Battery module with integrated battery management system with expansion / pressure detector and application thereof

Abstract

A battery module and a battery rack with enhanced fire safety features are provided. The battery module includes an expansion / pressure sensor that detects expansion of a battery cell. The output signal of the sensor is used to stop operation of a battery rack / battery system containing the battery module and to prevent charging and discharging of the battery module. In an embodiment, the battery module provides AC frequency power using an AC-to-AC power supply to balance battery cells of the battery module. In an embodiment, the battery rack includes an internal water fire extinguishing system that provides battery cooling in the event of a battery cell fire to prevent fire spread and / or reignition.

Description

Technical Field

[0001] The present disclosure relates to a battery module, a battery management system and a battery energy storage system. Background Art

[0002] Battery energy storage systems use a large number of batteries, which can pose a fire hazard if not managed properly. Conventional battery management systems typically only monitor battery cell voltage and temperature. They do not monitor or indicate the internal state of the battery cell. Battery cell voltage and cell temperature alone are not good indicators of conditions / pressure changes inside the cell that may cause a battery fire. Summary of the invention

[0003] Embodiments described herein help solve or mitigate the above-mentioned problems and additional disadvantages associated with battery storage systems.

[0004] In some cases, embodiments of the present invention include a battery module having a sensor that detects swelling of a battery cell. The output signal of the sensor is used to stop the operation of the battery rack / system containing the battery module and thereby stop the charging and discharging of the battery cell until the battery module containing the battery cell can be replaced and the battery rack / system inspected to verify its safe operation.

[0005] In an embodiment, high frequency AC power is used as a power source for balancing the battery module cells.Using high frequency AC power permits the use of an isolation transformer as part of a battery balancing circuit.

[0006] In an embodiment, a battery module according to the present invention includes a top cover that collects water and directs this water to the plates of the battery module to cool the batteries.

[0007] In an embodiment, a battery rack according to the present invention includes a water fire suppression system with cascading water flow between battery modules, which provides cooling in the event of a battery cell fire and thereby controls and prevents the battery cell fire from spreading to adjacent cells and racks.

[0008] In an embodiment, a battery rack according to the present invention includes an exhaust duct to remove gases and / or heat and direct these gases and / or heat to the outside of the room, container, building, etc. that houses the battery rack.

[0009] The additional features and advantages of the present disclosure and the structure and operation of various embodiments are described in detail below with reference to the accompanying drawings. It should be noted that the present disclosure is not limited to the specific embodiments described herein. Such embodiments are presented herein for illustrative purposes only. Based on the teachings contained herein, additional embodiments will be apparent to those skilled in the relevant art. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In addition to describing and demonstrating the various aspects and / or principles set forth in the present disclosure, the drawings together with the following detailed description illustrate several exemplary embodiments. The drawings and brief description are provided to enable those of ordinary skill in the art to practice the various aspects and / or principles set forth in the present disclosure.

[0011] Figure 1 An example battery module according to an embodiment of the invention is described.

[0012] Figure 2 An example battery module according to an embodiment of the invention is described.

[0013] Figure 3A illustrate Figure 1 Exploded view of the battery module in the .

[0014] Figure 3B illustrate Figure 1 An example top tray and an example sensor of a battery module.

[0015] Figure 4 An example battery module according to an embodiment of the invention is described.

[0016] Figure 5 An example battery module according to an embodiment of the invention is described.

[0017] Fig. 6A 1 through B illustrate example expansion / pressure sensors that may be used in accordance with embodiments of the present invention.

[0018] Fig. 7A 1 through C illustrate example expansion / pressure sensors that may be used in accordance with embodiments of the present invention.

[0019] Figure 8 An example battery module controller according to an embodiment of the invention is described.

[0020] Fig. 9A An example battery module controller according to an embodiment of the invention is described.

[0021] Fig. 9B An example power supply of a battery module controller according to an embodiment of the present invention is described.

