row connector are separated by a finger-width distance, and the finger-width distance between adjacent second metal fin portions of the inter-row connector depends on the spacing distance between adjacent batteries and is uniform, wherein the width of the second metal fin portions is uniform. The finger-width distance of the second metal fin portions of the inter-row connector depends on the width of the second metal fin portions and can be equivalent to or greater than the size of the battery in the row direction.

[0169] The first metal fin portion and the intermediate metal fin portion cooperate to form a first metal grating. The second metal fin portion and the intermediate metal fin portion cooperate to form a second metal grating. The first metal fin portion, the second metal fin portion, and the intermediate metal fin portion cooperate to form a main metal grating. Each metal grating can be flexible and can be exposed such that its main surface is neither thermally nor electrically insulating. The intermediate metal fin portions of the inter-row connector are integrally connected to extend along the row direction, thereby defining the dimensions of the inter-row connector in the row direction.

[0170] An exemplary inter-row connector includes an elongated strip 118, which is an inter-row connector extending in the row direction to interconnect a first metal wing portion and a second metal wing portion of a battery inter-row connector forming the inter-row connector.

[0171] The metal blade section has a main blade surface parallel to the row direction.

[0172] An exemplary row connector is formed from a single flexible metal sheet and includes multiple flexible tab portions.

[0173] Another exemplary row connector in Figure 7 As shown in the diagram, a pair of adjacent battery rows, each consisting of two rows of batteries, are connected in series via inter-row connectors. Each inter-row connector includes multiple (N) inter-battery connectors, and each inter-battery connector includes a first battery terminal contact tab 1112, a second battery terminal contact tab 1114, and an inter-terminal tab 1116 that interconnects the first battery terminal contact tab 1112 and the second battery terminal contact tab 1114. A window or aperture is formed on the inter-terminal tab 1116, extending a significant portion of the axial length of the inter-battery connector.

[0174] To assemble battery banks in parallel, inter-bank battery connectors are attached to the multiple batteries forming the battery banks, and modular components are assembled together to form sub-assemblies. When assembling the battery banks, a first battery terminal contact tab 1112 is located on a first axial end of the battery housing and is in physical and electrical contact with the first battery terminal. A second battery terminal contact tab 1114 protrudes from a second end of the battery housing and extends into another bank to make physical and electrical contact with the second battery terminal of the battery in that bank. An inter-terminal tab 1116 extends axially within the battery housing between the first and second axial ends, such that its first terminal connects to the first battery terminal contact tab 1112.

[0175] An exemplary battery module includes a battery tray 140 (or simply a tray), a plurality of batteries 160 held on the battery tray, and a plurality of inter-row connectors interconnecting the batteries. The inter-row connectors are used to connect the battery terminals of a battery in one receiving row to the battery terminals of a battery in an adjacent receiving row. In an exemplary embodiment, when the battery module has multiple (M) receiving rows, there are corresponding multiple (M) inter-row connectors.

[0176] In the case where a pair of adjacent receptacle rows of a battery module have multiple (N) battery receptacles, the inter-row connector includes multiple (N) inter-battery connectors interconnected by row couplings. Each inter-battery connector includes a first contact tab, a second contact tab, and an intermediate coupling that interconnects the first and second contact tabs. Since the first and second contact tabs are terminal contact tabs for connecting to different batteries, the intermediate coupling is also an inter-battery coupling. Unless the context otherwise requires, the contact tabs herein refer to battery terminal contact tabs. An exemplary first contact tab is used to connect to a first terminal of a battery in a receptacle row, and an exemplary second contact tab is used to connect to a second terminal of a corresponding battery in an adjacent receptacle row. The exemplary first contact tab protrudes away from the intermediate coupling and extends away from (e.g., orthogonally away from) the adjacent receptacle row. The exemplary second terminal protrudes away from (e.g., orthogonally away from) the intermediate coupling and extends away from the first contact tab. The first and second contact tabs are parallel and have an axial spacing equal to or equivalent to the length, axial range, or height (65 mm for an 18650-sized battery) of the cylindrical battery. An exemplary intermediate connector is an elongated metal wing having a main surface parallel to the row direction of the receiving section and parallel to the battery axis of the corresponding battery to which the inter-cell connector is connected. The metal wing forming the intermediate connector extends in the air gap between the first and second terminals of the corresponding battery. Because the contact tabs are physically and electrically connected to the battery terminals of the corresponding battery, heat accumulated in the battery is transferred to the inter-row connector and then to the substrate. The inter-row connector is configured to have a high surface area to volume ratio and is made of good thermal and electrical conductors to enhance heat transfer to the substrate and good heat dissipation. The substrate and the inter-row connector are configured to form a heat transfer network, thereby transferring the heat generated by the batteries in the battery module to the substrate via the inter-row connector. The heat transfer network includes a heat transfer matrix comprising rows of thermally conductive fins thermally bonded to a substrate. The thermally conductive fins extend axially along the length of the cell.

[0177] To facilitate efficient heat transfer from the cell interior of the battery assembly to the substrate for subsequent dissipation into the air compartment, a second contact tab permanently bonded to the substrate via a heat transfer interface medium has a size comparable to, equal to, or slightly larger than the second terminal of the cell it contacts.

[0178] The exemplary row connectors of this disclosure are configured to have a high surface area to volume ratio for use as good heat sinks.

[0179] The battery tray 140 of this disclosure includes a plurality of battery receptacles 142 for holding corresponding plurality of batteries, such that each battery has its own battery receptacle. The battery receptacles of the battery tray are organized into a plurality (M) rows of receptacles. Each row of receptacles (or simply a row) includes a plurality (N) of battery receptacles and extends along a row axis defining a row direction X. Each battery receptacle has a receptacle axis, which is the central axis of the battery receptacle defining the axial direction of the receptacle. The row axis of the receptacle is formed by joining the receptacle axes of the individual battery receptacles of the row. The battery receptacles forming the row of receptacles are distributed between a first row end and a second row end along the row axis of the row of receptacles. The first row end is a first lateral end where a first end receptacle (or first receptacle) is located, and the second row end is a second lateral end where a second end receptacle (or last receptacle) of the row of receptacles is located.

