Unit module assembly battery pack

Abstract

A battery pack includes a battery casing, a positive terminal, a negative terminal, a plurality of unit module assemblies, and a battery management system. The plurality of unit module assemblies are housed within a cavity of the battery casing and include a plurality of lithium-ion battery cells connected in parallel. The battery management system communicates with at least one of the plurality of unit module assemblies in the cavity and is configured to receive voltage tap measurements from each of the plurality of unit module assemblies in the cavity, compare the voltage tap measurements from each of the plurality of unit module assemblies with expected voltage tap measurements, and determine whether the voltage tap measurements of the unit module assemblies deviate from the expected voltage tap measurements to identify a faulty unit module assembly.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 942,649, filed December 2, 2019, the contents of which are incorporated herein by reference in their entirety. Background Technology

[0003] Battery packs can be used with various types of equipment, including outdoor power equipment, vehicles, aerial work platforms, floor care equipment, golf carts, lifts and other industrial vehicles, recreational multi-purpose vehicles, industrial multi-purpose vehicles, lawn and garden equipment, and energy storage or battery backup systems. Outdoor power equipment includes lawnmowers, ride-on tractors, snowplows, pressure washers, portable generators, tillers, log splitters, zero-turn radius mowers, walk-behind lawnmowers, ride-on lawnmowers, and turf equipment such as spreaders, sprayers, seeders, rakes, and blowers. For example, outdoor power equipment can use one or more electric motors to drive appliances such as the rotating blades of a lawnmower, the pump of a pressure washer, the auger of a snowplow, the alternator of a generator, and / or the drivetrain of the outdoor power equipment. Vehicles include cars, trucks, automobiles, motorcycles, scooters, boats, all-terrain vehicles (ATVs), personal water vehicles, snowmobiles, multi-purpose vehicles (UTVs), etc. Invention Overview

[0004] One exemplary embodiment relates to a battery pack. The battery pack includes a battery housing defining an inner cavity. A positive and a negative terminal each extend through the housing, allowing external access. A plurality of cell module assemblies (CMAs) are housed within the inner cavity. The plurality of CMAs are electrically connected to the positive and negative terminals. Each of the plurality of CMAs includes a top CMA cell support frame defining a plurality of first pockets, a bottom CMA cell support frame defining a plurality of second pockets, a top current collector connected to the top CMA cell support frame, a bottom current collector connected to the bottom CMA cell support frame, and a plurality of lithium-ion battery cells. The plurality of lithium-ion battery cells are connected in parallel, and each is partially housed in one of the plurality of first pockets and one of the plurality of second pockets. Each lithium-ion battery cell is connected to the top current collector and the bottom current collector. The battery pack also includes a battery management system. The battery management system communicates with at least one of the plurality of CMAs within the inner cavity. The battery management system is configured to receive voltage tap measurements from each of a plurality of CMAs within the cavity, compare the voltage tap measurements from each of the plurality of CMAs with expected voltage tap measurements, determine whether the voltage tap measurements of the CMAs deviate from the expected voltage tap measurements, and generate an alarm in response to determining that the voltage tap measurements of the CMAs deviate from the expected voltage tap measurements. This alarm includes location information identifying which of the plurality of CMAs has a voltage tap measurement that deviates from the expected voltage tap measurement, thereby enabling CMA repair.

[0005] Another exemplary embodiment relates to a battery pack. The battery pack includes a battery housing defining an inner cavity. Positive and negative terminals each extend through the housing, allowing external access. A plurality of cell module assemblies (CMAs) are housed within the inner cavity. The plurality of CMAs are electrically connected to the positive and negative terminals. Each of the plurality of CMAs includes a top CMA cell support frame defining a plurality of first pockets, a bottom CMA cell support frame defining a plurality of second pockets, a top current collector connected to the top CMA cell support frame, a bottom current collector connected to the bottom CMA cell support frame, and a plurality of lithium-ion battery cells. The plurality of lithium-ion battery cells are connected in parallel, and each is partially housed in one of the plurality of first pockets and one of the plurality of second pockets. The lithium-ion battery cells are respectively connected to the top current collector and the bottom current collector. The battery pack also includes a battery management system. The battery management system communicates with at least one of the plurality of CMAs within the inner cavity. The battery management system is configured to receive temperature measurements from at least one of a plurality of CMAs within the cavity, and, in response to each temperature measurement received from the plurality of CMAs within the cavity, activate a resistive heating element within the cavity to adjust the temperature within the battery housing cavity, thereby generating a more uniform temperature distribution within the cavity.

[0006] Another exemplary embodiment relates to a battery pack. The battery pack includes a battery housing defining an inner cavity. Positive and negative terminals each extend through the housing, allowing external access. A plurality of cell module assemblies (CMAs) are housed within the inner cavity, including a first layer of CMAs and a second layer of CMAs. The plurality of CMAs are electrically connected to the positive and negative terminals. Each of the plurality of CMAs includes a top CMA cell support frame defining a plurality of first pockets, a bottom CMA cell support frame defining a plurality of second pockets, a top current collector connected to the top CMA cell support frame, a bottom current collector connected to the bottom CMA cell support frame, and a plurality of lithium-ion battery cells. The plurality of lithium-ion battery cells are connected in parallel, and each is partially housed in one of the plurality of first pockets and one of the plurality of second pockets. Each lithium-ion battery cell is connected to the top current collector and the bottom current collector. The battery pack also includes a battery management system. The battery management system communicates with at least one of the plurality of CMAs within the inner cavity. The battery management system is configured to monitor a lifetime indicator of at least one CMA. The battery pack also includes a plurality of aluminum plates. The first aluminum plate is located below the first layer of CMA, and the second aluminum plate is located below the second layer of CMA. The bottom CMA unit support frame of each CMA is configured to separate multiple lithium-ion battery cells from the aluminum plate below each bottom CMA unit support frame.

[0007] This overview is illustrative only and is not intended to be limiting in any way. Other aspects, inventive features, and advantages of the apparatus or process described herein will become apparent from the detailed description herein, taken in conjunction with the accompanying drawings, wherein similar reference numerals denote similar elements. Attached Figure Description

[0008] The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings.

[0009] Figure 1 This is a top perspective view of the battery pack housing according to an exemplary embodiment.

[0010] Figure 2 This is a perspective view of a battery pack of unit module components according to an exemplary embodiment, wherein Figure 1 The casing has been removed.

[0011] Figure 3 According to the exemplary implementation scheme Figure 2 A top view of the battery pack.

[0012] Figure 4 According to the exemplary implementation scheme Figure 2 Bottom view of the battery pack.