[0022] Fig.10 (divided into Figures 10A to 10Q ) illustrates an example battery module controller according to an embodiment of the present invention.

[0023] Fig.11 (divided into Figures 11A to 11D ) illustrates an example power supply of a battery module controller according to an embodiment of the present invention.

[0024] Fig.12An example connector of a battery module controller according to an embodiment of the present invention is described.

[0025] Fig.13 An example battery module controller graphical user interface is illustrated in accordance with an embodiment of the present invention.

[0026] Fig.14A 1 to 2 illustrate an example battery rack controller according to an embodiment of the present invention.

[0027] Fig.15A 1 to 2 illustrate an example battery rack according to an embodiment of the present invention.

[0028] Fig.16 An example battery rack according to an embodiment of the invention is described.

[0029] Fig.17A 1 to 2 illustrate an example battery rack according to an embodiment of the present invention.

[0030] Fig.18A 1 to 2 C illustrate an example battery rack according to an embodiment of the present invention.

[0031] Fig.19 A fire extinguishing system for a battery rack according to an embodiment of the present invention is described.

[0032] Fig. 20 An example container system for accommodating a battery rack forming a battery energy storage system according to the present invention is described.

[0033] Fig.21 A plurality of containers for accommodating a battery rack forming a battery energy storage system according to the present invention are described.

[0034] Fig. 22 A building accommodating a battery rack forming a battery energy storage system according to the present invention is described.

[0035] Fig.23 A battery module according to an embodiment of the present invention is described.

[0036] Fig.24 A battery module according to an embodiment of the present invention is described.

[0037] Fig.25 A battery module according to an embodiment of the present invention is described.

[0038] Fig.26 A battery module according to an embodiment of the present invention is described.

[0039] Fig. 27 A battery module according to an embodiment of the present invention is described.

[0040] Fig.28 A battery module according to an embodiment of the present invention is described.

[0041] Fig.29 A battery module according to an embodiment of the present invention is described.

[0042] Fig.30 A battery module according to an embodiment of the present invention is described.

[0043] Fig.31 A battery module according to an embodiment of the present invention is described.

[0044] Fig.32 A battery module according to an embodiment of the present invention is described.

[0045] Fig.33 A battery module according to an embodiment of the present invention is described.

[0046] Fig.34A An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0047] Fig.34B A board suppressor according to an embodiment of the present invention is described.

[0048] Fig.34C A board suppressor according to an embodiment of the present invention is described.

[0049] Fig.34D A board suppressor according to an embodiment of the present invention is described.

[0050] Fig.34E A board suppressor according to an embodiment of the present invention is described.

[0051] Fig.35 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0052] Fig.36 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0053] Fig.37 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0054] Fig.38 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0055] Fig.39 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0056] Fig.40 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0057] Fig.41 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0058] Fig.42 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0059] Fig.43 An exploded view of a battery module according to an embodiment of the present invention is illustrated.

[0060] Fig.44 A battery module according to an embodiment of the present invention is described.

[0061] Fig.45 A battery module according to an embodiment of the present invention is described.

[0062] Fig.46 A battery module controller according to an embodiment of the present invention is described.

[0063] Fig.47 A battery system controller according to an embodiment of the present invention is described.

[0064] Fig.48 A 12 volt battery system according to an embodiment of the present invention is described.

[0065] Fig.49 A 24 volt battery system according to an embodiment of the present invention is described.

[0066] Fig.50 A 36 volt battery system according to an embodiment of the present invention is described.

[0067] Fig.51 A 48 volt battery system according to an embodiment of the present invention is described.

[0068] Fig.52 Various example vehicles that may be powered by a battery module according to the present invention are described.

[0069] Fig.53 Various example vehicles having auxiliary electrical systems that may be powered by a battery module according to the present invention are described.