[0180] The battery tray comprises multiple adjacent rows of receiving portions, which are parallel to each other. The rows of receiving portions forming the battery tray are distributed along a distribution direction Y. This distribution direction can be orthogonal to the receiving portion row direction X, or it can be at an angle to the receiving portion row direction. The receiving portion rows can be distributed such that the spacing between adjacent receiving portion rows (adjacent receiving portion rows) is the same or uniform. Each receiving portion row forming the battery tray can have the same or different numbers of battery portions.

[0181] Figure 8A and Figure 8BAn exemplary battery tray includes an exemplary plurality (fourteen) rows of receptacles (M = 14). The exemplary plurality of receptacles forming the exemplary battery tray include a first receptacle row 142_01, a last receptacle row 142_14, and an exemplary plurality (12) intermediate receptacle rows 142_02, ..., 142_13 evenly distributed between the first and last receptacle rows. The first receptacle row is a first end row of the battery tray, and the last receptacle row is a second end row. The first and second end rows cooperate to define a longitudinal end of the battery tray in the distribution direction Y. Each receptacle row of the battery tray includes an exemplary plurality (nine) battery receptacles (N = 9). For ease of reference, the battery receptacles in the receptacle rows are identified by a numbering system. In the numbering system, the position number of the battery housing is identified relative to the first end (or the first row end), such that the first housing is the housing on the first end, the second housing is the housing adjacent to the first housing, the third housing is the housing adjacent to the second housing, ..., and the last housing (the ninth housing in this example) is the housing on the second end (or the second row end).

[0182] The receiving rows are organized such that adjacent receiving rows are parallel to each other but laterally offset, and alternating receiving rows are laterally aligned. Utilizing this lateral offset configuration, each lateral boundary of the battery tray has a zigzag or sawtooth profile. The sawtooth profile on the first lateral side 146a is formed by the end walls of each first end receiving portion, while the sawtooth profile on the second lateral side 146b is formed by the end walls of each second end receiving portion. In this exemplary battery tray, the lateral offset between adjacent receiving rows is of the same range, such that each lateral boundary includes a plurality of recesses and protrusions having a uniform lateral range. An exemplary range of lateral offset is approximately half the width of the lateral range (or width) of the battery receiving portion, such that three consecutive adjacent receiving rows cooperate to define half a battery receiving portion 148a on the first lateral side. In the case where each receiving row has the same number of battery receiving portions, three consecutive adjacent receiving rows cooperate to define another half of the battery receiving portion 148b on the second lateral side. Despite the zigzag border, the exemplary battery tray has a generally rectangular shape defined by a first row of receiving portions, a last row of receiving portions, and lateral protrusions on the lateral boundaries.

[0183] An exemplary battery tray is organized such that odd-numbered rows are aligned laterally, even-numbered rows are aligned laterally, and odd-numbered and even-numbered rows are offset laterally relative to each other. When the receiving rows are aligned or laterally aligned, the battery receiving axis of the corresponding battery receiving portion on the aligned row is aligned in a direction parallel to the distribution direction Y. Here, the corresponding battery receiving portion refers to a battery receiving portion having the same receiving portion position number relative to the end of the row.

[0184] An exemplary battery tray has more than two even-numbered rows, such that the first and last receiving rows are laterally offset, and the first and penultimate receiving rows are laterally aligned. When the receiving rows are aligned, the receiving axis of the first end receiving portion of the aligned receiving row lies on a line parallel to the distribution direction Y. When the receiving rows have the same number of battery receptacles, the receiving axis of the second end receiving portion of the receiving row lies on a line parallel to the distribution direction Y. When the battery tray has more than three odd-numbered rows, without loss of generality, the first and last receiving rows are laterally aligned.

[0185] Each intermediate receiving row includes multiple row passageways. Each row passageway passes through two adjacent receiving rows and spans all battery compartments of the two adjacent receiving rows to define a row-channel. The row-channel is elongated and extends in a direction parallel to the row axis. The intermediate row of the battery tray includes a first row-channel located on a first side of the row axis and a second row-channel located on a second side of the row axis, such that the row axis is parallel to the first and second row-channels and located between the first and second row-channels. Exemplarily, the first and second row-channels are arranged symmetrically with respect to the row axis and are equidistant from the row axis of the intermediate row. The end receiving rows (first receiving row, last receiving row) have a single row passageway extending through the end receiving rows and the intermediate rows adjacent to the end receiving rows (or simply end rows).

[0186] Each passage has an end hole on the first row end and / or an end hole on the second row end to facilitate external electrical contact between connectors passing through the passage.

[0187] The exemplary battery tray is designed to hold cylindrical batteries, such as cylindrical rechargeable batteries. The exemplary battery housing is customized to hold 18650 lithium-ion rechargeable batteries, which are widely used in electric vehicles and have a rated voltage of approximately 3.6 volts. The 18650 battery is a single-cell battery with a nominal diameter of 18 mm and a nominal length of 65 mm. Where the battery tray is adapted to hold a single type of battery, the battery housing is designed such that the battery compartments used to hold the batteries have the same (including substantially the same) compartment dimensions. For an orderly design, the battery housings forming a row of housings are evenly distributed along the row direction, such that the spacing between the axes of adjacent housings is uniform and has the same dimensions throughout the row. Because the battery housings forming a row of housings have the same dimensions and uniform spacing, the row of housings with the same number of battery housings has the same length. Where the batteries in the battery assembly are single-cell batteries, the inter-cell connector is referred to, without loss of generality, as an inter-cell connector.

[0188] The battery receiving portion 142 (or simply "receiving portion") includes a first axial end, a second axial end aligned axially with the first axial end, and an intermediate portion interconnecting the first and second axial ends. The first axial end is an open end with an end hole large enough to expose the battery terminals for external contact but not large enough to allow the battery to leave. The second axial end is an open end with an inlet hole large enough for axial entry of the battery. The first axial end of the battery receiving portion defines a top surface of a tray, and the second end of the battery receiving portion defines a bottom surface of the tray. The intermediate portion includes a peripheral wall having an inner surface surrounding a battery cell compartment. A plurality of spacer fins are formed on the inner surface of the peripheral wall. Each spacer fin projects from the peripheral wall and extends inward, and the spacer fins cooperate to define an outer periphery of the battery cell compartment. The battery cell compartment or the outer periphery of the battery cell compartment is calculated to conform to the contour of the outer periphery of the battery, such that the battery is received within the battery cell receiving portion in a manner that allows for a tight fit between the battery and the outer periphery of the battery cell compartment or in a manner with a very small gap. Spacer fins are distributed around the inner surface of the peripheral wall to define cylindrical compartments and create an air gap between the cell and the peripheral wall, thereby aiding in heat dissipation when the cell generates heat during module operation. The cross-sectional dimensions of the cell compartments are slightly larger than 18 mm in diameter, for example, 18.2 mm to 18.5 mm. Typically, an air gap of about 0.5% or less on each side will be sufficient. The air gap size can be adjusted according to the cell size and / or capacity. For 18650 cells, the air gap fins are selected to be approximately 1 mm, but a range of 0.5 mm to 1.5 mm can be used.