[0013] Figure 5According to the exemplary implementation scheme Figure 2 Rear view of the battery pack.

[0014] Figure 6 According to the exemplary implementation scheme Figure 2 Front view of the battery pack.

[0015] Figure 7 According to the exemplary implementation scheme Figure 2 Left side view of the battery pack.

[0016] Figure 8 According to the exemplary implementation scheme Figure 2 Bottom perspective view of the battery pack. Detailed description

[0017] Before turning to the accompanying drawings, which detail exemplary embodiments, it should be understood that this application is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology is for descriptive purposes only and should not be considered limiting.

[0018] refer to Figure 1This image shows a top perspective view of a battery pack 100 with a housing 108 according to an exemplary embodiment. The housing 108 is an enclosure for housing and protecting the internal components of the battery pack 100. In some embodiments, the housing 108 is a battery pack enclosure including one or more removable parts, allowing easy access to the internal battery pack 100. The housing 108 includes a negative terminal 102, a panel-mounted data connection terminal 104, and a positive terminal 106. The data connection terminal 104 is located between the positive terminal 106 and the negative terminal 102 on a common side of the housing 108. In other embodiments, the data connection terminal 104 is located at other locations on the panel of the battery pack 100. In some embodiments, the housing 108 is a single five-sided enclosure covering the battery pack 100 and located on a bottom substrate. In some embodiments, the five sides of the housing 108 are made of a polymer material. In some embodiments, the interior cavity of the housing 108 is regulated by an internal circulating fan to create a uniform internal environment. In some embodiments, when the battery pack 100 is assembled, it is mounted on the base plate of the outer housing, and a five-sided plastic casing covers and seals the battery pack 100 to prevent water or debris from entering its interior. The housing 108 can be adapted to different sizes and capacities of the assembled battery pack 100. The housing 108 of the battery pack 100 includes a user interface with an electrically isolated front panel. Data connection terminals 104 mounted on the panel of the battery pack 100 can provide protection against short circuits at terminals 102 and 106 of the battery pack 100. The data connection terminals 104 mounted on the panel may also include poka-yoked pins for controlling different current capacities in individual connectors. In some embodiments, the poka-yoked pins prevent incorrect components from being connected to the data connection terminals 104 mounted on the panel.

[0019] refer to Figure 2 This diagram shows a perspective view of a battery pack 100 according to an exemplary embodiment. The battery pack 100 includes a top plate 218, a middle plate 210, an anti-rack plate 234, spacers 209, wiring harness cutouts 206, and mounting hardware 268. In some embodiments, the top plate 218 and the middle plate 210 (located between the top plate 218 and a substrate at the bottom of the battery pack 100) are made of aluminum. Each plate 210, 218 may include multiple wiring harness cutouts 206 to facilitate cabling throughout the battery pack 100. The wiring harness cutouts 206 can be used to secure the wiring harnesses of the battery pack 100. Furthermore, the wiring harness cutouts 206 in the plates of the battery pack 100 allow wires to pass between layers without expanding the form factor of the battery pack 100. The battery pack 100 can be constructed using a series of lip seals with fastening rails and latches.

[0020] The battery pack 100 may include a plurality of vertically layered cell module assemblies (CMAs) 270, wherein a first layer of CMAs 270 is directly above a second layer of CMAs 270. Each CMA 270 includes a top CMA cell support frame (e.g., Figure 7 The top CMA unit support frame 702 and the bottom CMA unit support frame shown (e.g., Figure 7 The components shown include a bottom CMA cell support frame 704, a top current collector (e.g., positive current collector 266), a bottom current collector (e.g., negative current collector 254), multiple battery cells 202, and a curable adhesive that connects the battery cells 202 to the top and bottom CMA cell support frames. The components included in CMA 270 are described below regarding... Figure 4-8 The CMA 270 may be spaced apart from each other and located in the battery pack 100, including the intermediate plate 210, the top plate 218, and / or the bottom intermediate plate 210 and the substrate 402 (as shown in more detail). Figure 4 (as shown). Each layer of the battery pack 100 may include two intermediate plates 210 and a plurality of CMA 270s. In some embodiments, the intermediate plates 210 are located between the positive terminals of the battery cells 202 of the CMA 270 within the battery pack 100.

[0021] In some implementations, the battery pack 100 is assembled such that there are gaps between the battery cells and plates (e.g., top plate 218, middle plate 210, or bottom plate or substrate of the housing 108) of each CMA 270. These gaps between the battery cells 202 and plates of the CMA 270 in each layer of the battery pack prevent damage to the battery pack 100 during thermal events. For example, the gaps between the battery cells and plates (e.g., top plate 218, middle plate 210) of the CMA 270 allow material emanating from the faulty battery cell to accumulate above the faulty battery cell, rather than allowing material to extend laterally into other battery cells 202 within the CMA 270. Advantageously, the likelihood of a thermal event cascading to other battery cells 202 and causing further damage to the components of the battery pack 100 when heat is dissipated from the faulty battery cell is reduced. A catastrophic cascade where a faulty battery cell ignites an adjacent battery cell (e.g., a battery cell above or below a runaway battery cell) and propagates through a short circuit to other battery cells 202 is a potential source of failure for conventional batteries. In CMA 270, the plate between the positive side of battery cell 202 and the adjacent plate helps prevent runaway battery cells from propagating runaway events and potentially causing battery pack 100 to fail.

[0022] Each plate in battery pack 100 can be electrically isolated to allow each layer of battery pack 100 to be disconnected when repairing a single CMA 270 of battery pack 100. In some embodiments, each CMA 270 of battery pack 100 can be replaced with removable fasteners and common repair tools such as wrenches and screwdrivers. In some embodiments, each layer of battery pack 100 is electrically disconnected from the rest of battery pack 100 until the final assembly of the battery pack is completed and the terminal wires are connected. The ability to isolate CMA 270s that require repair due to one or more faulty batteries can advantageously improve the overall health and battery life of battery pack 100.

[0023] Mounting hardware 268 may include fasteners that are easy to maintain with tools such as wrenches. In addition to the mounting hardware 268 used throughout the battery pack 100 to provide structure and stability for the battery pack 100, mounting hardware 268 may provide thermal conductivity along all structural components, plates, spacers, etc., of the battery pack 100. Spacers 209 between all layers of the battery pack 100 may include compression limiters 208. Compression limiters 208 may be made of steel or aluminum and are adapted to provide a thermal path through the layers of the battery pack 100 while still maintaining electrically independent layers. For example, compression limiters 208 may transfer heat throughout the battery pack 100. In some embodiments, each compression limiter 208 of spacers 209 has a unique serial number.

