Cable coupled grounding arrangement for structural battery modules and battery packs

Abstract

A battery module (106) for the construction of a battery pack (102), the battery module (106) comprising batteries sealed in a rectangular housing (108), the front and rear open ends (113) of the rectangular housing (108) being closed by front and rear plates (112), respectively. The rear plate (112) includes a plurality of rear plate (112) holes axially aligned with the plurality of housing holes (142) proximate the rear open end (113) of the housing (108). The front plate (110) includes a plurality of front plate (110) holes axially aligned with the plurality of housing holes (142) proximate the front open end (111) of the housing (108). The front plate (110) additionally includes a positive terminal and a negative terminal electrically connected to the battery. At least one of the back plate (112) and the front plate (110) further comprises at least one passive opening (410), and at least one of a ground cable (412), a clamping structure (414) adapted to receive the cable (416), or a complementary non-conductive accessory is received by the passive opening (410).

Description

Technical Field

[0001] The present invention relates generally to batteries, and more particularly to a structural battery module that enables different battery pack configurations while providing cable clamping points and / or grounding points. Background Art

[0002] Current industrial applications require a wide variety of battery sizes and performance requirements. For example, battery pack requirements can range from 20kW to 300kWh and from 48V to 700V. Maintaining a wide variety of battery sizes typically results in increased inventory and tooling costs, as well as increased R&D investments. In addition, a reduction in the capacity or performance characteristics of a battery used in a given application can result in increased costs and challenges in handling or recycling such batteries.

[0003] To address some of these challenges, manufacturers have developed a variety of arrangements in which multiple battery modules can be assembled into various sizes to meet the individual requirements of various applications. For example, Absolyte GP has developed a modular steel pallet design in which multiple single battery modules can be transported to the desired location and then assembled and connected to provide the required capacity with a modular steel pallet design, which is set between each row of modules.

[0004] However, multiple batteries also present challenges in organizing and maintaining a large number of cables and connections. U.S. Patent Publication No. 2017 / 0237052A1 of FCA US discloses a cable support including a conductive base member, a conductive clamping member, a clamping fastener, and at least one conductive protrusion for a ground connection. Summary of the invention

[0005] In one aspect, the present invention describes a battery module for the construction of a battery pack. The battery module includes a battery disposed in a rectangular housing, and a front plate and a rear plate. The rectangular housing includes a top surface, a bottom surface, a first side extending between the top surface and the bottom surface, a second side extending between the top surface and the bottom surface, a front open end, and a rear open end. The housing also includes a plurality of housing holes extending substantially vertically through the top surface, the bottom surface, the first side surface, and the second side surface near the front open end, and a plurality of housing holes extending substantially vertically through the top surface, the bottom surface, the first side surface, and the second side surface near the rear open end. The rear plate closes the rear open end of the housing. The rear plate includes a plurality of rear plate holes that are axially aligned with a plurality of housing holes near the rear open end of the housing. The front plate closes the front open end of the housing. The front plate includes a plurality of front plate holes that are axially aligned with a plurality of housing holes near the front open end of the housing. The front plate also includes a positive terminal and a negative terminal electrically connected to the battery. The battery is sealed in the rectangular housing, the rear plate, and the front plate. The battery module further includes at least one of a grounding cable, a clamping structure adapted to receive a cable, or a supplementary non-conductive accessory. At least one of the rear plate and the front plate includes at least one passive opening, and at least one of the grounding cable, the clamping structure adapted to receive a cable, or a supplementary non-conductive accessory is received by the passive opening.

[0006] On the other hand, the present invention describes a battery pack, which includes a plurality of battery modules and at least two couplers. Each battery module includes a battery disposed in a rectangular housing, and a front plate and a rear plate. The rectangular housing includes a top surface, a bottom surface, a first side extending between the top surface and the bottom surface, a second side extending between the top surface and the bottom surface, a front open end, and a rear open end. The housing also includes a plurality of housing holes extending substantially vertically through the top surface, the bottom surface, the first side surface, and the second side surface near the front open end, and a plurality of housing holes extending substantially vertically through the top surface, the bottom surface, the first side surface, and the second side surface near the rear open end. The rear plate closes the rear open end of the housing. The rear plate includes a plurality of rear plate holes, which are axially aligned with a plurality of housing holes near the rear open end of the housing. The front plate closes the front open end of the housing. The front plate includes a plurality of front plate holes, which are axially aligned with a plurality of housing holes near the front open end of the housing. The front plate also includes a positive terminal and a negative terminal electrically connected to the battery. The battery is sealed in the rectangular housing, the rear plate, and the front plate. At least two couplers secure at least a first battery module and a second battery module together. At least a first of the couplers is disposed through at least one of a plurality of rear plate holes, at least one of the plurality of rear plate holes being axially aligned with at least one of a plurality of housing holes proximate a rear open end of the housing. At least a second of the couplers is disposed through at least one of a plurality of front plate holes, at least one of the plurality of front plate holes being axially aligned with at least one of a plurality of housing holes proximate a front open end of the housing. At least one of the rear plate and the front plate of the battery pack further comprises at least one passive opening. The battery pack further comprises at least one of a grounding cable received by the passive opening, a clamping structure adapted to receive a cable, or a supplemental non-conductive accessory.