[0189] The battery tray has a first surface (or first tray surface), a second surface (or second tray surface), and a peripheral wall (or tray peripheral wall) interconnecting the first and second surfaces. Each battery housing defines a battery cell compartment having a compartment axis parallel to or coaxial with the housing axis. A plurality of corresponding battery cell compartments defined by the plurality of battery housings of the battery tray are distributed within the peripheral wall of the battery tray. The peripheral wall has a generally rectangular profile, although it has serrated sidewalls. The first tray surface is defined by a first axial end of the battery housing, and more specifically formed by the collection of the first axial ends of the battery housing and orthogonal to the housing axis of the battery housing. The second tray surface is defined by a second axial end of the battery housing, and more specifically formed by the collection of the second axial ends of the battery housing and orthogonal to the housing axis of the battery housing. The tray peripheral wall is parallel to the housing axis of the battery housing. In an exemplary embodiment, the battery tray is formed of a robust engineering plastic, such as polycarbonate or ABS, to withstand the expected harsh operating conditions.

[0190] The battery housing 142 includes a first sidewall portion 142a, a second sidewall portion 142b, a third sidewall portion, and a fourth sidewall portion, which cooperate to form a peripheral wall surrounding the middle portion of the battery compartment.

[0191] The first sidewall portion and the second sidewall portion are opposite sidewall portions on the opposite side of the housing axis, which includes the battery housing portion. The first sidewall portion defines a first lateral boundary of the battery housing portion, and the second sidewall portion defines a second lateral boundary of the battery housing portion. The first and second sidewall portions cooperate to define the lateral range (or width) of the battery housing portion. Here, the lateral range is the range in the direction of the housing axis.

[0192] When the battery housing is an intermediate battery housing adjacent to two adjacent battery housings in the same housing row, each of the first and second sidewall portions is a housing wall portion of the intermediate battery housing shared by the intermediate battery housing and one of the adjacent battery housings in the same housing row. In other words, the first and second sidewall portions of the intermediate battery housing are opposite housing sidewall portions shared by three consecutive battery housings in the housing row. The first and second sidewall portions also serve as partition walls providing separation between the three consecutive battery housing chambers in the housing row. When the battery housing is an end housing, i.e., a housing at the end of a row, one of the first and second sidewall portions is shared by that battery housing and its adjacent battery housing.

[0193] The third and fourth sidewall portions are sidewall portions on opposite sides of the row axis and opposite sides of the receiving portion axis, such that the receiving portion axis of the battery receiving portion and the row axis of the receiving portion row containing the battery receiving portion are located between the third and fourth sidewall portions. Each of the third and fourth sidewall portions is a sidewall portion that interconnects the first and second sidewall portions.

[0194] An exemplary battery tray includes a first tray end 144a as a first end of the tray, a second tray end 144b as a second end of the tray, a first tray side 146a as a first lateral side of the tray, and a second tray side 146b as a second lateral side of the tray. A first sidewall portion 142a of the battery receiving portion 142 is a sidewall portion adjacent to the first lateral side of the tray (and away from the second lateral side). A second sidewall portion 142b of the battery receiving portion is a sidewall portion adjacent to the second lateral side 146b of the tray (and away from the first lateral side). A third sidewall portion of the battery receiving portion is a sidewall portion adjacent to the first tray end 144a (and away from the second tray end). A fourth sidewall portion of the battery receiving portion is a sidewall portion adjacent to the second tray end 144b (and away from the first tray end).

[0195] The receiving sections are arranged in parallel and abut against the ends of the first and second trays. The receiving section includes a first end section, a last end section, and a plurality of intermediate sections between the first end section and the last end section. The first end section is the receiving section on the end of the first tray, and the last end section is the receiving section on the end of the second tray.

[0196] The battery tray has a first end wall serving as a peripheral wall on a first tray end and a second end wall serving as a peripheral wall on a second tray end. The first end wall is defined by a side wall portion (or more specifically, a third side wall portion) of a receiving portion on a first end row. The second end wall is defined by a side wall portion (or more specifically, a fourth side wall portion) of a receiving portion on a last end row. The first tray end includes a flange portion projecting away from the first end wall. No flange portion is formed on the second tray end, making it easier to identify the first and second ends. In some embodiments, a flange portion projecting away from the second end wall may be formed. During assembly, the flange portion will sit on a corresponding flange formed on the housing.

[0197] The battery tray has a first side wall serving as a peripheral wall on a first tray side and a second side wall serving as a peripheral wall on a second tray side. The first side wall is formed by a side wall portion (or more specifically, a first side wall portion) of a first receiving portion in a receiving portion row. The second side wall is formed by a side wall portion (or more specifically, a second side wall portion) of the last receiving portion in a receiving portion row.

[0198] Multiple conductor outlets are formed on the peripheral walls of the first tray side and / or the second tray side. Each conductor outlet is formed as an axially extending slit portion on a side wall portion of a receiving portion defining a part of the tray side wall. The slit portion is a continuation of the conductor passage on the receiving row, allowing a portion of an inter-row connector (e.g., a tab portion) to protrude or pass through. The required number of slit portions equals the number of inter-row connectors, which is equal to the number of rows minus one.

[0199] Multiple windows and corresponding protrusions are formed at selected locations on the peripheral walls of the first tray side and / or the second tray side. The windows are formed as axially extending slots on the sidewall portion of a receiving portion defining a part of the tray side wall. The protrusions are formed as axially extending rods projecting away from the sidewall portion of the receiving portion defining a part of the tray side wall. The windows and corresponding protrusions of adjacent trays are complementary to facilitate complementary engagement and latching of adjacent battery trays, thereby forming a combined battery tray, such as... Figure 9 As shown, the windows and protrusions are arranged such that the first and second ends of the component tray are located on opposite ends of the tray when assembled. This provides flexibility in tray assembly, allowing trays to be combined to form battery assemblies with the same number of rows as a single tray but with a larger number of battery compartments per compartment row or a smaller number of battery compartments per compartment row.