[0024] A thermistor 217 may be connected to one of the battery cells 202 within the CMA 270 of the battery pack 100. In some embodiments, the thermistor 217 is secured to the battery cell 202 with tape 216. In some embodiments, a closed-cell foam adhesive is used to mount the thermistor 217 to the battery cell 202. Each CMA 270 within the battery pack 100 includes a thermistor 217 to monitor the temperature of the individual CMA 270. The battery pack 100 may also include resistive heating strips on an on-plate for uniformly heating the battery pack 100. In some embodiments, each layer has a resistive heating strip that operates with a different heating capacity than the heating strips on other layers. The resistance of the resistive heating element may vary according to its own temperature. For example, the variable resistance of the heating element may be based on the temperature of the heating element. Therefore, when it is determined that the temperature of a certain area of ​​the battery pack 100 is higher than that of the rest of the battery pack 100 (e.g., the top layer of the battery pack is near components of an outdoor power unit that generates a large amount of external heat), the heating level of the resistive heating element near that area can be lower than that of other resistive heating elements in the battery pack 100. For example, the top layer of the battery pack 100 may have resistive heating elements with a lower wattage than those on lower layers (e.g., the bottom layer of the battery pack 100). The resistive heating strip and thermistor 217 can communicate with the battery management system (BMS) 222 to control the temperature within the battery pack 100.

[0025] In some embodiments, one layer of the battery pack 100 may include more resistive heating elements than different layers. In some embodiments, the resistive heating elements may have positive or negative coefficients to increase the thermal self-regulation capability of the battery pack 100. The battery pack 100 can receive external power from a charger or other energy source using existing external terminals to operate the internal battery pack heating elements (e.g., resistive heating bars). Therefore, the temperature of the battery pack 100 can rise above a threshold temperature level without any current flowing into or out of the battery pack 100 and battery cells 202. In some embodiments, an internal circulating fan helps create a uniform internal temperature for the battery pack 100 without exchanging air outside the housing 108 of the battery pack 100. Advantageously, by generating a more uniform temperature level within the housing 108, the battery pack 100 can avoid specific areas of the battery pack 100 having significantly higher temperatures than other components of the battery pack 100.

[0026] Each CMA 270 of the battery pack 100 includes multiple battery cells 202 that can work together to output power to operate a vehicle or other equipment, such as various outdoor power equipment. In some embodiments, the battery cells 202 are lithium-ion battery cells. For example, the battery cell 202 may be a lithium-ion battery cell with a rated voltage of 3.6 volts and 3 amp-hours. As shown, each of the fourteen CMA 270s includes 32 battery cells 202 arranged in 4 rows of 8 cells each, which can be used... Figure 4 As seen in more detail below, battery cells 202 are electrically connected to each other using wires having terminals (e.g., wire connections) to each cell 202 and a common conductor (e.g., positive current collector 266 or negative current collector 254). In some embodiments, the bonding wires are 20 mil wires between 3 / 8 and 1 / 2 inches to provide a continuous current of 60 amperes (A) to each bonding wire without melting. Each CMA 270 can be identified using a unique identifier (e.g., serial number, barcode, etc.) for the CMA 270 manufacturer to use for tracking, classifying, evaluating, or recording information or data about individual CMA 270s. The battery management system (BMS) 222 can then use the unique identifier to relay information about which CMA 270s in the battery pack 100 require servicing.

[0027] The battery pack 100 also includes a BMS 222 for regulating the current and / or voltage involved in charging and discharging to ensure that the battery cell 202 is not damaged or otherwise enters a problematic state of charge. For example, the BMS 222 may prevent current from being delivered to the battery cell 202 based on the current and voltage characteristics of the signal and / or CMA 270, or may prevent current from being drawn from the battery cell 202. The BMS 222 may also implement control based on the temperature detected by a temperature sensor (e.g., thermistor 217) and regulate the operation of the CMA 270 based on over-temperature or under-temperature conditions determined by the received detected temperature. Furthermore, the BMS 222 may allow operation with a battery pack having a variable power supply. Because the battery pack 100 has a protected BMS 222, the battery pack 100 can be connected in series or in parallel. In some embodiments, the same BMS 222 may be used with the battery pack 100 having a nominal voltage (V) of 24V, 36V, or 48V.

[0028] In some implementations, dual Controller Area Network (CAN) bus data communication lines are included in the battery pack 100 and electrically and communicatively connected to the BMS 222 to enable vehicle and / or machine functions. The two baud rates of the dual CAN buses allow the battery pack 100 to act as a gateway (e.g., an Internet of Things (IoT) gateway) between the vehicle (e.g., an outdoor power unit) and the dual CAN buses within the battery. In some implementations, the IoT gateway is also included in the battery pack 100 (e.g., integrated with the BMS 222) rather than externally. The dual CAN buses can enable IoT within the battery pack 100 for use as an IoT module for the vehicle (e.g., an outdoor power unit).

[0029] As battery pack 100 ages, the maximum charge capacity of the CMA 270 battery cells 202 within battery pack 100 decreases over its lifespan. This decrease is caused by cycling of battery pack 100 through discharge and recharge, temperature variations (e.g., high temperatures), and chemical degradation of battery cells 202. Cycling refers to the transition from a fully charged state of the battery pack (as permitted by BMS 222) to a partially or fully discharged state (as permitted by BMS 222). The maximum charge capacity of battery pack 100 decreases as the number of cycles within its lifespan increases.

[0030] The BMS 222 of the battery pack 100 may include an integrated data logger and may be programmed to store data related to the operation of the CMA 270 in the memory of the BMS 222. The information recorded by the BMS 222 can then be used to determine a lifespan measurement for each CMA. The lifespan measurement can be expressed as a percentage of lifespan (e.g., 100% lifespan for a brand new CMA 270). The lifespan measurement can be used to set multiple end-of-life thresholds related to certain applications of the CMA 270. For example, the first lifespan of a CMA may include 100% to 70% of its charge capacity, where the CMA 270 is suitable for powering outdoor power equipment (e.g., a commercial lawnmower). After the first lifespan ends (e.g., the lifespan measurement is below 70%), the CMA 270 can be repaired and put into use in its second lifespan (e.g., between 70% and 50%), where the CMA 270 is suitable for use in battery packs of devices with lower energy demands compared to devices powered by the CMA 270 during the first lifespan of the battery pack 100. In some implementations, the programming of the BMS 222 of the battery pack 100 used in the second life is reset or reconfigured. By resetting the programming of the BMS 222 at the start of the second life of the battery pack 100, the BMS 222 can display a charge capacity relative to its newly reduced charge capacity of 100%. For example, the BMS 222 may include a measurement similar to an "odometer," which is reset such that a 5 kWh (kW-hr) battery pack with 80% charge capacity is now a 4 kW-hr battery pack with 100% charge capacity.

