Battery module and battery module stack

Abstract

The use of the battery module and the intermediate module together for the module stack allows for flexible electrical configuration of the module stack. The battery module has a plurality of electrically conductive paths extending between a top side and a bottom side of the battery module; one of the paths is connected in series with a battery cell of a module, while at least one of the other paths functions as a through path that allows power or communication to pass through the module. The intermediate module also includes a through electrical path that may conduct power or communications from one battery module on one of the top and bottom sides of the intermediate module to a through path of the battery module on the other of the top and bottom sides of the intermediate module. This allows the modules in the stack to be electrically connected together in different series connection groups.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application No. 17 / 865,330, filed on July 14, 2022, the entire contents of which are hereby incorporated by reference. Technical Field

[0003] The present disclosure relates to a battery module and a battery module stack including a plurality of battery modules. Background Art

[0004] A rechargeable battery is a lithium-ion battery having a multilayer structure, the multilayer structure including: a positive electrode activated by various mixed oxides or olivines, a negative electrode activated by special carbon, and a separator all immersed in an organic electrolyte. The battery is usually placed in a housing to form a battery module. Under normal operating conditions, electrical energy is converted into chemical energy and stored during charging, and the stored chemical energy is converted into electrical energy during discharge. More specifically, during charging, the lithium in the positive electrode is ionized and moves from layer to layer to the negative electrode; during discharge, the ions move to the positive electrode and return to their original compounds. Multiple lithium-ion battery modules can be mounted on a rack assembly to form a battery pack together with a control module for controlling the battery modules.

[0005] A variety of different types of racks can be used to store and transport interconnected battery modules. In its simplest form, a rack can include a frame with multiple brackets into which the battery modules are inserted. Power lines and cooling lines can then be connected to the battery modules. In another variation, the rack can include a backplane that houses the power connection means. The battery modules (whose power connectors are located on the back of the modules) are inserted into the brackets and directly into the backplane.

[0006] However, in general, the use of racks complicates the battery pack. For example, using a rack to house the battery modules increases the number of components that form the battery pack, thereby increasing the manufacturing cost of the battery pack. In addition, a rack using a backplane may be prone to alignment issues between the power connectors of the battery modules and the power lines of the backplane.

[0007] Therefore, there remains a need in the art to provide a battery module that enables storage and transportation of multiple interconnected battery modules in a simpler and more efficient manner. Summary of the invention

[0008] According to a first aspect, a battery module is provided, which includes: a shell, the shell including opposite top and bottom sides; battery cells, the battery cells are accommodated in the shell and the battery cells are electrically connected to each other; a first top electrical contact and a second top electrical contact, the first top electrical contact and the second top electrical contact are located on the top side; a first bottom electrical contact and a second bottom electrical contact, the first bottom electrical contact and the second bottom electrical contact are located on the bottom side; and a first electrical conduction path and a second electrical conduction path, the first electrical conduction path and the second electrical conduction path terminate at the first top electrical contact and the first bottom electrical contact and the second top electrical contact and the second bottom electrical contact, respectively, wherein the first electrical conduction path is electrically connected to the battery cells in series.

[0009] The battery module may further include a third top electrical contact at the top side, a third bottom electrical contact at the bottom side, and a third electrical conduction path terminating at the third top electrical contact and the third bottom electrical contact.

[0010] The battery module may further include a fourth top electrical contact at the top side, a fourth bottom electrical contact at the bottom side, and a fourth electrical conduction path terminating at the fourth top electrical contact and the fourth bottom electrical contact.

[0011] The housing may be electrically conductive, and the battery module may further include a fifth top electrical contact at the top side, wherein each of the fifth top contact and the fifth bottom contact is electrically connected to the housing.

[0012] The battery module may also include a fifth electrical conduction path terminating at the fifth top contact and the fifth bottom contact.

[0013] The battery module may also include a male connector located on one of the top side and the bottom side of the module and a female connector located on the other of the top side and the bottom side of the module, wherein at least one of the top contacts terminates at the connector on the top side of the module and at least one of the bottom contacts terminates at the connector on the bottom side of the module.

[0014] All top contacts may terminate to a connector on the top side of the module, and all bottom contacts may terminate to a connector on the bottom side of the module.

[0015] According to another aspect, an intermediate module is provided, which is used to electrically connect the top battery module with the bottom battery module when the intermediate module is stacked between the top battery module and the bottom battery module. For example, the top battery module is the battery module at the top according to one or more of the above aspects, and the bottom battery module is the battery module at the bottom according to one or more of the above aspects. The intermediate module includes: a housing including opposite top and bottom sides; a first top electrical contact and a second top electrical contact located on the top side; a first bottom electrical contact and a second bottom electrical contact located on the bottom side; and a first electrical conduction path terminating at the first top electrical contact and the first bottom electrical contact, respectively, and a second electrical conduction path terminating at the second top electrical contact and the second bottom electrical contact, respectively, wherein the first top electrical contact of the intermediate module is positioned to contact the first bottom electrical contact of the top battery module, the first bottom electrical contact of the intermediate module is positioned to contact the third top electrical contact of the bottom battery module, the second top electrical contact of the intermediate module is positioned to contact the second bottom electrical contact of the top battery module, and the second bottom electrical contact is positioned to contact the fourth top electrical contact of the bottom battery module. The intermediate module may include battery cells electrically connected in series as part of the first electrical conduction path.