[0200] Each housing row of the combined battery tray has the same number of battery housings, but the combined battery tray has a larger number of battery rows, for example, a multiple of the number of housing rows, but the component trays are still in a side-by-side engagement or latching.

[0201] To avoid confusion, unless the context requires otherwise, ordinal numbers such as first, second, third, fourth, etc., are used only for ease of reference and description, and not to indicate the degree of importance or significance or the necessary order or sequence.

[0202] When the battery housing is an intermediate battery housing on an intermediate row, each of the third and fourth sidewall portions is a shared sidewall portion shared with two adjacent battery housings in an adjacent housing row. More specifically, the third sidewall portion on an intermediate row is also part of the fourth sidewall portion of the first adjacent battery housing in the first adjacent housing row and the fourth sidewall portion of the second adjacent battery housing; and the fourth sidewall portion on the intermediate row is also part of the third sidewall portion of the first adjacent battery housing in the second adjacent housing row and the third sidewall portion of the second adjacent battery housing.

[0203] The peripheral wall of the central portion of the exemplary battery receiver has a hexagonal prism shape, with the receiver axis as its central axis or prismal axis. Each of the first and second sidewall portions forms a wall of a hexagonal prism orthogonal to the row axis, and the first and second sidewall portions face away from each other. Each of the third and fourth sidewall portions includes two adjacent sidewalls of the hexagonal prism. The exemplary battery receiver has a regular hexagonal shape such that the hexagonal sidewalls have the same length. The battery receiver is distributed similarly to the cell layout of a beehive, such that a typical battery receiver is surrounded by six adjacent battery receivers, and the sidewalls of the typical battery receiver are shared with the six surrounding battery receivers.

[0204] A typical battery housing in a middle row includes a first passage portion formed on a third sidewall portion and a second passage portion formed on a fourth sidewall portion. Each passage portion is parallel to the row axis and is defined by a first slit portion and a second slit portion. Slit portions 143 are formed on the sidewall of the hexagonal battery housing for a portion of the third sidewall portion or a portion of the fourth sidewall portion. Each slit portion extends along a slit axis parallel to the housing axis and orthogonal to the row axis. In this context, the middle battery housing on a middle row is a typical battery housing.

[0205] The slit portions on the third sidewall portion of the battery receptacle on the intermediate receptacle row form an assembly of slit portions. This assembly of slit portions defines a first passage extending across all the battery receptacles on the receptacle row to provide a through channel for the conductor between the battery receptacles.

[0206] The slit portions on the fourth sidewall portion of the battery housing on the intermediate housing row form an ensemble of slit portions. This ensemble of slit portions defines a second passage extending across all the battery housings on the housing row to provide a through channel for the conductors between the battery rows.

[0207] The battery receiving portion on the end row has either a slit third sidewall portion or a slit fourth sidewall portion, the slit third sidewall portion or the slit fourth sidewall portion forming a through passage portion. A flange is formed on one of the end rows, and the flange protrudes away from the battery receiving portion in a direction parallel to the distribution axis.

[0208] Each passage section has a slit portion that begins at the second axial end of the tray and extends axially to a depth toward the first axial end. Each passage section has an inlet hole defined by the slit portion to allow a portion of the connecting member to enter the passage section.

[0209] Multiple windows and corresponding protrusions cooperate to form multiple tray alignment devices. Alignment devices are formed on some of the end battery receptacles. The alignment devices include axial protrusions and axial slots formed on end sidewall portions not shared with other battery receptacles. The end sidewall portion may be a first sidewall portion or a second sidewall portion. The axial protrusion projects away from the end sidewall portion along the row axis and extends in an axial direction located on the row axis and parallel to the receptacle axis. The axial slot has a slot axis intersecting the row axis and extending in an axial direction parallel to the receptacle axis. The height of the axial protrusion and axial slot is half or less of the height of the sidewall portion. The height of the sidewall portion is a dimension of the sidewall portion measured in a direction parallel to the receptacle axis. An axial through-hole is formed on the axial protrusion to allow a pin to pass through the axial through-hole to enter a perforated protrusion of another battery tray when the battery assembly includes more than one battery tray.

[0210] To assemble the battery module, the first contact tab of the inter-row connector is inserted from the second axial end into the receiving row and moved toward the first axial end until the first contact tab reaches the first axial end of the battery receiving section.

[0211] When the first contact tab reaches its designated position, the row tab 118 of the inter-row connector is positioned and seated within the passage, its main surface facing the interconnected batteries and parallel to the battery axis. The row tab extends through the battery receiving portion of the row along the path defined by the passage and has an end tab portion 118a protruding from the battery tray. When the row tab is in place, the first contact tab is located in the receiving portion of one receiving row, and the second contact tab is located in the receiving portion of another receiving row that shares the row tab passage with the one receiving row.

[0212] When the first contact tab reaches the first axial end, the second contact tab will be located on the second axial end of the battery housing.

[0213] After all the inter-row connectors are in place, insert the battery into the battery housing, and the battery terminals will be electrically connected to the corresponding contact tabs, for example, by fusion welding such as laser welding or spot welding, to connect the battery terminals and the corresponding contact tabs into one piece.

[0214] In the case where the battery comprises multiple battery modules, multiple battery trays for the corresponding multiple battery modules are placed side by side, and inter-row connectors with tabs are placed inside the battery trays, and similar steps are performed, wherein the tabs are long enough to pass through the battery modules.

[0215] In some embodiments, individual battery modules can be assembled independently, mounted on a housing, and then electrically connected together by inter-row connectors.