[0031] Lifespan measurements can be determined by multiple data points indicating lifespan, which can be monitored and stored by the BMS 222. These lifespan metrics include charging capacity, days or other time elapsed since the commissioning date of each CMA 270's initial use, number of cycles since the commissioning date, cycle depth of a single cycle or group of cycles, a fuel meter calculating the coulombs provided by the CMA 270 since the commissioning date, an event counter for CMA 270 operating under extreme temperature conditions (e.g., above 140 degrees Fahrenheit) for a single event or group of events, current provided by the CMA 270, charging current received by the CMA 270, voltage provided by the CMA 270, and / or voltage applied to the CMA 270 during charging. In other embodiments, different combinations of lifespan metrics are monitored and stored by the BMS 222. In some embodiments, the lifespan metrics identified above can be monitored individually, or in other embodiments, they can be monitored in any combination. In other implementations, for each individual battery cell 202 of each CMA 270 in the battery pack 100, lifespan metrics are tracked and stored in the integrated memory of the BMS 222.

[0032] Collecting and tracking lifespan metrics throughout the entire lifespan of the CMA 270, rather than a single instantaneous reading indicating the end of its life (e.g., 70% charge capacity), provides additional information for classifying the CMA 270 for repair to appropriate use. In some implementations, not every data point associated with a lifespan metric is stored; for example, temperature may be sampled and stored weekly instead of daily. CMA 270s can be classified, with different classifications suitable for use in different second lives, or based on different expected future performance in the second life determined by evaluating lifespan metrics in the first life. Tracking lifespan metrics also provides CMA 270 manufacturers with data that can be used for diagnostics to determine why a particular CMA 270 performs better or worse than similar CMA 270s, and then this diagnostic information can be used to improve the manufacturing of new CMAs or other processes.

[0033] For example, a CMA 270 with 70% charge capacity but a relatively large number of days operating under extreme temperature conditions may experience a faster rate of capacity degradation than a CMA 270 with 70% charge capacity but no days operating under extreme temperature conditions. Both CMA 270s may be suitable for repair and use in their second life, but their appropriate use in their second life may differ depending on the classification derived from their respective lifespan metric assessments. Tracking and storing lifespan metrics can also be used to evaluate returned or warranty-protected battery packs 100, repair or refurbish battery packs 100 returned within their first life, and improve manufacturing processes by comparing various CMA 270s.

[0034] Lifespan metrics are used to identify when a CMA 270 reaches its end-of-life threshold. A CMA 270 can have multiple end-of-life thresholds. For example, a CMA 270 may be suitable for use in its first application during its first lifespan (e.g., a commercial lawnmower). When a CMA 270 reaches its first end-of-life threshold (e.g., 80%, 75%, 70%, etc. of its lifespan), the CMA 270 ceases use for the first application and is returned to the CMA 270 manufacturer. The CMA 270 manufacturer then categorizes the CMA 270s based on their lifespan data to identify a second lifespan application suitable for that particular CMA. If necessary, the CMA 270 is repaired or refurbished and then combined with other similarly categorized CMA 270s to form a battery pack 100 for the second lifespan application. This new battery pack 100 can be used for the second lifespan application until the CMA 270 reaches its second end-of-life threshold (e.g., 50%, 45%, 40%, etc. of its lifespan). This approach of using the same CMA 270 for different applications based on the CMA lifecycle allows CMA 270 manufacturers to better utilize the available capacity of the CMA 270 by using it in multiple applications. Unlike discarding the CMA 270 at the end of its first life and leaving the remaining battery capacity unused, the CMA 270 can be used in multiple other applications. The maintainability of the battery pack 100 using conventional repair tools advantageously allows for the removal and replacement of the CMA 270 for second-life applications.

[0035] A CMA 270 manufacturer may lease battery packs consisting of multiple CMA 270s to users of devices powered by battery pack 100. This method would allow users of the CMA 270s during their first lifespan to return battery pack 100 to the CMA 270 manufacturer at the end of their first lifespan, thereby allowing the CMA 270 manufacturer to classify the CMA 270s and reuse the CMA 270s and / or battery pack 100 for second-life applications, where the resulting battery pack 100 can be leased or sold again to users of devices powered by battery pack 100 containing CMA 270s during their second lifespan. Alternatively, the CMA 270 manufacturer may sell battery packs 100 consisting of CMA 270s and repurchase battery packs 100 at the end of the first lifespan of the CMA 270s for classification and reuse in second-life applications.

[0036] BMS 222 can be configured to identify which CMA 270 in battery pack 100 requires maintenance. For example, BMS 222 can determine which CMA 270 has failed in battery pack 100. In some implementations, to identify the faulty CMA 270, BMS 222 measures the reading of each voltage tap on each CMA 270. For example, BMS 222 monitors each voltage tap 214 on each CMA 270 and determines whether the reading on each voltage tap 214 deviates from the expected measured value. BMS 222 can be configured to trigger a service alarm for the faulty CMA. For example, when monitoring current consumption patterns, if CMA 270 is the first to reach the highest voltage level or the first to reach the lowest voltage level (e.g., zero voltage), BMS 222 identifies the “bad” CMA and triggers a service alarm. BMS 222 can also monitor which CMA 270 in battery pack 100 is charged or discharged first to identify the faulty CMA. Advantageously, the battery pack 100 is configured to be serviceable. Therefore, when the BMS 222 identifies a CMA as faulty, the individual CMA 270 can be replaced with a functional CMA 270. In some embodiments, the BMS 222 also uses data received from temperature sensors (e.g., thermistors 217) connected to each CMA 270 to monitor and store the temperature of each CMA 270 within the battery pack 100.

[0037] refer to Figure 2-3 BMS 222 includes multiple connectors on one side of BMS 222. Input and output components of BMS 222 can be connected to BMS 222 via a resettable fuse. In some embodiments, a BMS cover 224 is located around BMS 222. The BMS cover 224 provides protection for BMS 222 and its connectors and connections to various wiring harnesses connected to BMS 222. In some embodiments, the BMS cover 224 is a structural enclosure resistant to crushing and impact, as well as to metal, thermal, and electromagnetic interference (EMI). BMS 222 includes a thermistor connector 226 for monitoring the temperature of each CMA 270 in battery pack 100. BMS 222 includes a CMA voltage connector 220 to receive data regarding the operation of battery cells 202 and CMA 270 throughout battery pack 100. In some embodiments, a measurement reading taken at positive voltage tap 232 is transmitted to BMS 222 via the CMA voltage connector 220. Each connector of the BMS 222 can be connected to a connection harness, similar to the contactor harness 228 or the shunt harness 230.