[0070] Fig.54 Various example equipment that may be powered by a battery module according to the present invention is described. DETAILED DESCRIPTION

[0071] Embodiments will be described in more detail below with reference to the accompanying drawings. The following detailed description is provided to help the reader fully understand the methods, devices and / or systems described herein and modifications thereof. Therefore, various modifications and equivalents of the methods, devices and / or systems described herein will be apparent to those of ordinary skill in the art. Descriptions of well-known functions and configurations may be omitted for clarity and brevity.

[0072] Figure 1 An example battery module 100 according to an embodiment of the present invention is described. Figure 3A As more clearly shown in FIG. 1 , the battery module 100 includes several features that enhance fire safety and prevent battery fires.

[0073] Over time, battery cells within a battery module may become defective or damaged and begin to swell. This swelling is a good indicator of changes in the internal pressure of the cell and a good indicator that the cell may catch fire if the cell is not replaced. For example, swelling may be caused by changes in the electrolyte and other active materials within the battery cell resulting in the formation of flammable and explosive gases within the cell. Cell swelling occurs before the cell vents and / or catches fire.

[0074] As described herein, according to embodiments of the present invention, new expansion / pressure sensors are designed and installed on battery modules that can detect and quantify the amount of expansion / pressure in a battery cell. When expansion / pressure beyond normal aging and cycling variations is detected using firmware / software and data from the sensor, an alarm / warning is generated by the firmware / software so that action can be taken so that the battery cell with abnormal expansion / pressure can be replaced before cell venting or can develop to the point where a fire is likely to occur. The alarm / warning can also be used to automatically disconnect, for example, a battery or battery rack containing a battery cell with abnormal expansion / pressure so that the battery cell is not further charged or discharged and therefore further damaged, which can lead to battery cell venting and / or battery cell fire.

[0075] In one embodiment, as described in more detail below, by attaching one expansion / pressure sensor to a plate of a battery assembly or battery module, the sensor can be used to monitor several battery cells simultaneously. In another embodiment, the expansion / pressure sensor is attached directly to the battery cell. As described herein, detection of abnormal expansion / pressure in a battery cell can be used to shut down the battery system and make it safe until the problematic cell is replaced and the system is verified to ensure that it is safe to operate again.

[0076] Figure 2 Another view of the battery module 100 is illustrated. Figure 2 The front, one side, and bottom of the battery module 100 are shown.

[0077] Figure 3AAn exploded view of a battery module 100 is illustrated. As shown in FIG. 3 , the battery module 100 has a front cover 300 a and a rear cover 300 b. The battery module 100 includes battery cells 302 a and 302 b. These battery cells have a predetermined amount of pressure applied thereto using side plates 303 a to 303 c, side bars 304 a and 304 b, and springs 306. Applying a predetermined amount of pressure to the battery cell 302 can extend the cycle life of the battery cell 302. By applying this pressure using springs 306, the side plates 303 can still move freely due to the swelling / expansion of the battery cell 302. As described in more detail below, according to an embodiment of the present invention, the movement of the side plates 303 can be monitored and measured using sensors.

[0078] like Figure 3A , the battery module 100 also includes a base plate 308 , a center plate 310 , a top tray 312 and a cover 314 , battery module controller circuit boards 316 a and 316 b , a bus bar 318 , a sensor 320 , and a connector 322 .

[0079] In an embodiment, the battery module 100 includes 8 battery cells 302. However, the battery module 100 may include fewer or more battery cells, such as 2, 4, 6, 10, 12, 14, 16, etc. The battery cells 302 are used to store electrical energy. The 8 battery cells 302 can be connected in series using busbars 318. A predetermined amount of pressure is applied to the battery cells 302 using side panels 303, center panels 310, and side bars 304. The side panels 303 and center panels 310 also provide cooling for the battery cells 302. The top tray 312 fits on top of the battery cells 302 and provides several functions, including providing a protective space for the sensor 320 and the battery module controller circuit boards 316a and 316b. Other functions of the top tray 312 are described below. The cover 314 is mounted on the top of the top tray 312. For example, the front cover 300a and the rear cover 300b are used to lift and carry the battery module 100. The front cover 300a includes connectors 322 that allow several battery modules 100 to be easily wired together to form a larger battery system. A battery module controller circuit board, described in more detail below, provides battery management functions for the battery module 100, such as, for example, monitoring the voltage, temperature, and pressure of the battery cells 302.