[0007] In yet another aspect, the present invention describes a method for constructing a battery pack. The method includes providing a plurality of battery modules. Each battery module includes a battery disposed in a rectangular housing, and a front plate and a rear plate. The rectangular housing includes a top surface, a bottom surface, a first side extending between the top surface and the bottom surface, a second side extending between the top surface and the bottom surface, a front open end, and a rear open end. The housing also includes a plurality of housing holes extending substantially vertically through the top surface, the bottom surface, the first side surface, and the second side surface near the front open end, and a plurality of housing holes extending substantially vertically through the top surface, the bottom surface, the first side surface, and the second side surface near the rear open end. The rear plate closes the rear open end of the housing. The rear plate includes a plurality of rear plate holes that are axially aligned with a plurality of housing holes near the rear open end of the housing. The front plate closes the front open end of the housing. The front plate includes a plurality of front plate holes that are axially aligned with a plurality of housing holes near the front open end of the housing. The front plate also includes a positive terminal and a negative terminal electrically connected to the battery. The battery is sealed in the rectangular housing, the rear plate, and the front plate. The method also includes arranging the rectangular housing of a first battery module among the plurality of battery modules adjacent to the rectangular housing of a second battery module among the plurality of battery modules. The method also includes arranging a first coupler through a rear plate hole of the first battery module, through a housing hole of the rectangular housing of the first battery module, through a housing hole of the rectangular housing of the second battery module, and through a rear plate hole of the second battery module to secure the first battery module and the second battery module together. The method also includes arranging a second coupler through a front plate hole of the second battery module, through a housing hole of the rectangular housing of the second battery module, through a housing hole of the rectangular housing of the second battery module, and through a front plate hole of the second battery module to secure the second battery module and the second battery module together. The method also includes arranging at least one of a grounding cable, a clamping structure suitable for receiving a cable, or a supplementary non-conductive accessory into at least one passive opening in at least one of the rear plate and the front plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is an isometric view of an exemplary mobile machine in which a battery system according to the teachings of the present invention may be used.

[0009] Figure 2 is a rear isometric view of an exemplary embodiment of a battery pack in accordance with the teachings of the present invention.

[0010] Figure 3 yes Figure 2 Front isometric view of a battery pack.

[0011] Figure 4 yes Figure 2 and Figure 3 An exploded isometric view of a battery pack.

[0012] Figure 5is an enlarged front isometric view of a battery module in accordance with the teachings of the present invention.

[0013] Figure 6 yes Figure 5 Front view of the battery module.

[0014] Figure 7 yes Figure 5 Rear view of the battery module.

[0015] Figure 8 is used Figures 5 to 7 A partial isometric view of an exemplary battery pack configuration of an alternative embodiment of a battery module.

[0016] Fig. 9 is used Figure 8 An isometric view of a further configuration of an exemplary battery pack of a battery module.

[0017] Fig.10 is an isometric view of an embodiment of a battery module in accordance with the teachings of the present invention.

[0018] Fig.11 yes Fig.10 An enlarged partial view of one end of a battery module.

[0019] Fig.12 At least the grounding cable Fig.10 and Fig.11 An isometric view of an embodiment of a battery module.

[0020] Fig.13 yes Fig.12 An exploded isometric view of an embodiment of a battery module.

[0021] Fig.14 The invention comprises at least one grounding cable and at least one cable clamping structure. Fig.10 and Fig.11 An isometric view of an embodiment of a battery pack.

[0022] Fig.15 yes Fig.14 An exploded isometric view of an embodiment of a battery module.

[0023] Fig.16 yes Fig.14 and Fig.15 An enlarged partial view of one end of a battery module.

[0024] Fig.17 is an isometric view of a battery pack including a panel in accordance with the teachings of the present invention.

[0025] Fig.18 yes Fig.17 An enlarged partial view of the panel coupler of a battery pack.