[0216] After one or more battery modules have been assembled, a substrate is attached to the bottom surface of one or more battery modules using an electrically insulating thermal contact medium to complete the construction of the module's heat exchange assembly, facilitating efficient heat exchange between the heat transfer network and the substrate. The heat transfer assembly includes inter-row connectors for the battery modules and a substrate as an example of a heat exchange device. Where the batteries are not connected via inter-row connectors, without loss of generality, the heat transfer assembly is formed by a collection of separate inter-cell connectors and heat exchange devices. In this example, the second battery terminal is the negative terminal of the battery, and the negative terminal of the battery in the battery module is welded to a second contact tab thermally bonded to the substrate. When assembling the battery modules, the batteries are housed within a battery housing, for example, with the battery axis aligned with the housing axis. A first contact tab is located near and exposed on the first module surface and physically and electrically bonded to the first battery terminal. A second contact tab is located near and exposed on the second module surface and physically and electrically bonded to the second battery terminal. The inter-cell connector of the inter-cell connector is located within the battery housing and extends between the first and second contact tabs. The inter-battery connector extends between two adjacent rows of receptacles and between adjacent receptacles on adjacent rows of receptacles. A first connecting portion of the inter-battery connector is located within the receptacle of one battery, while a second connecting portion of the inter-battery connector is located within the receptacle of another battery. An intermediate connecting portion, or row connector, is located in both receptacles. The row connecting portion is held in place by a passage formed in the battery receptacle and held at an axial height above the axial end by a slit portion of the battery receptacle. The exemplary slit portion defining the passage portion on the battery receptacle has an exemplary length of 22 mm, which is approximately one-third of the typical axial range of the battery receptacle of the exemplary tray. Typically, slit portions having an axial range greater than 20%, 25%, or 30% of the battery's axial length and less than 35% or 40% will provide a good balance. The connecting portion of the inter-battery connector is configured to extend within an air gap portion of the battery receptacle defined by spacer fins and the battery. The first and second connecting portions are laterally offset because adjacent receptacles on adjacent rows of receptacles are laterally offset.

[0217] In an exemplary embodiment such as this one, a first connecting portion extends axially within a battery housing, and a second connecting portion extends axially within an adjacent battery housing on an adjacent housing row. The exemplary first connecting portion extends and the row connectors are orthogonal to each other, thereby defining a T-shaped cross-section within the battery housing. The exemplary second connecting portion extends and the row connectors are orthogonal to each other, thereby defining another T-shaped cross-section within the battery housing. The T-shaped cross-section formed by the two mutually orthogonal tab portions creates a more stable connector structure within the battery housing. Each battery housing has either a first connecting portion or a second connecting portion, but not both.

[0218] To mitigate the risk of electrical contact between adjacent battery terminal contact tabs on adjacent receiving rows, while minimizing the space between adjacent rows, adjacent rows of contact tabs can be partially electrically insulated. For example, an electrically insulating medium can be applied to the portion of the second tab adjacent to the intermediate connection portion of the battery connector. In an exemplary embodiment, electrically insulating (preferably non-thermally insulating) tape can be applied across a row of second contact tabs to cover the portion of the second contact tabs near the intermediate connection portion, thereby mitigating the potential risk of electrical contact between second contact tabs in adjacent receiving rows. Since the first contact tabs typically have smaller surface dimensions than the second contact tabs, electrical insulation may not be necessary for the first contact tabs in adjacent rows.

[0219] refer to Figure 9 An exemplary battery tray includes an exemplary plurality (M=14) of accommodating rows and an exemplary plurality (N=9) of battery accommodating portions per row. Two battery modules forming an exemplary battery assembly are mounted side-by-side, wherein each row is aligned such that each row of the battery assembly includes N=18 batteries. The row-to-row connectors have N first terminal tabs and N second terminal tabs. Although the row-to-row connectors are distributed along the row direction and such that adjacent row-to-row connectors have a substantially uniform spacing, the spacing between two adjacent row-to-row connectors on two adjacent battery trays is greater than the spacing between two adjacent row-to-row connectors on the same battery tray. In the case of M rows of batteries connected in series, the output voltage of the battery assembly is equal to MVb, where Vb is the voltage of each row of batteries. For 18650 batteries, Vb is taken as 3.6V, and the voltage of the battery assembly is approximately 50.4V.

[0220] When the inter-row connectors and batteries are positioned as intended in the tray and the batteries are assembled, the batteries in the receiving row are electrically connected in parallel, and the battery rows or adjacent battery rows are connected in series. During this assembly, the first battery terminal of a row of batteries is connected to the first contact tab of one inter-row connector, and the second battery terminals of all batteries in that row are connected to the second contact tab of another inter-row connector. Because the first battery terminals are electrically interconnected through the tabs of one inter-row connector, the first battery terminals of the batteries in that row are at the same potential. Because the second battery terminals are electrically interconnected through the tabs of another inter-row connector, the second battery terminals of the batteries in that row are at the same potential.

[0221] After the battery module is assembled, a substrate 120 is attached to the battery module to form a battery assembly 100. The battery assembly is mounted on a housing and electrically connected to a battery management circuit. When the battery assembly is installed, its top surface is close to and faces the top plate of the discharge chamber. An exemplary battery of an exemplary battery module has a safety vent adjacent to the positive terminal, which serves as a first battery terminal. When the battery assembly is installed as intended, the first battery terminal of the battery is aligned on the top surface of the battery tray and exposed to the air chamber, facing away from the top plate of the air chamber.

[0222] Before the battery assembly is mounted on the upper housing portion, a thermal sensor is mounted on the discharge chamber to facilitate the detection of the temperature within the battery compartment. In this example, vents are formed on the top wall of the housing and symmetrically distributed on both sides of the longitudinal central axis of the housing. Vents 232 are distributed near the middle portion of the top wall of the upper housing portion. The inner surface of the top wall defines the top plate of the discharge chamber, which is also the top plate of the battery compartment in this example, as the discharge chamber is part of the battery compartment. The thermal sensor is mounted on the vents to allow monitoring of the temperature within the battery compartment and to detect the temperature of gaseous emissions exiting the battery compartment through the vents. In some embodiments, the thermal sensor may alternatively or additionally be mounted at other locations in the battery compartment 106 or the discharge compartment 108. The battery compartment is configured such that gaseous emissions from the batteries of the battery module can only exit through the vents. In an exemplary embodiment, the upper housing portion of the housing is integrally formed of an impermeable material (hard plastic) in which the vents are integrally molded. When the upper housing and battery assembly are assembled as intended, the substrate and upper housing cooperate to form an airtight battery compartment except at the vent.