[0038] In some implementations, BMS 222 includes pre-charge and discharge circuitry integrated on the same board as BMS 222. In some implementations, BMS 222 conducts the current profile of battery pack 100 to detect which components are inserted into battery pack 100. When an abnormal profile of battery pack 100 is detected, BMS 222 can issue an alarm as notification of the anomaly. In some implementations, when battery pack 100 is connected in parallel or series with another battery pack, BMS 222 writes to the adjacent BMS 222 of the connected battery pack 100 to update older firmware with the latest firmware. BMS 222 can also be configured to update the charger or other energy source of battery pack 100 with newer firmware and can receive updates from chargers using newer firmware. In some implementations, BMS 222 can operate in three different states: recharging, charging, and hybrid. During the hybrid state, BMS 222 can effectively charge battery pack 100 when intended to discharge, with or without communication. During charging, BMS 222 can use adaptive charging limits. For example, if regenerative charging is received, where battery pack 100 is being fully charged, BMS 222 can reduce the top charge limit to avoid top failure due to regenerative charging. The decision by BMS 222 to reduce the top charge limit can be based on the frequency of failure occurrence. In another embodiment, BMS 222 can change the top charge to 4.2 volts to prevent reaching a top failure, whereas the initial top charge is 4.1 volts per CMA 270.

[0039] The battery pack 100 may also include a CMA-to-CMA interlock device 204. The CMA-to-CMA interlock device 204 allows multiple CMAs 270s to be installed in a parallel configuration. An end-of-string mounting assembly 212 is also shown in the battery pack 100. When a CMA 270 is not connected to another CMA 270, the connection can be terminated at both ends of a layer of the battery pack 100 using the end-of-string mounting assembly 212. In some embodiments, the end-of-string mounting assembly 212 is connected to a negative current collector 254. The negative current collector 254 may extend outward from one side of the bottom CMA cell support frame of the CMA 270. In some embodiments, the negative current collector 254 extends outward from the outermost pocket group of the bottom CMA cell support frame of the CMA 270 to form a generally planar bottom surface connected to the end-of-string mounting assembly 212.

[0040] The battery pack 100 may also include a communication harness 236, a negative cable assembly 238, a contactor-to-contactor bus 240, a positive cable assembly 242, a positive terminal-to-contactor bus 244, a positive terminal 106, a data connection terminal 104, a negative terminal 102, a battery pack dual contactor 250, a contactor coil terminal 252, a negative CMA grounding cable assembly 256, a series layer flexible bus 258, a shunt isolator 262, and a CMA unit bracket 264. In some embodiments, the communication harness 236 connects the data connection terminal 104 mounted on the panel to the BMS 222. In some embodiments, the data connection terminal 104 is connected to the front panel of the housing 108 of the battery pack 100. The negative CMA grounding assembly 256 may operate below the battery pack 100 and uses negative cable wiring from the ground 272 of the first CMA 270 block to the last CMA 270 block, upwards to the string end mounting assembly 212. In some implementations, the negative CMA grounding assembly is wired from the first CMA270 on the top layer of the battery pack 100, on the front side of the battery pack 100 (e.g., as shown). Figure 6 (as shown) downwards, to the substrate of the battery pack 100 (e.g., as shown) Figure 4 Below (as shown), and on the rear side of battery pack 100 (e.g., as shown) Figure 5 (As shown) upwards to connect to the last CMA 270 on the bottom layer of the battery pack 100. Series layer flexible busbars 258 electrically connect the various layers of the battery pack 100. In some embodiments, the CMA cell bracket 264 is the bottom CMA cell bracket frame connected to the negative terminal of the battery cell 202 of each CMA 270 (e.g., Figure 7 The bottom CMA unit support frame 704 is shown.

[0041] According to an exemplary embodiment, a top view of the battery pack 100 is as follows: Figure 3 As shown. The contactor-to-contactor bus 244 extends near the top of the battery pack 100 and can be connected to multiple CMA 270s simultaneously. The positive cable assembly 242 extends to the positive terminal 106. The negative cable assembly 238 extends upward to the negative terminal 102. The communication harness 236 extends upward from the BMS 222 to the data connection terminal 104. The BMS cover 224 and the top plate 218 form the top of the battery pack 100.

[0042] Now for reference Figure 4 The bottom of a battery pack 100 according to an exemplary embodiment is shown. The battery bottom includes a substrate 402 and a bottom current collector 404. Each bottom current collector 404 is connected to the bottom of each CMA 270 block of the battery pack 100. Figure 4As shown, the negative CMA grounding cable assembly 256 passes beneath the battery pack 100. In some embodiments, some bottom current collectors 404 may be negative current collectors connected to the negative terminals of battery cells 202 in the CMA 270. Other bottom current collectors 404 may be positive current collectors connected to the positive terminals of battery cells 202 in the CMA 270 at the bottom layer of the battery pack 100.

[0043] The battery cells 202 in each CMA 270 of the battery pack 100 can be configured to communicate electrically with each other using a bottom current collector (e.g., bottom current collector 404) and a top current collector. The current collectors can be formed of a conductive metallic material (e.g., copper, aluminum) that can receive and conduct current through terminals extending from each battery cell 202. The thickness of the top and bottom current collectors can be selected to carry a certain amount of current without significantly increasing the temperature of the current collectors. The thickness of the current collectors can also provide sufficient area for current flow points at the overlap between the plates. The current collectors can also be arranged to reduce the torque requirements on the clamping plates by distributing clamping forces. The bolted connection pattern of the current collectors can allow current to flow symmetrically and uniformly through each CMA. In some embodiments, each battery cell 202 includes a positive terminal connected to the top current collector and a negative terminal connected to the bottom current collector. Conversely, each positive terminal can be connected to the bottom current collector, and each negative terminal can be connected to the top current collector.

[0044] Each current collector may include a series of holes formed through a base that is typically rectangular. The number of holes formed through each current collector may correspond to the number of battery cells 202 present or potentially present in the CMA 270. The bottom current collector may be connected to the bottom CMA cell support frame 704. Figure 7 This arrangement ensures that each hole is located below the pocket of the bottom CMA unit bracket frame 704. Each hole can be aligned with (i.e., overlap to some extent) the terminal holes in the bottom CMA unit bracket frame 704. This overlap direction allows the terminals of the battery unit 202 received within the pocket to extend downward through the bottom CMA unit bracket frame 704 and the bottom current collector to form an electrical connection with the bottom surface of the bottom current collector. Similarly, the top current collector can be connected to the top CMA unit bracket frame 702. Figure 7 This arrangement ensures that each hole is located above the pocket of the top CMA unit bracket frame 702. Each hole can also be aligned with a terminal hole in the top CMA unit bracket frame 702, allowing the terminals of the battery unit 202 housed in the pocket to extend through the base of the top CMA unit bracket frame 702 and the top current collector.