[0026] Fig.19 is an isometric view of a battery pack including a coupling structure in accordance with the teachings of the present invention.

[0027] Fig. 20 yes Fig.19 A partial exploded view of the coupling structure of a battery pack. DETAILED DESCRIPTION

[0028] The present invention relates to a battery system 100 that can be used to construct a battery pack 102 for various applications, such as Figure 1 Machine 104. Although the arrangement is illustrated in conjunction with a mobile machine (more specifically, a front-mounted loader), the arrangement disclosed herein also has general applicability in various other types of machines. The term "machine" can refer to any machine that performs a certain type of operation associated with an industry such as mining, construction, farming, transportation, or any other industry known in the art. For example, the machine can be an earth-moving machine such as a wheel loader, an excavator, a dump truck, a backhoe, a motor grader, a material handler, etc. In addition, an implement can be connected to the machine. Such an implement can be used for various tasks, including, for example, loading, compacting, lifting, brushing, and the implement includes, for example, a bucket, a compactor, a forked lifting device, a brush, a grab, a cutter, a shear, a blade, a crusher / hammer, an auger, etc.

[0029] The battery system 100 includes a plurality of battery modules 106 that can be coupled in various configurations to provide various battery packs 102 having desired power outputs and voltage outputs. Figures 5 to 7 , and includes a rectangular housing 108, a front plate 110, and a rear plate 112. The housing 108 has a channel configuration, including a top surface 300, a bottom surface 302, and a first side surface 304 and a second side surface 306 extending between the top surface 300 and the bottom surface 302. The front plate 110 closes the front open end 111 of the housing 108, and the rear plate 112 closes the rear open end 113 of the housing 108 to form a sealed structure.

[0030] The housing 108 and the front and rear panels 110, 112 may be manufactured by any suitable method and with any suitable material. For example, the housing 108 may be 3D printed, stamped, otherwise formed, molded, or extruded from a filled or unfilled polymer material. Similarly, the front and rear panels 110, 112 may be 3D printed, cast, or otherwise molded from a filled or unfilled polymer material.

[0031] As will be appreciated by those skilled in the art, each battery module 106 houses batteries 114 that may have any configuration. Positive terminals 116 and negative terminals 118 may be provided along the front plate 110. Since the batteries 114 are sealed within the battery modules 106, the battery modules 106 may be transported and processed to further construct a desired battery pack 102. Back Figures 2 to 4 To electrically couple the battery modules 106 , any suitable electrical couplers may be provided, such as a plurality of electrical cables 120 .

[0032] In at least one embodiment, the battery pack 102 also includes a base 122 on which the plurality of battery modules 106 can be supported and coupled together. Although the base 122 is not required in all embodiments, the base 122 can provide additional support for the constructed battery pack 102 and can facilitate further processing, particularly in larger battery packs 102. Figure 4 As can be seen in the figure, in particular, the base 122 can have a rectangular design and can include structural elements, such as a rectangular frame 124 with cross supports 126, which can enhance strength and stability while minimizing weight. The base 122 can also include structures for enhancing the attachment of the battery module 106. For example, the frame 124 can include a plurality of bosses 128, which can have internal threads for engaging with corresponding couplers 130 (such as bolts or screws), the importance of which will be discussed below. The illustrated base 122 is sized to support two battery modules 106. However, it should be understood that the battery system 100 may include bases of multiple sizes, such as bases sized to support one battery module 106 and three, four or more battery modules 106 side by side.

[0033] If desired, the battery pack 102 may also optionally include a distribution unit 132. The battery modules 106 may be electrically connected to the distribution unit 132 via cables 120. The distribution unit 132 may function as a controller to allow power to be distributed to one or more loads of the machine 104. For example, in an electric machine, power may be provided to a drive system and / or various components of the machine.

[0034] According to one aspect of the present invention, the battery modules 106 can be fixed together to provide a structurally stable battery pack 102 without the need for an external frame between the stacked battery modules 106. In order to fix the battery modules 106 together, each battery module 106 includes a plurality of coupling arrangements at the opposing plates 110, 112 of the battery module 106. More specifically, the front plate 110 and the rear plate 112 include a flange surface 139, the flange surface 139 includes a plurality of coupling bosses 140, and a plurality of plate holes 141 extend through the coupling bosses 140, and the housing 108 includes a plurality of housing holes 142, and the plurality of housing holes 142 are arranged to align with the plate holes 141 of the coupling bosses 140. In addition, although the front plate 110 and the rear plate 112 have been illustrated as having the coupling bosses 140, it should be understood that the flange surface 139 itself may include the plate holes 141. A plurality of couplers 130 (such as bolts or rivets) are provided for being set through the coupling bosses 140 to couple the battery modules 106 together.