[0080] Figure 3BFurther explanation of the top tray 312 and sensors 320a to 320d. In an embodiment, the top tray 312 includes four integrated expansion / pressure sensors 320a to 320d. In other embodiments, the sensors 320a to 320d are separate parts from the top tray 312. For example, integrating sensors according to the present invention into the tray can reduce manufacturing costs, processing costs, labor costs, etc. As shown and described below, the top tray 312 can be used to reduce the manufacturing costs, processing costs, labor costs, etc. Figure 3B Sensors other than those shown in .

[0081] In an embodiment, the top tray 312 has holes 330a and 330b for directing water (or other fluids) to the side plates 303 and the center plate 310 of the battery module 100 according to the present invention to cool the battery cells 302 in the event of a battery cell fire.

[0082] Figure 4 A battery module 400 according to an embodiment of the present invention is described. The battery module 400 is similar to the battery module 100, except that it has more battery cells 402 than the battery module 100. Figure 4 , the battery module 400 has two battery cells 402a and 402b between the side plate 302 and the center plate 310. Using different numbers of battery cells and / or different sizes of battery cells (e.g., 40AH, 50AH, 100AH, 200AH, 280AH, etc.) allows for battery modules that store different amounts of energy.

[0083] Figure 5 A battery module 500 according to an embodiment of the present invention is shown. The battery module 500 has a battery cell 502. Figure 5 , the battery cells 502 are separated using side plates 302a-302b and center plates 310a-310c. As will be appreciated by those skilled in the relevant art, battery cell configurations other than those described herein are possible and contemplated.

[0084] Fig. 6A An expansion / pressure sensor 602 that can be used with a battery module according to an embodiment of the present invention is illustrated. Fig. 6A6, in an embodiment, the sensor 602 has two plastic components 604a and 604b, two metal components 606a and 606b, and at least one strain gauge 608. At least one strain gauge is attached to the metal component 606. The strain gauge 608 can be attached using an adhesive or glue. The metal component 606 is inserted into the plastic component 604, which holds the metal component and is used to attach the sensor 602 to the battery module. When a force is applied to one or both of the plastic components 604, such as due to expansion of the battery cell, the metal component 606 bends and applies a force to the strain gauge 608. This change in the sensor 602 is described herein, for example, with respect to the following Fig. 10A Although components 604a-604b and 606a-606b are described as plastic and metal, respectively, other materials may be used. Throughout this disclosure, any component or assembly described as a particular material (eg, plastic or metal) may be constructed of other materials.

[0085] Figure 6B An expansion / pressure sensor 610 that may be used with a battery module in accordance with an embodiment of the present invention is illustrated. Sensor 610 is similar to sensor 602, except that strain gauge 608 is attached to the outer radius of metal component 606 rather than the inner radius.

[0086] Fig. 7A A sensor 702 according to an embodiment of the invention is illustrated. The sensor 702 has a single plastic component 704 and at least one strain gauge 706 attached to the inner radius of an elliptical center section of the plastic component 704. The strain gauge 706 may be attached using an adhesive or glue.

[0087] Figure 7B An expansion / pressure sensor 710 that may be used with a battery module in accordance with an embodiment of the present invention is illustrated. Sensor 710 is similar to sensor 702, except that strain gauge 706 is attached to the outer radius of plastic component 704, rather than the inner radius.

[0088] Figure 7C A sensor 730 according to an embodiment of the present invention is illustrated. The sensor 730 has a plastic component 732 and two strain gauges 734 attached to a central circular or elliptical section. The two strain gauges are connected together in series by wires 736. The wires 736 are then connected to a monitoring circuit, such as described below with respect to Fig. 10A to Q describes the monitoring circuit.