[0045] The top and bottom current collectors (e.g., bottom current collector 404) each have generally complementary geometries for mounting on the bottom CMA unit bracket frame 704 and the top CMA unit bracket frame 702. For example, the apertures in both the top and bottom current collectors 404 can be defined by generally elongated ellipses that can be accommodated around positioning features of the top and bottom CMA unit bracket frames 702 and 704. The shape of the apertures can create a clearance fit around the positioning features to aid in positioning the top and bottom current collectors 404 during CMA assembly.

[0046] Now for reference Figure 5 A rear view of a battery pack 100 according to an exemplary embodiment is shown. Figure 5 As shown, BMS222 is located inside BMS cover 224 and on top of three different layers of CMA 270 in battery pack 100. A rear view depicts the connections between the different layers of battery pack 100. Series layer flexible busbars 258 are shown connecting the top layer to the intermediate layer. Spacers 209 are shown between the layers. Spacers 209 can hold the top CMA unit support frame 702 of each CMA 270 in each layer of battery pack 100. Figure 7 ) Connected to the bottom CMA unit bracket frame 704 ( Figure 7 The intermediate plate 210 is located between the layers of the battery pack 100 and the negative CMA grounding cable assembly 256 connected at ground 272 to one of the string end mounting assemblies 212. In some embodiments, the top layer includes four CMA 270s, the intermediate layer of the battery pack 100 includes five CMA 270s, and the bottom layer includes five CMA 270s. In other embodiments, the battery pack 100 may have more or fewer than fourteen total CMA 270s.

[0047] Each CMA 270 in battery pack 100 may be identical to other CMA 270s in battery pack 100 (e.g., same number of cells, same output ratings, etc.) and includes an end connection to an interface to provide up / down routing or termination, since the “end” CMA 270 is not connected to another CMA 270. The end connection components of each CMA 270 are collectively connected to the other CMA 270s in battery pack 100. In some embodiments, one or more CMA 270s in battery pack 100 may have the same form factor as CMA 270s without “power control”, but may also include contactors, current sensors (e.g., shunt resistors), and a BMS controller to manage the power of the CMA 270 “power control” block.

[0048] In some embodiments, all 32 battery cells 202 are connected in parallel via a single top current collector (e.g., positive current collector 266) and a single bottom current collector (e.g., negative current collector 254) in a 1S32P (one in series, thirty-two in parallel) arrangement, with all battery cells 202 pointing in one direction. In other embodiments, two groups of 16 battery cells 202 are connected in parallel, and two groups are connected in series, arranged in a 2S16P (two in series, sixteen in parallel) arrangement. In some embodiments, the battery cells 202 can be connected in parallel via a 1S16P (one in series, sixteen in parallel) arrangement, while in other embodiments, the battery cells 202 can be connected in a 2S32P (two in series, thirty-two in parallel) arrangement via contactor plates. The top and bottom current collectors can be used to connect the 32 battery cells 202. In some embodiments, each top current collector 266 and each bottom current collector 254 can support and connect the 16 parallel battery cells 202. These two groups of 16 battery cells 202 can then be electrically connected together to connect these groups of 16 battery cells 202 in series with each other. Arranging a relatively large number of battery cells 202 in parallel in this way helps to mitigate the degradation of the CMA 270's charging capacity. In other embodiments, the number of battery cells 202 in the CMA 270 can be more or less, and the connection arrangement between the battery cells 202 can vary depending on the ratings required for a particular CMA 270 (e.g., voltage, capacity, power, etc.). Each battery cell 202 has a positive terminal and a negative terminal.

[0049] Now for reference Figure 6 The image shows a front view of a battery pack 100 according to an exemplary embodiment. Figure 6 As shown, contactor 250, positive terminal 106, data connection terminal 104 mounted on the panel, negative terminal 102, positive cable assembly 242, negative cable assembly 238, and communication harness 236 are each located near the front of battery pack 100. In some embodiments, dual contactors 250, positive terminal 106, negative terminal 102, and data connection terminal 104 mounted on the panel are aligned with the top layer of battery pack 100. Thermistor strip 216 and thermistor 217 are respectively connected to the battery cells 202 of CMA 270 in battery pack 100. In some embodiments, each CMA 270 of battery pack 100 includes a thermistor 217 to monitor the current temperature level of each CMA 270 throughout battery pack 100. Therefore, BMS 222 can track and manage temperature changes throughout battery pack 100. The different layers of battery pack 100 are also visible from the front of battery pack 100. In some implementations, the battery pack 100 may have more or fewer than three layers of CMA.

[0050] Now for reference Figure 7The battery pack 100 is shown in additional detail. Battery cells 202 are supported by a top CMA cell support frame 704 and a bottom CMA cell support frame 706. The top CMA cell support frame 702 and the bottom CMA cell support frame 704 may each be a continuous (e.g., single or integral) assembly formed of an insulating polymeric material. The bottom CMA cell support frame 704 may include a generally rectangular base comprising a series of cylindrical protrusions extending upward from the base. For example, the cylindrical protrusions define a series of pockets, each capable of accommodating the battery cell 202. Each pocket may include a generally circular base surrounded by the cylindrical protrusions associated with the pocket. In some embodiments, terminal holes are formed through the bottom of the bottom CMA cell support frame 704. The terminal holes may be generally centered within the base to allow terminals of the battery cell 202 to extend through the bottom CMA cell support frame 704. Alternatively, the terminals may be completely contained within the pockets, and the terminal holes allow access to the terminals of the battery cell 202. Typically, touching the terminals of battery cell 202 during assembly and / or maintenance can be helpful, where solder wires are created or repaired between the terminals and battery cell 202. Windows can be formed in the base and / or cylindrical protrusions to define an adhesive flow path through the bottom CMA cell bracket frame 704 to the battery cell 202 located within a pocket of the bottom CMA cell bracket frame 704. Curable adhesives can be used to ensure a strong connection between the battery cell 202 and the bottom CMA cell bracket frame 704. Furthermore, curable adhesives can be used to attach a bottom current collector (e.g., negative current collector 254) to the bottom CMA cell bracket frame 704.