[0035] According to one aspect of the present invention, the plate hole 141 and the housing hole 142 may extend substantially perpendicular to the housing 108. In this way, the coupler 130 may be easily assembled through the plate hole 141 and the housing hole 142 of the adjacently disposed battery module 106. It will be appreciated by those skilled in the art that the coupling arrangement may provide enhanced stability for the battery module 106 because the coupler 130 extends through both the plate hole 141 and the housing hole 142, thereby further stabilizing the relationship between the front plate 110 and the rear plate 112 and the housing 108.

[0036] When assembled, the first battery module 150 can be optionally positioned on the base 122, which is sized to support the desired number of battery modules 106 in a horizontal configuration. When positioning the first battery module 150, the housing holes through the housing 151 and the aligned plate holes through the coupling bosses 152, 153 at the lower edge 154 of the rear plate 159 of the first battery module 150 are arranged to align with the bosses 128 of the base 122. The coupler 130 is then inserted and fixed into the coupling bosses 152, 153 of the rear plate 159 of the first battery module 150 and the bosses 128 of the base 122 to fix the first battery module 150 to the base 122. The process has been explained in detail with respect to the rear plate 159 of the first battery module 150, and the same process is followed with respect to the front plate 158 of the first battery module 150, inserting the coupler 130 into the plate holes along the lower edge of the front plate of the first battery module 150, through the shell holes of the shell 151, and into the bosses 128 of the base 122.

[0037] The second battery module 160 may be positioned on the upper surface of the first battery module 150; similarly, the housing holes through the housing 161 and the plate holes through the coupling bosses 162, 163 along the lower edge 164 of the rear plate 169 of the second battery module 160 are positioned to align with the housing holes through the housing 151 and the plate holes through the coupling bosses 155, 156 of the rear plate 159 along the upper edge 157 of the first battery module 150. The coupler 130 is then inserted into the housing holes of the housings 151, 161 and fixed within the plate holes through the coupling bosses 162, 163 of the second battery module 160 and the plate holes through the coupling bosses 155, 156 of the first battery module 150 to fix the second battery module 160 to the first battery module 150. As with fixing the first battery module 150 to the base 122, the same process is performed with respect to the front plate 158 of the first battery module 150 and the front plate 168 of the second battery module 160.

[0038] The process can continue by fixing the third battery module 170 at the plate holes passing through the coupling bosses 165, 166 at the plate holes passing through the coupling bosses 172, 173 along the upper edge 167 of the second battery module 160 at its front plate 168 and rear plate 169. The process is further continued until the desired number of battery modules 106 are fixed together.

[0039] According to another aspect of the present invention, additional battery modules 106 may be coupled at sides 180, 181 of the first battery module 150 (and subsequently coupled battery modules 160, 170). Figures 2 to 4 In the embodiment of the present invention, the fourth battery module 190 is positioned on the side of the first battery module 150. That is, the housing 191 of the fourth battery module 190 is positioned on the base 122 and adjacent to the side 181 of the first battery module 150. When the fourth battery module 190 is positioned, the housing hole through the housing 191 and the plate hole through the coupling boss 192 along the side edge 193 of the fourth battery module 190 are positioned to be axially aligned with the housing hole through the housing 151 and the plate hole through the coupling boss 182 along the side edge 183 of the first battery module 150, and the plate hole through the housing 191 and the plate holes of the coupling bosses 194, 195 along the lower edge 196 of the fourth battery module 190 are positioned to be axially aligned with the boss 128 of the base 122. Then, the mating coupler 130 is engaged in the coupling bosses 192 of the fourth battery module 190 and the coupling bosses 182 of the first battery module 150 , and the coupler 130 is engaged in the coupling bosses 194 , 195 of the fourth battery module 190 and the bosses 128 of the base 122 .

[0040] As with the assembly of the first battery module 150, the second battery module 160, and the third battery module 170, the process is explained in detail with respect to the rear plate 198 of the fourth battery module 190, and the same process is followed with respect to the front plate 197 of the fourth battery module 190, inserting the coupler 130 into the holes of the coupling bosses along the side edges and lower edges of the front plates of the fourth battery module 190 and the first battery module 150, and the bosses 128 of the base 122. Similarly, the fifth battery module 185 can be secured to the side 186 of the second battery module 160 and the upper face 199 of the fourth battery module 190. Likewise, the process can continue, adding the sixth battery module 187 and any additional battery modules 106, until the desired battery pack 102 is constructed.