[0089] According to the present invention, the expansion / pressure of the battery cells may be monitored using sensors other than sensors 602, 610, 702, 710, and 730. For a description of several more sensors that may be used, see U.S. Patent Application No. 17 / 691,948, which is incorporated herein by reference in its entirety.

[0090] Figure 8 An example battery module controller 800 according to an embodiment of the present invention is described. Figure 8 8, the battery module controller 800 includes two battery module controller circuit boards 316a and 316b connected together by a ribbon cable 802. In an embodiment, the battery module controller circuit board 316a includes a power supply 804 and control and monitoring circuits 806. The battery module controller circuit board 316b includes monitoring circuits 808. The battery module controller circuit boards 316a-316b are shown mounted on the battery module 100 with the cover 314 removed, according to an embodiment of the invention.

[0091] Fig. 9A The example battery module controller 800 is further described. Fig. 9A 8, in addition to the power supply 804, the battery module controller 800 also includes a microcontroller unit (MCU) 900, a cell voltage monitor 902, a cell temperature monitor 904, a cell pressure monitor 906, a cell balancing controller 908, a balancing transformer 910, and a balancing rectifier 912. In an embodiment, the MCU 900 communicates with a higher-level controller using a CANBus communication circuit 914. The CANBus communication circuit is connected to the higher-level controller using a connector 916. In an embodiment, the higher-level controller is a battery rack controller described herein.

[0092] In operation, the power supply 804 draws power from the grid and converts this power into the higher frequency AC power and DC voltage required to operate the components of the battery module controller 800. The higher frequency AC power output by the power supply 804 is supplied to the cell balancing transformer 910 and the balancing rectifier 912 for balancing the cells 918. The power supply 804 generates the DC power required to operate the various components of the battery module controller 800, such as, for example, the MCU 900, the cell voltage monitor 902, the cell temperature monitor 904, the cell pressure monitor 906, and the cell balancing controller 908. The MCU 900 runs firmware and software that controls the operation and functions of the battery module controller 800. These functions include monitoring the voltage, temperature, and pressure of the battery cells that make up the battery modules controlled by the battery module controller 800. Functions also include balancing the battery cells of the battery modules and communicating data about the battery modules and battery cells to a higher level controller, such as, for example, the battery rack controller described below. The cell voltage monitor 902, cell temperature monitor 904, and cell pressure monitor 906 are the hardware sensors and circuits required to monitor battery cell voltage, temperature, and pressure. The cell balancing controller 908 is the hardware required to provide balancing current / power to the individual battery cells 918 of the battery module controlled by the battery module controller 800. More details on these functions and associated hardware are provided below.

[0093] Fig. 9B An example power supply 804 that may be used with a battery module controller according to an embodiment of the present invention is further described. Fig. 9B 8, power supply 804 includes connector 850, electromagnetic interference (EMI) filter 852, rectifier 854, quasi-resonant power processor 856, isolation transformers 858 and 860, regulated 5V power supply circuit 862, regulated 12V power supply circuit 864, and one or more DC to DC 6V power converter circuits 866 for battery cell balancing. In an embodiment, isolation transformers 858 and 860 can be multiple windings on the same transformer core. Power supply 804 is connected to grid power using connector 850. In one embodiment, quasi-resonant power processor 856 is implemented using 5QR1680AG integrated circuit chip from Infineon Technologies.

[0094] Fig.10 and 10A 1 to 4 illustrate a detailed circuit diagram of the battery module controller 800 according to an embodiment of the present invention. Fig. 10AAs shown in Figure 1, in an embodiment, two converters each drive a transformer that each creates 4 isolated outputs. These 8 outputs are used with a constant current circuit to charge the battery cells in the battery module. The temperature of each of the battery cells is monitored. The circuit is controlled by a microprocessor and communicates with a higher level controller using CANBus communication. The microprocessor also measures the voltage across each battery cell. The controller also includes circuitry to measure the expansion / pressure of the battery cells.