[0016] The intermediate module may also include: a third bottom electrical contact and a fourth bottom electrical contact located on the bottom side; and a third electrical conduction path terminating at the third bottom electrical contact and the fourth bottom electrical contact, wherein the third bottom electrical contact of the intermediate module is positioned to contact the first top electrical contact of the bottom battery module, and the fourth bottom electrical contact of the intermediate module is positioned to contact the second top electrical contact of the bottom battery module.

[0017] The intermediate module may also include a male connector located on one of the top side and the bottom side of the intermediate module and a female connector located on the other of the top side and the bottom side of the intermediate module, wherein at least one of the top contacts of the intermediate module terminates at the connector on the top side of the intermediate module, and at least one of the bottom contacts of the intermediate module terminates at the connector on the bottom side of the intermediate module.

[0018] All of the top contacts of the intermediate module may terminate at a connector on the top side of the intermediate module, and all of the bottom contacts of the intermediate module may terminate at a connector on the bottom side of the intermediate module.

[0019] According to another aspect, a battery module stack is provided, the battery module stack comprising: a top battery module, for example, the top battery module is a battery module according to one or more of the above aspects and located at the top; a bottom battery module, for example, the bottom battery module is a battery module according to one or more of the above aspects and located at the bottom; and an intermediate module, the intermediate module being stacked between the top battery module and the bottom battery module, the intermediate module comprising: a shell comprising opposite top and bottom sides; a first top electrical contact and a second top electrical contact located on the top side; a first bottom electrical contact located on the bottom side The intermediate module may include a first top electrical contact and a second bottom electrical contact; and a first electrical conduction path terminating at the first top electrical contact and the first bottom side electrical contact, respectively, and a second electrical conduction path terminating at the second top electrical contact and the second bottom side electrical contact, respectively, wherein the first top electrical contact of the intermediate module is positioned to contact the first bottom electrical contact of the top battery module, the first bottom electrical contact of the intermediate module is positioned to contact the third top electrical contact of the bottom battery module, the second top electrical contact of the intermediate module is positioned to contact the second bottom electrical contact of the top battery module, and the second bottom electrical contact is positioned to contact the fourth top electrical contact of the bottom battery module. The intermediate module may include battery cells electrically connected in series as part of the first electrical conduction path.

[0020] The intermediate module may also include: a third bottom electrical contact and a fourth bottom electrical contact located on the bottom side; and a third electrical conduction path terminating at the third bottom electrical contact and the fourth bottom electrical contact, wherein the third bottom electrical contact of the intermediate module is positioned to contact the first top electrical contact of the bottom battery module, and the fourth bottom electrical contact of the intermediate module is positioned to contact the second top electrical contact of the bottom battery module.

[0021] The intermediate module may also include a male connector located on one of the top side and the bottom side of the intermediate module and a female connector located on the other of the top side and the bottom side of the intermediate module, wherein at least one of the top contacts of the intermediate module terminates at the connector on the top side of the intermediate module, and at least one of the bottom contacts of the intermediate module terminates at the connector on the bottom side of the intermediate module.

[0022] All of the top contacts of the intermediate module may terminate at a connector on the top side of the intermediate module, and all of the bottom contacts of the intermediate module may terminate at a connector on the bottom side of the intermediate module.

[0023] According to another aspect, a battery module is provided, comprising: a shell; battery cells contained in the shell and electrically connected to each other; a first electrical contact portion and a second electrical contact portion located on a first side of the shell; a first electrical contact portion and a second electrical contact portion located on a second side of the shell; and a first electrical conduction path and a second electrical conduction path, wherein the first electrical conduction path and the second electrical conduction path terminate at the first electrical contact portion and the second electrical contact portion, respectively, wherein the first electrical conduction path is electrically connected to the battery cells in series.

[0024] The first side of the shell may be a top side, the first electrical contact portion and the second electrical contact portion located on the first side of the shell may be a first top electrical contact portion and a second top electrical contact portion, the second side of the shell may be a bottom side, and the first electrical contact portion and the second electrical contact portion located on the bottom side of the shell may be a first bottom electrical contact portion and a second bottom electrical contact portion.

[0025] The present disclosure does not necessarily describe the complete scope of all aspects. After reading the following description of the specific embodiments, other aspects, features and advantages will be apparent to those of ordinary skill in the art. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Embodiments of the present disclosure will now be described with reference to the accompanying drawings, in which:

[0027] Figure 1 shows a battery module stack according to an exemplary embodiment;

[0028] Figure 2 shows a top portion of a battery module according to an exemplary embodiment;

[0029] Figure 3 Shows Figure 2 The bottom of the battery module;

[0030] FIG. 4A to FIG. 4D and Figure 5 shows a circuit diagram of interconnected battery modules according to an exemplary embodiment;

[0031] Fig. 6A depicts a schematic diagram of a battery module according to another exemplary embodiment;

[0032] Figure 6B depicts an example of an intermediate battery module according to another exemplary embodiment;

[0033] Figure 6C Depicted include Fig. 6A and Figure 6B An exemplary battery stack of a battery module;

[0034] Figure 7 depicts an example battery module according to another exemplary embodiment showing various electrical conduction paths extending between a top and a bottom of the module;

[0035] Figure 8 and 9A to 9C Depicted include Fig. 6A and Figure 6B Various example configurations of battery module stacks;

[0036] Fig. 10A Depicted include Fig. 6A and Figure 6B An example stack of battery modules; and

[0037] FIG. 10B to FIG. 10D Depicted include Fig. 6A The battery module is omitted Figure 6B Example stacking of battery modules. DETAILED DESCRIPTION

[0038] The present disclosure is intended to provide improved battery modules and battery packs. Although various embodiments of the present disclosure are described below, the present disclosure is not limited to these embodiments, and variations of these embodiments may fully fall within the scope of the present disclosure, which is limited only by the appended claims.