[0051] The top CMA unit support frame 702 may include many of the same features present in the bottom CMA unit support frame 704. Since in some embodiments, the top CMA unit support frame 702 may be a substantial mirror image of the bottom CMA unit support frame 704, components present in the top CMA unit support frame 702 that share the same name in both the bottom and top CMA unit support frames 704 should be considered to have the same or substantially similar geometry, orientation, structure, or relationship to other components as described with reference to the bottom CMA unit support frame 704. The top CMA unit support frame 702 also includes a generally rectangular base. A series of cylindrical protrusions may extend upward from the base to define another series of pockets, each of which may accommodate a battery unit 202. Each pocket may include a generally circular base surrounded by the cylindrical protrusions associated with the pocket. Terminal holes may be formed through the base. Windows may be formed in the base and / or the cylindrical protrusions to define an adhesive flow path through the top CMA unit support frame 704 to the battery unit 202 located within the pocket. The top surface of the top CMA unit support frame 702 may include grooves formed within it to define an adhesive flow path. These grooves can guide the curable adhesive around the battery cell 202 during CMA 270 assembly, which can facilitate the formation of a strong bond between the battery cell 202 and the top CMA unit support frame 702. Furthermore, the curable adhesive can be used to attach a top current collector (e.g., positive current collector 266) to the top CMA unit support frame 702.

[0052] In some implementations, the CMA 270 can be scaled so that it can be adjusted according to variations in the length and diameter of the battery cells 202 used in the CMA 270. The lengths of the top CMA cell support frame 702 and the bottom CMA cell support frame 704 can vary depending on the number of cells used in the CMA 270 and the type of battery cells 202 used in each CMA 270. For example, the cylindrical battery shape factor of the pockets in the top CMA cell support frame 702 and the bottom CMA cell support frame 704 can be varied according to the diameter of the battery cells 202 used in the battery pack 100. The battery pack 100 can also be assembled to use longer or shorter battery cells 202, in which case the top CMA cell support frame 702 and the bottom CMA cell support frame 704 can be closer together or further apart in height. In some implementations, when the battery cells 202 have different diameters, the same mounting points (e.g., bolt patterns) are used for the construction of each CMA 270, but the top CMA cell support frame 702 and the bottom CMA cell support frame 704 change the size of the pocket to accommodate different battery cells 202.

[0053] The spacer 209 may be defined by a height (i.e., longitudinal length) greater than the height of each battery cell 202. By extending above the battery cell 202, the compressive load borne by either the top CMA cell support frame 702 or the bottom CMA cell support frame 704 is first transferred to the spacer 209, which engages with the collar of the frame. The spacer 209 maintains a fixed distance between the bottom CMA cell support frame 704 and the top CMA cell support frame 702, preventing the top CMA cell support frame 702 and the bottom CMA cell support frame 704 from applying extreme or other unwanted compressive stresses to each battery cell 202, for example, which could be caused by the load of another CMA 270 in a layer of the battery pack 100 located above the CMA 270.

[0054] Now for reference Figure 8 The view depicts the three layers of the battery pack 100 and the substrate 402 connected to the bottom of the battery pack 100. The bottom current collector 404 is also shown as the bottom of the CMA 270 connected to the bottom layer of the battery pack 100. From this view, the positive electrode cable assembly 242, top plate 218, middle plate 210, negative electrode CMA grounding cable assembly 256, and series flexible busbar 258 (extending between layers) and other components of the battery pack 100 can be seen.

[0055] As used herein, the term "circuit" can include hardware configured to perform the functions described herein. In some embodiments, each corresponding "circuit" can include a machine-readable medium for configuring the hardware to perform the functions described herein. The circuit can be embodied as one or more circuit components, including but not limited to processing circuitry, network interfaces, peripherals, input devices, output devices, sensors, etc. In some embodiments, the circuit can take the form of one or more analog circuits, electronic circuits (e.g., integrated circuits (ICs), discrete circuits, system-on-a-chip (SoC) circuits, etc.), telecommunications circuits, hybrid circuits, and any other type of "circuit". In this respect, "circuit" can include any type of component used to implement or facilitate the implementation of the operations described herein. For example, a circuit as described herein can include one or more transistors, logic gates (e.g., NAND, AND, NOR, OR, XOR, NOT, XNOR, etc.), resistors, multiplexers, registers, capacitors, inductors, diodes, wiring, etc.

[0056] The “circuit” may also include one or more processors communicatively connected to one or more memories or memory devices. In this regard, the one or more processors may execute instructions stored in memory or instructions otherwise accessible to the one or more processors. In some embodiments, the one or more processors may be implemented in various ways. The one or more processors may be constructed in a manner sufficient to at least perform the operations described herein. In some embodiments, the one or more processors may be shared by multiple circuits (e.g., circuit A and circuit B may include or otherwise share the same processor, which in some exemplary embodiments executes instructions stored or otherwise accessed through different memory regions). Alternatively or additionally, the one or more processors may be configured to perform or otherwise perform certain operations independently of one or more coprocessors. In other example embodiments, two or more processors may be connected via a bus to enable independent, parallel, pipelined, or multithreaded instruction execution. Each processor may be implemented as one or more general-purpose processors, application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), or other suitable electronic data processing components configured to execute instructions provided by memory. One or more processors may take the form of a single-core processor, a multi-core processor (e.g., a dual-core processor, a triple-core processor, a quad-core processor, etc.), a microprocessor, etc. In some implementations, one or more processors may be external to the device; for example, one or more processors may be remote processors (e.g., cloud-based processors). Alternatively or optionally, one or more processors may be internal to the device and / or local. In this regard, a given circuit or its components may be located locally (e.g., as part of a local server, a local computing system, etc.) or remotely (e.g., as part of a remote server (e.g., a cloud-based server)). Therefore, the term "circuit" as used herein may include components distributed across one or more locations.

[0057] An exemplary system used to implement an entire system or part of an implementation may include a general-purpose computing computer in the form of a computer, including a processing unit, system memory, and a system bus connecting various system components, including the system memory, to the processing unit. Each storage device may include a non-transient volatile storage medium, a non-volatile storage medium, a non-transient storage medium (e.g., one or more volatile and / or non-volatile memories), etc. In some implementations, the non-volatile medium may take the form of ROM, flash memory (e.g., flash memory like NAND, 3D NAND, NOR, 3D NOR, etc.), EEPROM, MRAM, magnetic storage, hard disk, optical disk, etc. In other implementations, the volatile storage medium may take the form of RAM, TRAM, ZRAM, etc. The above combinations are also included within the scope of machine-readable media. In this regard, machine-executable instructions include, for example, instructions and data that cause a general-purpose computer, a special-purpose computer, or a special-purpose processing machine to perform a particular function or group of functions. According to the example implementations described herein, each respective storage device may be used to maintain or otherwise store information related to operations performed by one or more associated circuits, including processor instructions and associated data (e.g., database components, object code components, script components, etc.).