[0095] Fig.11 and 11A Detailed circuit diagrams of the power supply 804 according to an embodiment of the present invention are shown in FIG. Fig.11A As shown in Figure D, the power supply 804 includes a universal 100V to 240V, 50Hz / 60Hz input with circuits to limit EMI and inrush current. It also includes an offline quasi-resonant switch mode power supply. AC power is supplied to the connector and passes through fuses and EMI filters. The input voltage is then rectified and stored on capacitors. The power supply controller causes energy to be stored as magnetic flux in the transformer, where it is intermittently removed by two isolation output diodes. In an embodiment, the power supply circuit produces +5V and +12V that are dielectrically isolated from each other and from the input. Optocouplers are used to sense and regulate the output voltage.

[0096] Fig.12 An example connector of a battery module controller according to an embodiment of the present invention is described. In an embodiment, for example, it can be as follows Figure 8 As seen in FIG. 31 , circuitry on circuit board 316b is generally used to connect circuitry on circuit board 316a.

[0097] Fig.13 An example battery module controller graphical user interface (GUI) 1300 is illustrated in accordance with an embodiment of the invention. The values ​​displayed on the GUI 1300 illustrate the firmware and / or software running on a battery module controller described herein (such as, for example, the battery module controller 800).

[0098] Starting from the upper left corner of the GUI 1300, the GUI displays the unique ID of the battery module controller (BMC UID) and the node ID. In an embodiment, the unique ID is the serial number of the processor of the battery module controller. The node ID is an assigned ID used to identify the battery module controller CANBus messages sent to a higher-level battery rack or battery system controller.

[0099] Below the identification fields in the GUI 1300 are fields that display the battery cell voltage, battery cell temperature, and battery cell balance status. In an embodiment, the cell voltage is displayed in millivolts. The cell temperature is displayed in tenths of a degree Celsius. The balance status is on or off, with on meaning that the cell is currently balanced and off meaning that the cell is currently unbalanced. Below these fields are the cell high, average, and low voltage and temperature fields. In order to reduce the number of messages that would normally be sent by the battery module controller to a higher level controller, in an embodiment, the battery module controller sends these calculated values ​​rather than measured values. These calculated values ​​are sufficient to safely monitor and manage the battery cells. Fields for the following are also displayed: maximum cell voltage and temperature; average cell voltage and temperature; minimum cell voltage and temperature; the difference between the maximum cell voltage and cell temperature and the minimum cell voltage and cell temperature, respectively.

[0100] In the top middle section of the GUI 1300, two fields display the number of messages received by the battery module controller and the number of messages sent by the battery module controller. These displayed message counts show that the battery module controller is active and communicating.

[0101] Below the message count field is the Swelling / Pressure (S / P) meter value and meter calibration value. The S / P meter value is used to determine if any of the battery cells have a problem and therefore indicate if the battery module should be disconnected from the battery system DC bus to prevent a battery fire. The battery cells will swell, for example due to the liquid electrolyte in the battery cells decomposing into explosive and dangerous gases before they vent and catch fire. Therefore, in an embodiment of the present invention, the battery management system continuously monitors each battery module for swelling and / or the presence of increased pressure in one or more cells of the battery module, and when this is detected, the battery module is disconnected from the battery system so that it can no longer be charged and / or discharged in order to prevent further damage to the battery cells and prevent battery fires.

[0102] For example, refer to Fig. 10A As described to Q, in an embodiment of the present invention, one or more calibration resistors are measured and used to calibrate the S / P meter values ​​obtained by the battery module controller. These calibration measurements ensure the accuracy of the S / P meter values ​​used to monitor battery cell expansion or the presence of increased pressure in one or more cells of the battery module. The last field in the middle section of the GUI 1300 shows the highest S / P meter reading; the average S / P meter reading; the lowest S / P meter reading; and the difference between the highest S / P meter reading and the lowest S / P meter reading.