[0223] To facilitate more accurate detection of the temperature inside the battery compartment, or more specifically, the temperature of the discharge chamber, which is the part between the battery assembly and the casing, the upper casing is made of an insulating material such as rigid plastic. This thermally isolates the discharge chamber from the surrounding air, mitigating the possibility of undetected abnormally high temperatures due to heat exchange between the air inside the discharge chamber and the ambient air passing through the upper casing. Such heat exchange can cause the temperature inside the battery compartment to drop, adversely affecting the accurate detection of adverse battery conditions and the timing of initiation of countermeasures.

[0224] When the battery assembly is in place, the battery's safety vent is close to and exposed to the top surface of the battery assembly and the discharge chamber. When the safety vent of a faulty battery operates to release hot gases from the battery, the hot gases inside the faulty battery will exit from the top or top portion of the battery along with the hot gas emissions and move directly into the discharge chamber.

[0225] Batteries can degrade and gradually become faulty, for example, due to aging and weathering. When a battery becomes faulty, it may begin to have a high temperature and hot gases may be released from it. The initial rate of gas emission is usually relatively low, and the initial temperature of the hot gases is also relatively low, for example, between 100 and 120 degrees Celsius. When the battery temperature rises further to a critical temperature, such as the melting temperature of the battery's electrode separator, the melting of the separator will accelerate and exacerbate the battery damage, and the temperature of the hot gases emitted from the faulty battery may rapidly reach 500, 650, or even 800 or 1000 degrees Celsius. The high temperature of the faulty battery may spread to adjacent cells in the battery module and may cause thermal runaway and possible explosion. The electrode separator is typically made of polyethylene with a melting temperature of 133 degrees Celsius or polypropylene with a melting temperature of 159 degrees Celsius. The melting temperature of the separator can be considered a critical temperature for battery state monitoring.

[0226] In some embodiments, a first cooling power may be applied when a first activation temperature is detected, and a second higher cooling power may be applied when a second higher activation temperature is detected after a predetermined time has elapsed since the cooling power was activated to cool the battery assembly.

[0227] To detect the temperature within the battery compartment without requiring a thermal sensor for each battery, multiple thermal sensors are distributed to detect the temperature within the discharge compartment. The number of these thermal sensors is significantly less than the number of batteries. In this example, the thermal sensors are distributed within the discharge compartment and configured to detect the temperature of the discharge compartment, which is the portion of the battery compartment near the battery safety vent and that defines the discharge chamber.

[0228] To reduce the mixing of hot gas emissions from the battery with the air in the discharge chamber, the discharge chamber is constructed such that the gas emissions can flow to the vents within a short distance. For example, the vents and thermal sensors are located on the top plate of the discharge chamber, allowing the hot gas from the battery to travel upwards to the top plate and then to the vents at or near the location of the thermal sensors.

[0229] To minimize the distance that hot gas emissions must travel to reach the thermal sensor or vent, the axial extent of the discharge chamber is configured to be significantly smaller than that of the battery compartment. For example, the axial extent of the air chamber may be 5%, 10%, or 15% greater than that of the battery compartment but less than 20%, 25%, or 30% of its axial extent. The axial extent of the discharge chamber may be less than 20%, 25%, 30%, or 40% of the axial extent of the battery assembly but greater than 5%, 10%, or 15%.

[0230] To ensure that hot gas emissions are guided only a short distance within the discharge chamber before reaching the nearest thermal sensor or vent closest to the discharge battery, multiple fluid movement guides are formed on the top plate to surround the vent. Each fluid movement guide defines a guide track extending radially relative to the vent, and the guide track formed by the multiple fluid movement guides defines multiple tapering channels, each tapering narrowing as it extends toward the vent. The guide track extends orthogonally to the axial direction of the battery assembly, which is also the axial direction of the battery, and guides the hot gas emissions to move them from the battery's safety vent to the vent 232 within a short distance, minimizing mixing of the hot gas emissions with the air in the air chamber, so that the temperature of the hot gas emissions is substantially maintained upon reaching the thermal sensor (also known as the temperature sensor).

[0231] The end tab portion 118a of the inter-row connector at the end row of the battery assembly is connected to the power input and power output terminals of the module. The end tab portion of the inter-row connector at the middle row is connected to the battery management circuitry to facilitate the management of the battery voltage at each battery row.

[0232] In an exemplary embodiment, the control circuit is configured to monitor the battery temperature by, for example, monitoring the temperature at multiple vents using a thermal sensor. When the temperature detected at a vent exceeds a predetermined threshold, the control circuit can activate safety measures. Safety measures may include shutting down the battery module, isolating the battery or battery pack by, for example, a fuse, or activating cooling measures by operating a fan. When the battery cooling measures are activated within a short period after detecting the alarm temperature, the movement of cooling air through the air compartment is expected to rapidly cool one or more damaged batteries below a critical temperature above which the risk of battery melting due to thermal runaway may significantly increase.

[0233] In some embodiments, active cooling measures, such as the use of thermoelectric cooling devices like Peltier devices, can further accelerate the cooling process. As a convenient example, the active cooling element may be attached to a heat exchange device and / or attached to the bottom portion of the housing.

[0234] Since the inter-cell connectors are directly connected to the battery terminals, especially those with battery safety vents, the network of inter-cell connectors serves as a heat transfer network for transferring heat from the battery's interior to the heat exchange device. Furthermore, the construction of the inter-cell connectors, particularly the exposed metal fins in the intermediate connection portion, also facilitates heat dissipation during normal operation of the battery assembly and helps maintain the battery at its preferred or desired operating temperature.

[0235] During operation, if the thermal sensor detects an activation temperature, the control circuitry activates countermeasures to cool the battery assembly, thereby preventing or mitigating the risk of thermal runaway and potential melting. In an exemplary embodiment, once the thermal sensor detects a critical temperature, such as 80°C or 90°C, a fan is activated to accelerate heat exchange between the battery module and the air in the air compartment, a process that helps cool the battery assembly. In some embodiments, active thermal cooling may be used additionally or as an alternative. In some embodiments, an external fan may be used, and cool air may be supplied from an external source. The battery pack may also be shut down, for example, by a fuse, upon detection of a critical temperature. In some embodiments, when the temperature reaches a second higher temperature, such as 100°C, the control circuitry may operate to shut down the battery module or battery assembly. The battery module may be shut down, for example, by isolation by an electronic switch such as a semiconductor switch or a fuse. Additionally, the control circuitry may generate an alarm signal upon reaching a critical temperature. The alarm signal may include a local alarm on the module and / or a remote alarm transmitted from the module, for example, via a telecommunications network through the module's telecommunications front end.