[0039] In the claims and / or the specification, the word "a" or "an" when used with the term "comprising" or "including" can mean "one", but it is also consistent with the meaning of "one or more", "at least one", and "one or more than one", unless the context clearly dictates otherwise. Similarly, the word "another" can mean at least a second or more, unless the context clearly dictates otherwise.

[0040] As used herein, the terms "coupled," "coupling," or "connected" can have several different meanings, depending on the context in which the terms are used. For example, the terms coupled, coupled, or connected can have mechanical or electrical meanings. For example, as used herein, the terms coupled, coupled, or connected can indicate that two elements or devices are directly connectable to each other, or are connected to each other via electrical elements, electrical signals, or mechanical elements through one or more intermediate elements or devices, depending on the particular context. When used in association with a list of items, the term "and / or" herein refers to any one or more of the items that include the list.

[0041] As used herein, reference to "about" or "approximately" a number or reference to being "substantially" equal to a number means within + / - 10% of that number.

[0042] Hereinafter, a battery module generally refers to a housing for accommodating a plurality of interconnected battery cells. The battery cells form one or more battery cell stacks (also referred to as battery cell strings). A plurality of battery modules stacked one on top of another generally form a battery module stack (or simply a module stack). When one or more battery modules are connected to a pack controller, the combination of the battery module and the module controller generally forms a battery pack. The pack controller may be stacked with the battery module stack, or may be located outside the module stack.

[0043] Go to Figure 1 , Figure 1 A battery module stack 100 according to an embodiment of the present disclosure is shown. The module stack 100 is formed by a stacked arrangement of different components. Specifically, the module stack 100 includes: a module stack base 10 at its bottom, a stack of interconnected battery modules 50 stacked on top of the module stack base 10, and a module stack cover 80 positioned at the top of the module stack 100 and directly adjacent to the topmost battery module 50. The module stack 100 is stacked on top of the interface base 95 so that the module stack base 10 engages with the upper surface of the interface base 95. Those skilled in the art will understand that the present disclosure extends to battery packs having any number of stacked battery modules and any number of columns of stacked battery modules. In addition, in some embodiments, a module stack can be formed without a module stack cover 80 and / or without a module stack base 10. Therefore, in some embodiments, the module stack may include only one or more columns of stacked battery modules.

[0044] The footprint of the module stack 100 is approximately the same as the footprint of a standard size pallet. Specifically, the footprint of the module stack 100 is approximately the same as a standard EUR2 Euro size pallet (e.g., 1,200×1,000×144 mm) defined by the Euro Pallet Association, but as will be appreciated by those skilled in the art, the present disclosure extends to module stacks having any other suitable footprint dimensions.

[0045] Go to Figure 2 and Figure 3 , showing a top view and a bottom view of a battery module 50. The battery module 50 includes a pair of cell housings 52a, 52b, each of which has a battery cell stack 72a, 72b ( Figure 2 and Figure 3 The left, right and lower sides of the unit housings 52a and 52b away from the battery module 50 are provided with cooling fins 53 for promoting heat transfer from the inside of the unit housings 52a and 52b to the outside of the battery module 50.

[0046] An exhaust assembly is provided at the back of the battery module 50, which consists of a pair of exhaust channels 57a, 57b. The exhaust channels 57a, 57b extend from exhaust holes formed in the lower and upper sides of the battery module 50. Therefore, the exhaust channels 57a, 57b extend from the lower side of the battery module 50 to the upper side of the battery module 50. The exhaust channels 57a, 57b are used to convey exhaust gases (e.g., gases formed in response to thermal runaway of one or more battery cell stacks in the battery cell stack) that may be formed inside the battery cell housing 52a, 52b away from the battery module 50. In particular, each exhaust channel 57a, 57b is connected to the internal fluid of one of the battery cell housings 52a, 52b, so that the exhaust gas from one of the battery cell stacks in the battery cell housing can be directed away from the battery module 50.

[0047] A cooling assembly extends between the battery cell housings 52a and 52b, which includes a cooling channel 56. The cooling channel 56 extends from a cooling hole formed in each of the lower and upper sides of the battery module 50. Therefore, the cooling channel 56 extends from the lower side of the battery module 50 to the upper side of the battery module 50. The cooling channel 56 is used to transfer cooling liquid between the battery cell housings 52a and 52b. The cooling channel 56 extends substantially along the entire length of the battery cell housings 52a and 52b, and is separated from the exhaust channels 57a and 57b by a physical joint so that the cooling liquid flowing through the cooling channel 56 does not mix with the exhaust gas flowing through the exhaust channels 57a and 57b. The cooling liquid may include, for example, a liquid coolant, a forced airflow (e.g., cooling air forced to flow upward or downward through the battery module 50 through the cooling channel 56) or a passive airflow (e.g., air flowing through the battery module 50 by free convection via the cooling channel 56).