[0041] If used, the distribution unit 132 may be secured to the battery pack 102 once all desired battery modules 106 have been coupled together. Figures 2 to 4 In the illustrated embodiment, the distribution unit 132 is secured to the upper face 134 of the coupled battery pack 102, but if appropriate for a given application, the distribution unit may alternatively be secured to the side 136 of the battery pack 102. Once secured together, the battery modules 106 may be electrically connected to each other via the cables 120 or the like, and to the distribution unit 132 if used.

[0042] Although Figures 2 to 4 The illustrated embodiment includes a battery pack 102 comprised of two columns of seven battery modules 106, but it should be understood that battery packs having alternative voltages and power delivery and different geometries may be comprised of battery modules 106. Figure 8 In at least one embodiment, the front plate 210 and the rear plate 212 of the battery module 214 may be provided with coupling bosses 220, 221, 222, 223, 224, 225 along each of the top edge 230, the bottom edge 232, and the side edges 234, 236, with corresponding plate holes (in Figure 8 216 is provided with corresponding housing holes (relative to Figure 8 In this way, additional battery modules 240, 242, 244, 246 can be secured to each of the top, bottom, and side surfaces of the housing 216 of the battery module 214. Additional battery modules can be secured to the battery modules 240, 242, 244, 246 secured to the battery module 214, thereby allowing the construction of battery packs of various sizes and geometries, such as Fig. 9 Further illustrated in FIG.

[0043] In at least one embodiment, the boss 128 of the base 122 and the plate hole 141 of the coupling boss 140 of the battery module 106 have internal threads. In at least one embodiment, a portion of the boss 128 of the base 122 and the plate hole 141 of the coupling boss 140 of the battery module 106 have internal threads, while the remaining boss 128 of the base 122 and the plate hole 141 of the coupling boss 140 of the battery module 106 have no threads; or in other words, the remaining boss 128 of the base 122 and the plate hole 141 of the coupling boss 140 of the battery module 106 are unthreaded. In this way, the assembly of the battery pack 102 can be simplified. However, it should be noted that when the boss 128 of the base 122 and / or the hole 141 of the coupling boss 140 of the battery module 106 include an unthreaded hole, the coupler 130 is first inserted through the unthreaded hole and then screwed into the threaded hole.

[0044] As an example only, Figures 2 to 4 In the illustrated embodiment, the boss 128 of the base 122 may have internal threads, while the coupling bosses 152, 153 of the first battery module 150 may include unthreaded plate holes. In this way, the coupler 130 may be inserted through the unthreaded plate holes of the coupling bosses 152, 153 of the first battery module 150, and then fixed in the threaded holes of the boss 128 of the base 122. Similarly, the coupling bosses 155, 156 of the first battery module 150 may include threaded plate holes, while the coupling bosses 162, 163 of the second battery module 160 may include unthreaded plate holes, so that the coupler 130 inserted through the unthreaded plate holes of the coupling bosses 162, 163 of the second battery module 160 can be fixed in the threaded plate holes of the coupling bosses 155, 156 of the first battery module 150. Similarly, the coupling boss 192 of the fourth battery module 190 may include a non-threaded plate hole, and the coupling boss 182 of the first battery module 150 may include a threaded plate hole. In this way, the mating coupler 130 can be inserted through the non-threaded plate hole of the coupling boss 192 of the fourth battery module 190 and fixed in the threaded plate hole of the coupling boss 182 of the first battery module 150.

[0045] Therefore, it should be understood by those skilled in the art that the configuration of the battery module 106 can be standardized. For example, the coupling bosses provided along the lower edge of the face may include unthreaded plate holes, while the coupling bosses along the opposite upper edge may include threaded plate holes; similarly, the coupling bosses along one side edge of the face may include unthreaded plate holes, while the coupling bosses along the opposite side edge may include threaded plate holes.

[0046] Now turn to Figures 10 to 16 , another battery module 106 for constructing the battery pack 102 is shown. In this embodiment, a similar structure is used as Figures 5 to 9The battery module 106 is identified by the same reference numerals. Although the arrangement is described with respect to the particular battery module 106 shown, aspects of the present invention may be applicable to different battery designs. The battery module 106 includes a battery 114 sealed within a rectangular housing 108, the rectangular housing 108 having a top surface 134, a bottom surface 135, and first and second sides 136 extending between the top surface 134 and the bottom surface 135, which define a front open end 111 and a rear open end 113. The battery module 106 may also include a rear plate 112 that encloses the rear open end 113 of the housing 108, and a front plate 110 that encloses the front open end 111 of the housing 108. Those skilled in the art will appreciate that for simplicity, the inner surface of the front plate 110 is schematically shown. In at least one embodiment, at least one of the front plate 110 and the rear plate 112 is a casting.