[0103] The date and time of the last data received from the battery module controller is displayed on the upper right side of the GUI 1300. This date and time will continue to update and indicate how long the data has been displayed on the GUI.

[0104] Below the date and time values ​​are several fields that display control values ​​and status values. The control values ​​include a balance target value, a balance control value, an S / P meter limit value, a cell voltage difference limit value, a target cell voltage difference limit value, and a cell temperature difference limit value. The balance target value is a value used by the battery module controller to control the balancing of the battery cells. The balance control value indicates whether the battery cell balancing is enabled or disabled. The three limit values ​​(i.e., the S / P meter limit, the cell delta-voltage limit, and the cell delta-temperature limit) are used to determine whether the battery module is operating under safe and expected conditions. The module status value gives a quick indication of the overall operating status of the battery module (e.g., "green" indicates that the battery module is operating correctly, "yellow" indicates that the battery module has a minor operating problem, and "red" indicates that the battery module has a serious operating problem), and the module error field will display an error code to indicate whether there are any current problems with the battery module.

[0105] Fig.14A 1400 according to an embodiment of the present invention. Fig.14A , the battery rack controller 1400 includes four DC power connectors 1402a to 1402d, two AC power connectors 1404a to 1404b, two system-level communication connectors 1406a to 1406b, two battery module communication connectors 1408a to 1408b, a status indicator 1410, and a power switch 1412. The battery rack controller 1400 can control multiple battery modules, such as Fig.16 and Fig.18A To the battery module 100 shown in C and described below.

[0106] The DC power connectors 1402a to 1402d are used to connect the battery modules of the battery rack to the DC bus of the battery energy storage system. In an embodiment, the DC power connectors 1402a and 1402c connect the battery rack controller 1400 to the energy storage system DC bus. The power connectors 1402b and 1402d connect the battery rack controller 1400 to the battery modules that make up the battery rack. The AC grid power is provided to the battery rack controller 1400 using the AC power connector 1404a. This power is then provided to the battery modules using the AC power connector 1404b.

[0107] System level communication connectors 1406a to 1406b are used to communicate with a higher level energy storage system controller. In an embodiment, these communications are implemented using TCP / IP communications. Battery module communication connectors 1408a to 1408b are used to communicate with battery modules of a battery rack. In an embodiment, these communications are implemented using CANBus communications. In one embodiment, CANopen communications are used.

[0108] In the embodiment of the battery rack controller 1400, when powered on, the status indicator 1410 shows the status of the battery rack, for example, a green light indicating that everything is operating correctly or a yellow or red light indicating that the battery rack has a minor or major operating problem. The power switch 1412 is used to turn the power of the battery rack controller 1400 on and off.

[0109] Fig. 14B The battery rack controller 1400 according to an embodiment of the present invention is further described. Fig. 14B , the battery rack controller 1400 includes a battery rack controller circuit board 1420, an ammeter 1422, two voltmeters 1424a to 1424b, three contactors 1426a to 1426c, a power resistor 1428, and two fuses 1430a to 1430b. The battery rack controller circuit board 1420 includes a microcontroller unit that runs firmware and / or software that implements the functions of the battery rack controller 1400. These functions include measuring battery rack current, battery rack voltage, and data communication with the battery module controller and the battery energy storage system controller. In operation, the battery rack controller circuit board 1420 opens and closes the contactor 1426 to connect the battery module to the battery system DC bus. The contactor 1426a and the power resistor 1428 are used to pre-charge and match the voltage of the battery rack to the DC system bus before the contactor 1426b is closed. If an abnormal current or abnormal voltage is detected by the current meter 1422 or one of the two voltage meters 1424a to 1424b during operation, the battery rack controller circuit board 1420 opens the contactor 1426 to isolate the battery rack from the DC system bus until the abnormal condition is corrected. In the event of a short circuit or other over-current problem, fuses 1430a to 1430b are included. In an embodiment, fuse 1430 is a very fast acting fuse.