[0048] When two or more such battery modules 50 are stacked on each other, the cooling channels 56 of one battery module 50 are aligned with the cooling channels 56 of an adjacent battery module 50. In addition, the exhaust channels 57a, 57b of one battery module 50 are aligned with the exhaust channels 57a, 57b of an adjacent battery module 50.

[0049] In some embodiments, the exhaust channels 57a, 57b and the cooling channels 56 may be located at other locations of the battery module 50. For example, cooling channels may be provided along each side of the battery module 50, with the cooling channels facing away from the battery module 50. As another example, the battery module 50 may include a single exhaust channel serving the battery cell housings 52a and 52b. Those skilled in the art will recognize that any number of cooling channels and exhaust channels may be included in the battery module 50, and the number of these channels may vary according to the needs of those skilled in the art, provided that the cooling channels and exhaust channels extend through the battery module 50 in a manner extending from one side of the battery module 50 to another side of the battery module 50.

[0050] The module 50 has a plurality of male or female self-locking members 59. The self-locking members 59 are configured to engage or mate with corresponding self-locking members 51 disposed in the lower side of another battery module 50. Each self-locking member 51 includes a tapered portion to facilitate engagement with a matching self-locking member 59 of an adjacently placed battery module 50. The tapered portion allows for a certain misalignment tolerance between the battery modules 50, making it easier for the battery modules 50 to "self-align" when engaging with each other.

[0051] The battery module 50 is provided with a power connector 83 in front of each of its upper and lower sides. The power connector 83 includes a pair of conductive pins, and a ground connection. The conductive pins may be retractable, as described in conjunction with the power pins 67 in Figures 24A and 24B. Each power connector 83 includes a tapered portion to facilitate engagement with the power connector 83 of an adjacently placed battery module 50. Therefore, the male power connector 83 located at the top of the battery module 50 includes a tapered portion to facilitate engagement with the tapered female power connector 83 located on the lower side of the adjacently placed upper battery module 50. The tapered portion allows a certain misalignment tolerance between the battery modules 50, making it easier for the battery modules 50 to "self-align" when engaging with each other.

[0052] In combination with tapered portions on one or both of the male power connector 8 and the female power connector 83, the power connector 83 can "float" relative to the battery cell housings 52a and 52b, thereby providing additional tolerance when the power connector 83 of the battery module 50 is coupled to the power connector 83 of an adjacent battery module.

[0053] See also FIG. 4A to FIG. 4D , showing different example interconnections of the battery modules 50 of the battery module stack 100 .

[0054] Figure 4A A battery pack 200 is depicted in which a pack controller 202 is integrated with the module stack 100. In particular, Figure 4AA first left-hand column 206 of battery modules is shown positioned adjacent to a right-hand column 208 of battery modules. The orientation of the battery modules in the right-hand column 208 is flipped relative to the orientation of the battery modules in the left-hand column 206 so that the power connections on one column are immediately adjacent to the power connections on the other column, thereby minimizing the electrical path length of the battery module string.

[0055] Figure 4B An alternative example arrangement is depicted having a single column of interconnected battery modules. A return conductive path 210 is provided from the cover 212 back to the pack controller 202 . Figure 4C Another similar arrangement is shown, which has a single row of interconnected battery modules. However, each battery module 50 includes two adjacent battery cell stacks (similar to Figure 2 implementation method). Figure 4D Shown with Figure 4C The same setup, except that instead of using an optical communication port, a wireless communication transceiver or module 214 is used to enable communication between the battery modules. As mentioned above, a wired connection may alternatively be used for communication.

[0056] Figure 5 An alternative configuration is shown that includes multiple module stacks 100 and a single pack controller 202 for controlling the module stacks 100. Each battery module includes two battery cell stacks. A return conductive path 210 connects the top of each module stack 100 to the interface base 95, after which the electrical path is directed to the pack controller 202. A wireless communication transceiver or module 214 is used to provide communication between the battery modules 50. In some embodiments, two or more module stacks 100 can be connected in series before connecting them to the pack controller 202, thereby providing better configurability for the height and footprint of the battery pack.

[0057] Discrete stacking

[0058] See also Fig. 6A and Figure 6B , shows an example schematic diagram of battery modules 50 and intermediate modules 612 that can be used to assemble a group of battery module stacks 100, the total energy density of which is higher than a group of similar battery module stacks 100 assembled without the intermediate modules 612.

[0059] Fig. 6A The module 50 includes a module housing 614 (such as Figure 7 In at least some embodiments, the housing 614 includes the battery cell housings 52a, 52b and a module chassis, wherein the module chassis provides support for the battery cell housings 52a, 52b and serves as the front side wall, rear side wall, left side wall, and right side wall of the housing 614, as shown in FIG. Figure 7 . At the top of the housing 614 is a top power connector 83a and at a corresponding position on the bottom side is a bottom power connector 83b. One of the top and bottom power connectors 83a, 83b is a male connector and the other of the top and bottom power connectors 83a, 83b is a female connector. This allows several modules 50 to be stacked on top of each other, in which the top power connector 83a of the first module 50 mates with the bottom power connector 83b of the second module 50, where the second module 50 rests on the top surface of the first module 50.