[0047] In order to couple the front plate 110 and the rear plate 112 to the rectangular housing 108, the housing 108 may include a plurality of housing holes 142, and the front plate 110 and the rear plate 112 may each include a plurality of front plate holes 141 and a plurality of rear plate holes 141 that are axially aligned with the plurality of housing holes 142. A plurality of connectors such as bolts (not shown in this embodiment, but may be used in the embodiment of the present invention) may be provided. Figure 8 ) can be used to couple the front plate 110 and the rear plate 112 to the rectangular housing 108.

[0048] At least one of the front plate 110 and the rear plate 112 includes at least one passive opening 410. In at least one embodiment, the at least one passive opening 410 does not extend completely through the front plate 110 or the rear plate 112. Thus, the at least one passive opening 410 is not electrically connected to the battery 114 sealed within the rectangular housing 108 and the front plate 110 and the rear plate 112. Figures 10 to 16 In the embodiment of FIG. 4 , four such passive openings 410 are shown in the rear plate 112 .

[0049] According to one aspect of the present invention, the battery module 106 further includes a ground cable 412 (see Figures 12 to 16 ), a clamping structure 414 adapted to receive a cable 416 (see Figures 14 to 16 ) or supplementary non-conductive accessories 418 (see Figures 17 to 20 ) at least one of the grounding cables 412 (see Figures 12 to 16 ), a clamping structure 414 adapted to receive a cable 416 (see Figures 14 to 16 ) or supplementary non-conductive accessories 418 (see Figures 17 to 20 ) is received in the passive opening 410 of the battery module 106 or the battery pack 102.

[0050] Further turn Figures 12 to 16 , shows an exemplary ground cable 412 received within the passive opening 410. Fig.13 and Fig.15 As shown, the ground cable 412 may include a probe 420 coupled to the cable 416. The probe 420 may be received within one of the passive openings 410. Those skilled in the art will appreciate that this coupling of the ground cable 412 is not electrically connected to the battery 114 sealed within the rectangular housing 108 and the front and rear plates 110, 112.

[0051] To help organize the cables coupled to the battery module 106 or battery pack 102, a clamping structure 414 adapted to receive the cable 416 can be provided. The clamping structure 414 can include a probe 422 and an annular channel 424 that is sized to receive the cable 416. The probe 422 is sized to be received within one of the passive openings 410. Although the clamping structure 414 can be of any suitable design, in the illustrated embodiment, the clamping structure includes a band 426 that can be opened to provide an access opening to receive the cable 416, or tightened to secure the cable 416. Although the cable 416 of the assembly of the ground cable 412 is shown to be located within the clamping structure 414, those skilled in the art will appreciate that any cable, including an active connection cable, can be coupled to the clamping structure 414 in this manner.

[0052] While the probes 420, 422 and the passive openings 410 may be of any suitable design that allows the probes 420, 422 to be relatively securely received and retained within the passive openings 410, one or more of the passive openings 410 may include an engagement structure 428 adapted to prevent the probes 420, 422 from being separated from the passive openings 410. For example, the engagement structure 428 may be one or more protrusions, such as an annular protrusion or an internal thread.

[0053] Now go to Figure 17 to Figure 18 , the front plate 110 including the positive terminal 116 and the negative terminal 118 electrically connected to the battery 114 may also include a passive opening 410. In order to shield the front plate 110 or a portion of the front plate 110 of the battery module 106 or the battery pack 102, a panel 430 may be provided. A plurality of non-conductive coupling structures, such as a plurality of panel couplers 432, may be provided. The panel coupler 432 may include, for example, a tubular structure 434 through which an elongated threaded shaft 436 may extend. In the illustrated embodiment, the elongated threaded shaft 436 is received within the passive opening 410. The elongated threaded shaft 436 may extend through the tubular structure 434, or the threaded shaft and the tubular structure may be integrally formed. Then, the hole (not visible) of the panel 430 may be placed on the threaded shaft 436, and a coupler such as a nut 438 is coupled to the threaded shaft 436 to secure the panel 430 to the passive opening 410 of at least one of the front plate 110 and the rear plate 112.