[0236] The heat exchange component of this disclosure is configured as a heat sink, and more specifically, as a distributed heat sink comprising a distributed heat transfer network formed by inter-cell connectors. As a distributed heat sink, the heat exchange component has an inherent ability to equalize the temperature of the cells forming the battery module or battery assembly. This temperature equalization capability can be enhanced by active cooling or thermoelectric cooling that accelerates heat exchange with the heat exchange component through forced air movement.

[0237] Batteries typically have a defined operating temperature range, defined between a minimum and a maximum operating temperature. Most lithium-ion batteries are manufactured to operate below the maximum temperature of approximately 60°C to 65°C. For longer battery life and greater long-term safety, an operating temperature significantly lower than the maximum temperature is generally preferred.

[0238] Exemplary modules can be configured to operate the battery within a preferred operating temperature range, which is an intermediate temperature range selected between a maximum and a minimum temperature. For example, the device can be configured to operate such that the battery's operating temperature is maintained at or below an upper temperature limit, such as 40°C or 42°C. When the battery reaches the upper temperature limit, control circuitry activates a cooling arrangement to lower the battery temperature towards the lower limit of the intermediate temperature range, for example, lowering the battery temperature to or a few degrees below the upper temperature limit, such as 1, 2, or 3 degrees, and this process continues and repeats. Typically, an intermediate temperature range between 25°C and 42°C is found to be preferred.

[0239] Controlling the battery operating temperature within the intermediate temperature range selected between the maximum and minimum temperatures requires more extensive and precise battery temperature monitoring. To facilitate this, multiple temperature sensors, such as temperature probes, are placed within the battery housing to monitor the battery temperature and control the operation of the cooling system via control circuitry.

[0240] Temperature sensors can be used to control temperature imbalances between batteries in a battery assembly or module. For example, when a temperature imbalance exceeding a threshold is detected, the control circuit will activate a cooling structure to lower the battery temperature, thereby mitigating the temperature imbalance. As a convenient example, an exemplary imbalance threshold can be selected between 3°C and 5°C.

[0241] The heat transfer network includes a matrix of heat transfer members physically connected to and extending through a battery housing of the battery assembly. Each heat transfer member has a first end physically connected to a first battery terminal of one battery and a second end connected to a second battery terminal of another battery. The second end of the heat transfer member is also connected to a main heat exchange device physically connected to an axial end of the battery assembly. The main heat exchange device has a thermal contact surface that is physically in contact with but electrically isolated from the heat transfer network. The main heat exchange device has a heat exchange surface physically connected to the thermal contact surface for efficient heat transfer. In an exemplary embodiment, the heat exchange surface and the thermal contact surface are opposite main surfaces of a conductive plate, such that the heat exchange surface and the thermal contact surface are integrally connected by a thermally and electrically conductive material. In some embodiments, the thermal contact surface is defined as a plurality of insulated or isolated electrically conductive regions, each electrically conductive region being for thermal contact but not electrical contact with a set of heat transfer members, such as an array of heat transfer members. The heat transfer members are connected to the thermal contact surface via a thermally conductive medium that is electrically insulating to impede electrical contact between the heat transfer network and the main heat exchange device. The heat transfer components are arranged in an array or row, and the array or row of heat transfer components extends in an axial direction generally orthogonal to the thermal contact surface to form a 3D heat transfer assembly. An exemplary heat transfer component is also a battery connector, which includes a first battery terminal tab that is in physical and electrical contact with a first battery terminal, and a battery connector that is within and extends through the battery housing to reach the thermal contact surface.

[0242] Although the invention has been disclosed with reference to examples and embodiments, the examples and embodiments are not intended to be limiting.

Claims

1. A mobile power supply device, comprising a main housing supported by a plurality of wheels, a plurality of battery modules electrically connected to each other and held on the main housing, and electronic circuitry for controlling the operation of the power supply device; in, The electronic circuit includes a power circuit, a communication circuit, and a control circuit, wherein the power circuit includes a power input circuit and a power output circuit; The main housing is organized into multiple shelves and / or receptacles for housing the battery module and the electronic circuitry; The battery module includes: -Module housing; - Multiple battery cells, which are held in corresponding multiple battery accommodating portions and include multiple battery rows; - Temperature sensor or thermal sensor; - A ventilation device for moving air into and / or out of the battery module; - Battery tray, the battery tray including the plurality of battery accommodating portions; - A power interface that facilitates power input and power output; and - Multiple inter-battery connectors, including inter-row connectors that connect two battery banks in series and are configured as heat dissipation components. -The row connector includes a row connector that extends in the row direction and interconnects the battery inter-connectors that form the row connector, the row connector being an elongated metal sheet; -Including the heat exchange device of the row connector; The control circuit is configured such that when the temperature of the battery module reaches a threshold temperature, the control circuit activates the ventilation device upon receiving a temperature signal from the temperature sensor or the thermal sensor to remove hot air from the battery module and supplement it with cooler ambient air, which is then exchanged through the heat exchange device to cool the battery cells of the battery module.

2. The power supply equipment according to claim 1, wherein, - The heat exchange device further includes a substrate that forms a heat transfer network with the inter-row connector, the inter-row connector transferring the heat generated by the battery of the battery module to the substrate; - The substrate includes an exchange surface heat exchanger for performing the heat exchange.

3. The power supply equipment according to claim 1, The main housing includes a top portion having a top panel, a bottom portion having a bottom panel, and a peripheral wall connecting the top portion and the bottom portion. -in, The top panel, the bottom panel, and the perimeter wall cooperate to form a cabinet with an internal compartment, in which the components of the power supply equipment, including the electronic circuitry and battery assembly, are housed. -The battery module includes a first group of battery cells and a second group of battery cells connected in series by an inter-group connector, wherein the inter-group connector is the row connector. Wherein, the first group of battery cells includes a first plurality of battery cells housed in a first group of battery housings, and the second group of battery cells includes a second plurality of battery cells housed in a second group of battery housings. - and wherein the row connector of the row connector extends through the first set of battery accommodating portions and the second set of battery accommodating portions; The power supply equipment has a tower shape factor, meaning its height is greater than the width or length of its base. - Wherein, the inter-group connector includes: a first connector portion extending from the first group of battery cells to a third connector portion; and a second connector portion extending from the third connector portion to the second group of battery cells; and - wherein the first connector portion extends within the first battery housing, the second connector portion extends within the second battery housing, and the third connector portion extends through the first battery housing and the second battery housing; -The row connector is integrally formed from a single metal sheet.