[0060] Fig. 6A The top power connector 83a of the module 50 includes the first top electrical contact 604a to the fifth top electrical contact 604e, which are sequentially connected in series to the first bottom electrical contact 606a to the fifth bottom electrical contact 606e constituting a part of the bottom power connector 83b through the first electrical conductive path 608a to the fifth electrical conductive path 608e. Therefore, the first electrical conductive path 608a to the fifth electrical conductive path 608e terminate at the first top electrical contact 604a to the fifth top electrical contact 604e and the first bottom electrical contact 606a to the fifth bottom electrical contact 606e, respectively. The first electrical conductive path 608a is connected in series with the battery cell 602 constituting a part of the module 50. The fifth electrical conductive path 608b and the contacts 604e, 608e are used to combine the housing 614 of the module 50 together to reduce the possibility of electric shock. Therefore, the housing 614 is conductive and connected to the fifth electrical conductive path 608b and the contacts 604e, 606e. In at least some different embodiments, the connectors 83a, 83b may include different combinations of contacts. For example, the connectors 83a, 83b may include one or two grounding electrical contacts for grounding, and contacts for wired communication between modules 50; these contacts may be in addition to or replace at least part of the first top electrical contact 604a to the fifth top electrical contact 604e and the first bottom electrical contact 606a to the fifth bottom electrical contact 606e.

[0061] The second through fourth paths 608b through 608d may serve as bypass paths to allow power and / or signals to be routed to the module 50. Although these paths 608b through 608d are Fig. 6A 608b to 608d are shown as being electrically shorted, but in at least some different implementations, a non-zero impedance circuit may be provided along one or more of the paths 608b to 608d.

[0062] Figure 7 A front view of an example embodiment of a module 50 is shown with the back plate removed to reveal potential electrical connections. Figure 7The top power connector 83a and the bottom power connector 83b are shown; Fig. 6A In contrast to the example implementation of the module 50 shown in FIG. Figure 7 The fifth top electrical contact 604e and the fifth bottom electrical contact 606e in the embodiment no longer constitute a part of the power connectors 83a, 83b. More specifically, the fifth top electrical contact 604e and the fifth bottom electrical contact 606e are replaced by electrically conductive key pins 616, which are directly connected to the housing 614 of the module 50 and are positioned so that when two modules 50 are stacked together, the key pins 616 located on the bottom side of the top module 50 are received by the corresponding receiving portion 617 on the top side of the other module 50, thereby forming an electrical short circuit between the housings 614.

[0063] One example implementation has a Figure 7 The first top electrical contact 604a to the fourth top electrical contact 604d in the top power connector 83a and the first bottom electrical contact 606a to the fourth bottom electrical contact 606d in the bottom power connector 83a of the middle module 50. The second electrical conductive path 608b to the fourth electrical conductive path 608d are busbars, which directly connect the second top electrical contact 604b to the fourth top electrical contact 604d and the second bottom electrical contact 606b to the fourth bottom electrical contact 606d, respectively. Figure 7 Only a portion of the first electrical conductive path 608a is visible. The visible portion includes: a first busbar extending downward from the first top electrical contact 604a, the first busbar being fixed adjacent to the battery cell housing 52a to connect to the battery cells 602 in the battery cell housing 52a; a second busbar extending horizontally and connecting the battery cells 602 in the two battery cell housings 52a, 52b together; and a third busbar being fixed adjacent to the other battery cell housing 52b to connect the battery cells 602 in the battery cell housing 52b to the first bottom electrical contact 606a. Thus, the first electrical conductive path 608a connects the first top electrical contact 604a and the first bottom electrical contact 606a to the battery cells 602 in the battery cell housings 52a, 52b.

[0064] and Fig. 6A Similar to module 50, Figure 6B The intermediate module 612 has a housing 614, a top power connector 83a and a bottom power connector 83b, first top electrical contacts 604a to fifth top electrical contacts 604e, and first bottom electrical contacts 606a to fifth bottom electrical contacts 606e. Fig. 6A The module 50 has five different electrical conduction paths 608a to 608e, Figure 6BThe intermediate module 612 has only four electrical conduction paths 608a to 608d. The first electrical conduction path 608a connects the first top electrical contact 604a on the top side of the intermediate module 612 in series with several battery cells, then connects in series with the third electrical conduction path 608c, and terminates at the first bottom electrical contact 606a on the bottom side of the intermediate module 612.

[0065] The fourth electrical conductive path 608d terminates at the second top electrical contact 604b on the top side of the intermediate module 612 and the second bottom electrical contact 606b on the bottom side of the intermediate module 612. The first top electrical contact 604a and the second top electrical contact 604b and the first bottom electrical contact 606a and the second bottom electrical contact 606b are positioned so that when the intermediate modules 612 are stacked on top of each other, the first and second top electrical contacts 604a and 604b are located on the intermediate module 612. Fig. 6A 612) and a second module 50 (on the bottom side of the intermediate module 612), the first bottom electrical contact 606a of the first module 50 contacts the first top electrical contact 604a of the intermediate module 612, the first bottom electrical contact 606a of the intermediate module 612 contacts the third top contact 604c of the bottom module 50, the second bottom electrical contact 606b of the first module 50 contacts the second top electrical contact 604b of the top module 50, and the second bottom electrical contact 606b of the intermediate module contacts the fourth top electrical contact 604d of the bottom module 50. Thus, by using the intermediate module 612, the first electrical conductive path 602a of the first module 50 (which is in series with the cell 602) is routed to the third electrical conductive path 608c of the bottom module 50. If the first module 50 were directly on top of the second module 50, the first electrical conductive paths 604a of the first and second modules 50 would be in series. Similarly, by using the intermediate module 612, the second electrically conductive path 608b of the first module 50 is routed to the fourth electrically conductive path 608d of the second module 50. If the first module 50 were directly on top of the second module 50, the second electrically conductive paths 604b of the first and second modules 50 would be connected in series. This path rerouting allows for increased power density when the modules 50, 612 are deployed, as discussed further below. Figure 7 Like the module 50 , the busbars may also be used for the electrical conduction paths 608 a to 608 e of the intermediate module 612 .