[0054] Go to Fig.19 and Fig. 20 , the passive opening 410 can also be used to secure one or more coupling structures 440 to the battery module 106 or the battery pack 102. In this embodiment, the coupling structure includes an elongated strip 442 disposed along the back plate 112 of the battery pack 102, and a pair of supports 444 disposed between the elongated strips 442. The supports 444 are coupled to the passive opening 410 through the elongated strips 442 using a coupling structure coupler 446 or other arrangement. For example, the elongated strip 442 or the supports 444 can be used to couple the battery pack 102 to a device.

[0055] Thus, the method of constructing the battery pack 102 may include disposing at least one of a ground cable 412 , a clamping structure 414 adapted to receive a cable 416 , or a supplemental non-conductive accessory into at least one passive opening 410 in at least one of the rear panel 112 and the front panel 110 .

[0056] Industrial Applicability

[0057] The present invention can be applied to battery packs used in various machines and applications. The battery system can include multiple battery modules including batteries with varying power output values ​​and voltage output values, optional bases with varying sizes, and couplers (such as bolts or rivets), thereby constructing battery packs of various sizes and configurations. As a result, the battery system can provide a personalized battery pack with a desired power output and voltage output based on the configuration.

[0058] The battery system can provide an arrangement for organizing and maintaining a large number of cables and connections. The battery system can utilize the battery module structure itself to provide a structure for cable grounding. In addition, the battery system can provide a structure for the connection organization within the battery module and between battery modules. The battery system can provide a mechanism for non-conductive connection to external structures without increasing the physical size of the battery module. In addition, the battery system can provide connection points for dual purposes. The battery system can provide a single casting suitable for a range of configurations. The battery system can provide an economical arrangement for increasing the versatility of battery modules and battery packs.

[0059] The battery system can use standard-sized battery modules to address the design needs of various applications. Since the battery pack can be assembled to meet the requirements of the application, the battery system can facilitate the construction of battery packs to meet the battery requirements and volumes of low-volume applications as well as high-volume applications.

[0060] The use of such standardized dimensions and properties can reduce the cost and investment in inventory and warehousing as well as the investment in inspection.

[0061] In at least some applications, the battery system can facilitate the construction of a battery pack to meet not only power output and voltage requirements, but also the physical constraints of the application. That is, in at least some applications, the battery pack can be configured to fit within a given geometric space provided, for example, in a machine.

[0062] A battery pack constructed according to the teachings of the present invention may not require an external frame or bracket to support the individual modules. This practical construction can simplify the design of the battery pack and minimize the manufacturing cost of such a construction, especially in small volume applications.

[0063] It should be appreciated that assembly and electrical connections of at least some embodiments may be performed partially or completely at a manufacturing facility, assembly facility, or in the field, allowing flexibility in the construction and shipping of such battery packs.

[0064] When battery modules are used in various applications, the power output and voltage output may decrease over time. Therefore, the battery system according to the teachings of the present invention can be used to reuse the battery modules in different battery packs. This reuse can reduce the amount of batteries that are scrapped or disassembled to recover the internal metals. Therefore, this reuse can lead to an environmentally friendly arrangement because it can minimize the batteries sent to landfill.

[0065] It should be understood that the foregoing description provides examples of the disclosed systems and techniques. However, it is contemplated that other implementations of the present invention may differ in detail from the foregoing examples. All references to the present invention or its examples are intended to refer to the specific examples discussed at that point, and are not intended to imply any limitation on the scope of the present invention more generally. All language regarding distinction and disparagement of certain features is intended to lack preference for these features, but unless otherwise indicated, is not completely excluded from the scope of the present invention.

[0066] Recitation of ranges of values ​​herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or clearly contradicted by context.

[0067] Unless otherwise specified herein or clearly contradicted by context, the use of the terms "a", "an", "the", "at least one" and similar referents in the context of describing the invention (especially in the context of the appended claims) should be interpreted to cover both the singular and the plural. Unless otherwise specified herein or clearly contradicted by context, the use of the term "at least one" followed by a list of one or more items (e.g., "at least one of A and B") should be interpreted to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B).

[0068] Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Additionally, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or clearly contradicted by context.