[0058] As shown in the various exemplary embodiments, the structures and arrangements of this disclosure are illustrative only. Although only a few embodiments have been described in detail in this invention, many modifications can be made (e.g., variations in the size, extent, structure, shape, and proportions of various elements, parameter values, mounting arrangements, material use, color, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be composed of multiple parts or elements, the positions of elements may be reversed or otherwise changed, and the nature or number of discrete elements or positions may be changed or varied. The order or sequence of any process, logical algorithm, or method steps may be changed or reordered according to alternative embodiments. Other substitutions, modifications, alterations, and omissions may also be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of the invention.

Claims

1. A battery pack, comprising: Battery casing that defines the internal cavity; A positive terminal and a negative terminal, each extending through the housing; Multiple CMAs (Cellular Module Components) are housed within the cavity and electrically connected to the positive and negative terminals, wherein each of the multiple CMAs comprises: -A top CMA unit support frame that defines multiple first pockets; - Bottom CMA unit support frame that defines multiple second pockets; - The top current collector is connected to the top CMA unit support frame; - The bottom current collector is connected to the bottom CMA unit support frame; and - A plurality of lithium-ion battery cells connected in parallel, each of the plurality of lithium-ion battery cells being partially housed in one of the plurality of first pockets and partially housed in one of the plurality of second pockets, each of the plurality of lithium-ion battery cells being connected to the top current collector and the bottom current collector; An aluminum intermediate plate is disposed between at least two of the plurality of CMAs, wherein the at least two of the plurality of CMAs are spaced apart from each other, and the aluminum intermediate plate is disposed therebetween to form an air gap between the at least two of the plurality of CMAs and the aluminum intermediate plate; and A battery management system, which communicates with at least one of the plurality of CMAs in the cavity, is configured to: - Receive voltage tap measurements from each of the plurality of CMAs in the cavity; - Compare the voltage tap measurement from each of the plurality of CMAs with the expected voltage tap measurement; - Determine whether the voltage tap measurement of one of the plurality of CMAs deviates from the expected voltage tap measurement, and - In response to determining that the voltage tap measurement of one of the plurality of CMAs deviates from the expected voltage tap measurement, an alarm is generated, including location information identifying which of the plurality of CMAs has a voltage tap measurement that deviates from the expected voltage tap measurement.

2. The battery pack of claim 1, wherein each of the plurality of CMAs is detachably connected to each of the positive terminal and the negative terminal.

3. The battery pack of claim 1, wherein each of the plurality of CMAs includes at least one thermistor mounted to the lithium-ion battery cell using a closed-cell foam adhesive, wherein the thermistor is configured to communicate a temperature measurement of the at least one lithium-ion battery cell to the battery management system.

4. The battery pack of claim 1, wherein each of the CMAs in the inner cavity is connected in parallel and at least two of the CMAs in the inner cavity are connected in series.

5. The battery pack according to claim 1, wherein the battery management system is housed within an electromagnetic interference resistant metal casing.

6. The battery pack of claim 1, wherein the battery pack is configured to output a nominal voltage of 24 V to 48 V through the positive terminal and the negative terminal.

7. The battery pack of claim 1, wherein the battery management system is connected to a dual controller area network (CAN) bus, the dual controller area network (CAN) bus being configured to transmit information from the battery management system at at least two baud rates.

8. The battery pack of claim 7, wherein the battery management system includes a memory configured to store firmware updates that can be received and transmitted using the dual controller area network (CAN) bus.

9. The battery pack of claim 1, wherein the battery management system conducts the current profile of the battery pack to detect the type of device connected to the positive and negative terminals of the battery pack.

10. The battery pack of claim 1, wherein data connection terminals extend through the battery housing and define a series of data terminals for communication with the battery management system.

11. The battery pack of claim 1, wherein the battery management system controls the charging threshold of each CMA in the battery pack, wherein the battery management system adjusts the upper limit of the charging threshold based on the recharge type.

12. The battery pack of claim 1, wherein the circulating fan is housed within the housing.

13. The battery pack of claim 1, wherein the battery housing is a five-sided structure detachably connected to a substrate, the substrate supporting the plurality of CMAs.

14. The battery pack of claim 1, further comprising a CMA grounding cable extending at least partially beneath the plurality of CMAs within the battery pack and configured to connect each of the plurality of CMAs to a common ground.

15. A battery pack, comprising: Battery casing that defines the internal cavity; A positive terminal and a negative terminal, each extending through the housing; Multiple CMAs (Cellular Module Components) are housed within the cavity and electrically connected to the positive and negative terminals, wherein each of the multiple CMAs comprises: -A top CMA unit support frame that defines multiple first pockets; - Bottom CMA unit support frame that defines multiple second pockets; - The top current collector is connected to the top CMA unit support frame; - The bottom current collector is connected to the bottom CMA unit support frame; and - A plurality of lithium-ion battery cells, the plurality of lithium-ion battery cells being connected in parallel, each of the plurality of lithium-ion battery cells being partially housed in one of the plurality of first pockets and partially housed in one of the plurality of second pockets, each of the plurality of lithium-ion battery cells being connected to the top current collector and the bottom current collector; and A battery management system, which communicates with at least one of the plurality of CMAs in the cavity, is configured to: - Receive voltage tap measurements from each of the plurality of CMAs in the cavity; - Compare the voltage tap measurement from each of the plurality of CMAs with the expected voltage tap measurement; - Determine whether the voltage tap measurement of one of the plurality of CMAs deviates from the expected voltage tap measurement, and - In response to determining that the voltage tap measurement value of one of the plurality of CMAs deviates from the expected voltage tap measurement value, an alarm is generated, including location information identifying which of the plurality of CMAs has a voltage tap measurement value that deviates from the expected voltage tap measurement value. The battery pack is defined by at least two CMA layers, wherein the first CMA layer is separated from the second CMA layer by an intermediate plate extending therebetween, thereby forming air gaps between the first CMA layer, the second CMA layer and the intermediate plate, and wherein the first CMA layer and the second CMA layer are electrically connected together by a busbar extending between at least one CMA layer in the first CMA layer and at least one CMA layer in the second CMA layer.

16. The battery pack of claim 15, wherein the battery pack is defined by at least three CMA layers, wherein the third CMA layer contains fewer CMA layers than the second CMA layer.

17. The battery pack of claim 15, wherein the first layer CMA is electrically isolated from the second layer CMA by disconnecting the bus.

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