[0066] Figure 6C Three stacks 100 are depicted: a leftmost stack 100, a center stack 100, and a rightmost stack 100. Each stack 100 is located on an interface base 95 and is covered with a module stack cover 80. Each of the leftmost stack and the rightmost stack includes four modules stacked between the interface base 95 and the cover 80. Fig. 6AThe center stack consists of four Fig. 6A A module of 50 and a Figure 6B The intermediate module 612 is located in the middle of the stack 100, two of which Fig. 6A The module 50 is located between it and the cover 80, and the other two Fig. 6A The module 50 of the cover 80 is located between it and the base 95. Each cover 80 includes a return path 210 that connects the first electrically conductive path 604a to the second electrically conductive path 604b of the module 50 where the cover 80 is located.

[0067] The first electrical conduction path 608a of the leftmost stack 100 and the second electrical conduction path 608b of the rightmost stack 100 are connected to an electrical load (not shown) through a first wire 618a and a fourth wire 618d. Similarly, the first electrical conduction path 608a and the fourth electrical conduction path 608d of the lowest module 50 in the center stack 100 are connected to an electrical load (not shown) through a second wire 618b and a third wire 618c. The second electrical conduction path 608b of the leftmost stack 100 is connected to the third electrical conduction path 608c of the lowest module 50 in the center stack through a fifth wire 618e. The second electrical conduction path 608b of the lowest module 50 in the center stack 100 is connected to the first electrical conduction path 608a of the rightmost stack through a wire 618f. The middle module 612 in the middle of the center stack 100 reroutes the first electrically conductive path 608a and the second electrically conductive path 608b of the top two modules 50 of the center stack 100 so that they are electrically connected in series with the leftmost stack 100 instead of being electrically connected in series with the bottom two modules 50 of the center stack 100. Thus, the leftmost stack 100 is connected in series with the top two modules 50 of the center stack 100, and the rightmost stack 100 is connected in series with the bottom two modules 50 of the center stack, thereby making the two series-connected stacks 100 of six modules 50 available for one or more electrical loads (not shown). If another Fig. 6A Module 50 replaces the middle module 612, then Figure 6C The configuration will result in two stacks 100 of four modules 50 and one stack 100 of five modules 100 .

[0068] 9A to 9C Describes the use Fig. 6A and Figure 6B There are a variety of example configurations that may be achieved by combining modules 50 and 612. Fig. 9AThree stacks 100 are shown, which are electrically connected together using an intermediate module 612 located in the middle of the center stack 100 to create two groups of twelve modules 50 connected in series, wherein the center stack 100 is split so that its four modules 50 are grouped with eight modules 50 from the leftmost stack 100 and its four modules 50 are grouped with eight modules 50 from the rightmost stack 100. Fig. 9B A similar configuration is shown where three stacks 100 are electrically connected together using an intermediate module 612 located in the middle of the center stack 100 to create two sets of thirteen modules connected in series, where the center stack 100 is again separated. Fig. 9C A similar configuration for creating two groups of fourteen modules 50 is shown.

[0069] like 9A to 9C As shown, the intermediate module 612 does not need to have Fig. 6A The modules are 50 the same size.

[0070] Figure 8 Describes the use Fig. 6A Module 50 and Figure 6B Another example configuration that may be achieved by combining the modules 612 is shown in FIG. Figure 8 In the embodiment, the intermediate modules 612 are located at different positions in the plurality of stacks 100, so that different numbers of modules 50 can be combined in series. Figure 8 In the example configuration, placing the intermediate module 612 directly on the second module 50 from the bottom (second stack 100 from the left), the fifth module 50 from the bottom (third stack 100 from the left), and the eighth module 50 from the bottom (third stack from the left) allows three groups of twelve modules 50 in series and one group of ten modules 50 in series, with a maximum height of 2.75m.

[0071] FIG. 10A to FIG. 10D An example configuration of a stack 100 using an intermediate module 612 is depicted. Fig. 10A ) compared to the comparison configuration in which the intermediate module 612 is omitted ( FIG. 10B to FIG. 10D ).exist FIG. 10A to FIG. 10D In each of the figures in FIG. 1 , it is assumed that the stack 100 has a length L and a height H. The length L and the height H are not necessarily the same for each of the different configurations. The stack 100 is connected to the bag controller 202 having a length of 0.8 m. The stack 100 rests on a base having a height of 0.50 m, which acts as an air chamber for the stack 100, with a 0.4 m high stack cover 80 on top, and a 0.7 m clearance is required above the stack cover 80.