4. The power supply equipment according to claim 3, wherein, The multiple battery modules are vertically aligned to form a stack of battery modules; The first connector portion includes a first plurality of spaced-apart first battery cell connectors that interconnect the first group of battery cells and the third connector portion; wherein the first battery cell connector includes a first sheet connector extending within the battery housing portion of the first group of battery housing. Wherein, the first connector portion includes an array of first contact tabs, the second connector portion includes an array of second contact tabs, and the third connector portion includes an array of inter-terminal tabs; and wherein, The third connector portion is integrally formed from a copper sheet, a copper alloy sheet, or a steel sheet.

5. The power supply equipment according to claim 4, wherein, The first sheet connector extends a first axial range within the battery housing of the first set of battery housings to reach the third connector portion, and wherein the first sheet connector has a main surface facing the battery cell held within the battery housing. The power circuit is configured as a power input module and a power output module. The power input module includes a power input port, a power output port, and an AC-DC converter interconnecting the power input port and the power output port. The power output module includes a power input port, a power output port, and a DC-DC converter that interconnects the power input port and the power output port.

6. The power supply equipment according to any one of claims 3 to 5, wherein, The second connector portion includes a second plurality of spaced-apart second battery cell connectors interconnecting the second group of battery cells and the third connector portion, wherein the second battery cell connectors include a second sheet connector extending within the battery housing of the first group of battery cells; wherein the derating energy storage capacity of the power supply device is higher than 16, 20, 25, 30 or 35 kWh per cubic meter.

7. The power supply equipment according to claim 6, wherein, The second plate connector extends a second axial range within the battery housing of the second set of battery housings and extends away from the third connector portion, wherein the second plate connector has a main surface facing the battery cell held within the battery housing; wherein the main housing includes a rigid frame frame including slotted vertical posts, wherein the power module, control module, communication module and the battery module are mounted on the slotted vertical posts.

8. The power supply equipment according to claim 7, wherein, The main surface of the first sheet connector and the main surface of the second sheet connector are parallel, and the maximum output current of the battery assembly is 100 amps.

9. The power supply equipment according to any one of claims 3 to 5, wherein, The third connector portion includes a third sheet connector or a plurality of third sheet connector segments that interconnect the first connector portion and the second connector portion.

10. The power supply equipment according to any one of claims 3 to 5, wherein, The first connector portion extends to physically and electrically connect the battery terminal of the first battery cell of the first group of battery cells to the third connector portion, and the second connector portion extends to physically and electrically connect the third connector portion to the battery terminal of the second battery cell of the second group of battery cells, wherein the first polarity and the second polarity are opposite polarities.

11. The power supply equipment according to any one of claims 3 to 5, wherein, The battery cell includes a first electrical terminal of a first polarity, a second electrical terminal of a second polarity opposite to the first polarity, and a battery body extending axially and physically interconnecting the first electrical terminal and the second electrical terminal; and wherein the inter-group connector is thermally connected to the battery body of the plurality of battery cells of the first group of battery cells and the second group of battery cells.

12. The power supply equipment according to claim 11, wherein, The first connector portion is thermally connected to the battery body of the plurality of battery cells in the first group of battery cells, the second connector portion is thermally connected to the battery body of the plurality of battery cells in the second group of battery cells, and / or the third connector portion is thermally connected to the battery body of the plurality of battery cells in the first group of battery cells and the battery body of the plurality of battery cells in the second group of battery cells.

13. The power supply equipment according to any one of claims 3 to 5, wherein, The first group of battery cells is separated by a partition wall, and the partition wall is a common wall shared by the first group of battery cells and the second group of battery cells.

14. The power supply equipment according to claim 13, wherein, The common wall is an insulated Z-shaped wall.

15. The power supply equipment according to any one of claims 3 to 5, -in, The first connector portion includes N spaced-apart sheet conductors arranged in a first array extending along a first row direction, and the inter-group connector includes M spaced-apart sheet conductors arranged in a second array extending along a second row direction, the second row direction being a row direction parallel to the first row direction, where N and M are natural numbers greater than 1. as well as - wherein the N spaced-apart sheet conductors and the M spaced-apart sheet conductors are arranged alternately along the first row direction.

16. The power supply equipment according to claim 3, wherein, The first group of battery accommodating portions and the second group of battery accommodating portions are adjacent to each other, and the inter-battery connector is an inter-group connector that extends through both the first group of battery accommodating portions and the second group of battery accommodating portions.

17. The power supply equipment according to claim 1, wherein, The battery housing is configured as a housing chamber and includes a peripheral wall surrounding a battery cell held in the housing chamber, wherein the peripheral wall includes a shared wall portion shared among a plurality of housing chambers, and wherein the inter-battery connector extends through the shared wall portion.

18. The power supply equipment according to claim 17, wherein, The perimeter wall is shared by three to seven accommodating chambers.

19. The power supply equipment according to claim 17 or 18, wherein, A slit with an open end is formed on the shared wall portion, and the battery connector extends through the slit from one receiving chamber to an adjacent receiving chamber.

20. The power supply equipment according to claim 3, wherein, The first group of battery cells has a battery terminal of a first polarity connected to the inter-group connector, and the second group of battery cells has a battery terminal of a second polarity connected to the inter-group connector, wherein the first polarity and the second polarity are opposite polarities; wherein the power supply device includes a controller and a charging coupler for connection to a load, wherein when the load is connected to the charging coupler, the controller establishes a data connection with the onboard controller on the load and identifies the correct protocol to be communicated, and determines the charging data and standard.

21. The power supply equipment according to claim 3, wherein, The first group of battery housings forms a first housing row, and the second group of battery housings forms a second housing row parallel to the first housing row; the power supply device also includes different charging connectors configured for different charging standards, and after detecting the required charging standard and charging voltage, it starts charging according to the requirements of the standard of the connected load.

22. A power supply device according to claim 1, wherein, The power supply equipment includes a controller capable of establishing a data connection with an onboard controller on the load, which controls the charging current via a protocol.

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