Claims

1. A battery module (106) for use in the construction of a battery pack (102), the battery module (106) comprising: A rectangular shell (108), the shell (108) comprising a top surface (134), a bottom surface (135), a first side surface (136) extending between the top surface (134) and the bottom surface (135), a second side surface (136) extending between the top surface (134) and the bottom surface (135), a front open end (111) and a rear open end (113), the shell (108) comprising a plurality of shell holes (142) extending substantially vertically through the top surface (134), the bottom surface (135), the first side surface (136) and the second side surface (136) near the front open end (111), and a plurality of shell holes (142) extending substantially vertically through the top surface (134), the bottom surface (135), the first side surface (136) and the second side surface (136) near the rear open end (113); A battery (114) disposed in the rectangular housing (108); a rear plate (112), the rear plate (112) closing the rear open end (113) of the housing (108), the rear plate (112) comprising a plurality of rear plate (112) holes, the plurality of rear plate (112) holes being axially aligned with the plurality of housing holes (142) proximate the rear open end (113) of the housing (108); a front plate (110), the front plate (110) enclosing the front open end (111) of the housing (108), the front plate (110) comprising a positive terminal (116) and a negative terminal (118) electrically connected to the battery (114), the battery (114) being sealed within the rectangular housing (108), the rear plate (112) and the front plate (110), the front plate (110) comprising a plurality of front plate (110) holes, the plurality of front plate (110) holes being axially aligned with the plurality of housing holes (142) proximate the front open end (111) of the housing (108); and at least one of a grounding cable (412), a clamping structure (414) adapted to receive a cable (416), or a supplemental non-conductive accessory; At least one of the rear panel (112) and the front panel (110) includes at least one passive opening (410), wherein at least one of the ground cable (412), the clamping structure (414) adapted to receive the cable (416), or the supplementary non-conductive accessory is received by the passive opening (410).

2. A battery module (106) according to claim 1, wherein at least one of the passive openings (410) includes a joining structure (428), the joining structure (428) is suitable for retaining at least one of the grounding cable (412), the clamping structure (414) suitable for receiving the cable (416), or the supplementary non-conductive accessory, and the joining structure (428) inhibits at least one of the grounding cable (412) and the clamping structure (414) from being separated from the passive opening (410).

3. The battery module (106) of claim 2, wherein the engagement structure (428) is at least one of at least one protrusion and at least one internal thread.

4. The battery module (106) of claim 1, wherein at least one of the rear plate (112) and the front plate (110) is a casting.

5. The battery module (106) of claim 1, wherein the clamping structure (414) includes a probe (422) adapted to be received within the at least one passive opening (410).

6. The battery module (106) of claim 5, wherein the clamping structure (414) further comprises at least one annular channel (424) sized to receive the cable (416).

7. The battery module (106) of claim 1, wherein the at least one passive opening (410) is a groove that does not extend through at least one of the rear plate (112) and the front plate (110).

8. A battery pack (102), comprising: The plurality of battery modules (106) according to any one of claims 1 to 7, further comprising at least two couplers (130), the at least two couplers (130) fixing at least the first battery module (106) and the second battery module (106) together, at least a first one of the couplers (130) being disposed through at least one of the plurality of rear plate holes (141), at least one of the plurality of rear plate holes (141) being axially aligned with at least one of the plurality of shell holes (142) near the rear open end (113) of the shell (108), and at least a second one of the couplers (130) being disposed through at least one of the plurality of front plate holes (141), at least one of the plurality of front plate holes (141) being axially aligned with at least one of the plurality of shell holes (142) near the front open end (111) of the shell (108); and A plurality of electrical couplers electrically couple the terminals (116, 118) of the at least first battery module (106) and the second battery module (106) together.

9. The battery pack (102) according to claim 8 further includes a panel (430), and the non-conductive coupling structure includes a plurality of panel couplers (432), which secure the panel (430) to the passive opening (410) of at least one of the front plate (110) and the rear plate (112).

10. A method of constructing a battery pack (102), the method comprising: Providing a plurality of battery modules (106) according to any one of claims 1 to 7; Disposing a rectangular housing (108) of a first battery module (106) among the plurality of battery modules (106) adjacent to a rectangular housing (108) of a second battery module (106) among the plurality of battery modules (106); A first coupler is provided through the hole of the rear plate (112) of the first battery module (106), the shell hole (142) of the rectangular shell (108) of the first battery module (106), the shell hole (142) of the rectangular shell (108) of the second battery module (106), and the hole (141) of the rear plate of the second battery module (106) to fix the first battery module (106) and the second battery module (106) together; A second coupler is provided through the front plate (110) hole of the second battery module (106), the housing hole (142) of the rectangular housing (108) of the second battery module (106), the housing hole (142) of the rectangular housing (108) of the second battery module (106), and the front plate hole (141) of the second battery module (106) to fix the first battery module (106) and the second battery module (106) together; and At least one of a ground cable (412), a clamping structure (414) adapted to receive a cable (416), or a supplemental non-conductive accessory is disposed in at least one passive opening (410) in at least one of the rear panel (112) and the front panel (110).

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