[0072] FIG. 10A to FIG. 10DEach of the configurations represents eight groups of modules 50 connected in series, as shown in these figures. However, their physical arrangement and the number of modules 100 in each stack 100 are different. Fig. 10A Each group in the configuration ("3S discrete stack configuration") is formed using modules 50 from 1.5 stacks 100, where the stacks 100 are discrete using intermediate modules 612 as needed. In contrast, Fig. 10B Each group in the configuration ("2S standard stack configuration") is formed by two complete stacks 100 of modules 50 in series; Fig. 10C Each group in the configuration ("3S standard stack configuration") is formed by three complete stacks 100 of modules 50 connected in series; and Fig. 10D Each group in the configuration ("4S standard stack configuration") is formed by four complete stacks 100 of modules 50 connected in series.

[0073] The main advantage of the discrete stack configuration is that it allows flexibility by decoupling the system voltage and number of modules from the height of the mounting system to better fill any given installation location. It allows series-connected modules to be placed in adjacent stacks. This helps to efficiently utilize the limited space that can be used for battery storage (such as on ships).

[0074] In at least some example embodiments, the electrically conductive paths 608a-608e may be connected to switches that allow a single module 50, 612 to operate in different states. For example, a single module may operate as a battery module 50 when its switch is in a first state and as an intermediate module 612 when its switch is in a second state. More generally, one or both of the modules 50, 612 may include one or more switches that allow any one or more of the electrical contacts 602a-602e, 604a-604e to be routed to any other one or more of the electrical contacts 602a-602e, 604a-604e.

[0075] Furthermore, while the above-described example embodiments place the electrical contacts 602a-602e, 604a-604e on the top and bottom sides of the modules 50, 612, in at least some example embodiments, one or more of the electrical contacts 602a-602e, 604a-604e can be placed on one or more different sides (e.g., the left side, right side, front side, or back side) of the modules 50, 612. This allows the modules 50, 612 to be arranged and connected laterally within a room, rather than stacking the modules 50, 612 on top of each other. These lateral connections can be made using the bottom-most modules 50, 612 (i.e., close to the floor), or can be made between any higher modules 50, 612.

[0076] In the figure, the battery module 50 and the intermediate module 612 are shown as different modules. In at least some different example embodiments, the modules 50, 612 can be combined into the same housing so that a single module has the functions of both the battery module 50 and the intermediate module 612 described above.

[0077] Although described in conjunction with conducting power through the modules 50, 612, the electrically conductive paths 608a to 608e and / or additional electrically conductive paths not depicted in the figure may be used in addition or alternatively to conduct other digital or analog signals. These signals may be used, for example, to communicate between the modules 50, 612 and the package controller 202. The modules 50, 612 may use the electrically conductive paths to simply relay or passively transfer or conduct digital or analog signals received from one of the modules 50, 612 to another module 50, 612. Alternatively, the modules 50, 612 may include circuitry that repeats and / or switches these digital or analog signals between different electrically conductive paths. In at least some example embodiments, in addition to or as an alternative to the electrically conductive paths 608a to 608e, optical transmission paths may be used. The optical transmission paths may include, for example, optical fibers; the electrical contacts on the housings of the modules 50, 612 may accordingly include optical fiber couplers or adapters, or optical fiber transmitters / receivers / transceivers.

[0078] Although the present disclosure has been described in conjunction with specific embodiments, it should be understood that the present disclosure is not limited to these embodiments and that changes, modifications and variations may be made to these embodiments by a skilled person without departing from the scope of the present disclosure. In addition, it is contemplated that any aspect or any portion of an embodiment discussed in this specification may be implemented or combined with any portion of any other aspect or embodiment discussed in this specification. For example, without limiting the generality of the foregoing, the teachings of the present disclosure regarding conducting power or signals between the top and bottom of a module may be applied to conducting power or signals between any other sides of a module.

Claims

1. A battery module, comprising: (a) Housing; (b) one or more battery cells, the one or more battery cells being accommodated in the housing and the one or more battery cells being electrically connected to each other; (c) a first electrical contact and a second electrical contact located on a first side of the housing; (d) a first electrical contact and a second electrical contact located on a second side of the housing; and (e) a first electrical conduction path and a second electrical conduction path, the first electrical conduction path and the second electrical conduction path terminate at the first electrical contact and the second electrical contact, respectively, wherein the first electrical conduction path is electrically connected in series with the one or more battery cells.

2. The battery module according to claim 1, wherein: The first side of the shell is the top side, the first electrical contact portion and the second electrical contact portion located on the first side of the shell are the first top electrical contact portion and the second top electrical contact portion, the second side of the shell is the bottom side, the first electrical contact portion and the second electrical contact portion located on the bottom side of the shell are the first bottom electrical contact portion and the second bottom electrical contact portion.

3. The battery module according to claim 2, further comprising: A third top electrical contact is located at the top side, a third bottom electrical contact is located at the bottom side, and a third electrical conduction path terminated at the third top electrical contact and the third bottom electrical contact.

4. The battery module according to claim 3, further comprising: A fourth top electrical contact is located at the top side, a fourth bottom electrical contact is located at the bottom side, and a fourth electrical conduction path terminated at the fourth top electrical contact and the fourth bottom electrical contact.

5. The battery module according to any one of claims 2 to 4, wherein: The housing is electrically conductive, and the battery module further includes a fifth top electrical contact at the top side and a fifth bottom electrical contact at the bottom side, wherein each of the fifth top contact and the fifth bottom contact is electrically connected to the housing. 6 . The battery module of claim 5 , further comprising a fifth electrical conduction path terminating at the fifth top contact and the fifth bottom contact.

7. The battery module according to any one of claims 2 to 6, further comprising: a male connector on one of the top side and the bottom side of the module; and a female connector on the other of the top side and the bottom side of the module, wherein at least one of the top contacts terminates at the connector on the top side of the module and at least one of the bottom contacts terminates at the connector on the bottom side of the module.

8. The battery module according to claim 5, wherein: All top contacts terminate at the connector on the top side of the module, and all bottom contacts terminate at the connector on the bottom side of the module.

9. An intermediate module for electrically connecting a top battery module with a bottom battery module when the intermediate module is stacked between a battery module according to claim 4 at the top and a battery module according to claim 4 at the bottom, the intermediate module comprising: (a) a housing comprising opposing top and bottom sides; (b) a first top electrical contact and a second top electrical contact located on the top side; (c) a first bottom electrical contact and a second bottom electrical contact located on the bottom side; and (d) a first electrically conductive path and a second electrically conductive path, the first electrically conductive path terminating at the first top electrical contact and the first bottom electrical contact, respectively, and the second electrically conductive path terminating at the second top electrical contact and the second bottom electrical contact, respectively, wherein the first top electrical contact of the intermediate module is positioned to contact the first bottom electrical contact of the top battery module, the first bottom electrical contact of the intermediate module is positioned to contact the third top electrical contact of the bottom battery module, the second top electrical contact of the intermediate module is positioned to contact the second bottom electrical contact of the top battery module, and the second bottom electrical contact of the intermediate module is positioned to contact the fourth top electrical contact of the bottom battery module.

10. The intermediate module according to claim 9, further comprising one or more battery cells, the one or more battery cells being accommodated in the housing and the one or more battery cells being electrically connected to each other, wherein The first electrical conduction path is electrically connected in series with the one or more battery cells.

11. The intermediate module according to claim 9, further comprising: (a) a third bottom electrical contact and a fourth bottom electrical contact located on the bottom side; as well as (b) a third electrical conduction path terminating at said third bottom electrical contact and said fourth bottom electrical contact, wherein the third bottom electrical contact of the middle module is positioned to contact the first top electrical contact of the bottom battery module, and the fourth bottom electrical contact of the middle module is positioned to contact the second top electrical contact of the bottom battery module.

12. The intermediate module according to claim 9 or 10, further comprising: a male connector on one of the top side and the bottom side of the intermediate module; and a female connector located on the other of the top side and the bottom side of the intermediate module, wherein at least one of the top contacts of the intermediate module terminates at the connector on the top side of the intermediate module and at least one of the bottom contacts of the intermediate module terminates at the connector on the bottom side of the intermediate module.

13. The intermediate module according to claim 11, wherein: All top contacts of the intermediate module terminate at the connector at the top side of the intermediate module, and all bottom contacts of the intermediate module terminate at the connector at the bottom side of the intermediate module.

14. A battery module stack, the battery module stack comprising: (a) The battery module according to claim 4 at the top; (b) the battery module according to claim 4 at the bottom; as well as (c) an intermediate module stacked between the top battery module and the bottom battery module, the intermediate module comprising: (i) a housing comprising opposing top and bottom sides; (ii) a first top electrical contact and a second top electrical contact located on the top side; (iii) a first bottom electrical contact and a second bottom electrical contact located on the bottom side; and (iv) a first electrically conductive path and a second electrically conductive path, the first electrically conductive path terminating at the first top electrical contact and the first bottom electrical contact, respectively, and the second electrically conductive path terminating at the second top electrical contact and the second bottom electrical contact, respectively, wherein the first top electrical contact of the intermediate module is positioned to contact the first bottom electrical contact of the top battery module, the first bottom electrical contact of the intermediate module is positioned to contact the third top electrical contact of the bottom battery module, the second top electrical contact of the intermediate module is positioned to contact the second bottom electrical contact of the top battery module, and the second bottom electrical contact is positioned to contact the fourth top electrical contact of the bottom battery module.

15. The battery module stack according to claim 13, wherein: The intermediate module also includes: (a) a third bottom electrical contact and a fourth bottom electrical contact located on the bottom side; and (b) a third electrical conduction path terminating at a third bottom electrical contact and a fourth bottom electrical contact, wherein the third bottom electrical contact of the middle module is positioned to contact the first top electrical contact of the bottom battery module, and the fourth bottom electrical contact of the middle module is positioned to contact the second top electrical contact of the bottom battery module.

16. The battery module stack according to claim 13 or 14, wherein: The intermediate module also includes: a male connector located on one of the top side and the bottom side of the intermediate module; and a female connector located on the other of the top side and the bottom side of the intermediate module, wherein at least one of the top contact portions of the intermediate module terminates at the connector on the top side of the intermediate module, and at least one of the bottom contact portions of the intermediate module terminates at the connector on the bottom side of the intermediate module.

17. The battery module stack according to claim 15, wherein: All top contacts of the intermediate module terminate at the connector at the top side of the intermediate module, and all bottom contacts of the intermediate module terminate at the connector at the bottom side of the intermediate module.

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