[0110] like Fig. 14B , the battery rack controller 1400 includes a power supply 1432 to power the components of the battery rack controller 1420. The power of this power supply is grid power. The relay 1434 controlled by the battery rack controller circuit board 1420 controls the supply of grid power to the battery modules of the battery rack. In an embodiment, if necessary, the opening and closing of the relay 1434 can be used to reset the battery module controllers of the battery modules constituting the battery rack.

[0111] Fig.15A 1 to 3 illustrate an example battery rack 1500 according to an embodiment of the present invention. Fig.15A1, the battery rack 1500 includes a base 1502, doors 1504a-1504b, a hood 1506, a water suppression system 1508, and an exhaust duct 1510. The base 1502 can be used to move and position the battery rack 1500, for example using a forklift. The doors 1504a-1504b allow access to the battery modules and battery module controllers housed within the battery rack housing. The hood 1506 provides space for the fire extinguishing system sprinkler at the top of the battery rack. The exhaust duct 1510 is used to draw air through the batteries and cool the battery modules. It is also used to direct heat and any gases, such as in the case of battery cell exhaust, to the outside of the container or room where the battery rack is located. In an embodiment, the fan used to move air through the battery rack is located in the exhaust duct 1510, which makes it easier to replace the fan and is a better design than including many small fans in a housing that is part of, for example, the battery module.

[0112] like Fig. 15B 1500. In the example of FIG. 1500, one or more sprinklers 1520 are positioned within the battery rack 1500. In the event of a fire, the sprinklers activate and spray water directly within the battery rack 1500. This water is collected by the top tray of the battery modules, and the water is then directed to flow down through the center plate of the battery modules and onto the side plates of the battery modules to extinguish the fire and cool the surrounding battery modules so that the fire does not spread to other modules and the problematic module does not catch fire again. If the battery is to vent and possibly catch fire, the heat and gases will be removed from the battery rack via the exhaust duct 1510.

[0113] Fig.16 An example battery rack 1600 according to an embodiment of the present invention is described. Fig.16 16, the battery rack 1600 includes a base 1602, a door 1604, a hood 1606, a water suppression system 1608, and an exhaust duct 1610. The base 1602 can be used to move and position the battery rack 1600, for example using a forklift. The door 1604 allows access to the battery modules 100 and the battery module controller 1400 housed within the battery rack housing. The hood 1606 provides space for the fire extinguishing system sprinkler head at the top of the battery rack. The exhaust duct 1610 is used to draw air through the battery rack and cool the battery modules. It is also used to direct heat and any gases, such as in the case of battery cell exhaust, to the outside of the container or room where the battery rack is located. In an embodiment, the fan used to move air through the battery rack is located in the exhaust duct 1610, which makes it easier to replace the fan and is a better design than including many small fans in a housing that is part of, for example, the battery module 100.

[0114] Battery rack 1600 and other battery racks described herein allow water (or other fluid) to be supplied from a commercial fire sprinkler system (e.g., see Fig.19) cascades down onto the battery module 100 to provide cooling and fire suppression. The water flows down to the top of the battery module where it is collected / gathered by the plastic top with berms positioned on the top of the battery module. This water flows down through the middle plate and onto the side plates or heat sinks of each of the battery modules or battery cell assemblies and cools the battery cells. As the water leaves the middle plate, it is collected / gathered by the battery modules below and may then flow through the middle plate of this battery module and onto the side plates as described herein.

[0115] Fig.17A 1 to 3 illustrate an example battery rack 1700 according to an embodiment of the present invention. Fig.17A , the battery rack 1700 includes a base 1702, a door 1704, a hood 1706, a water suppression system 1708, and an exhaust duct 1710. The base 1702 can be used to move and position the battery rack 1700, for example using a forklift. The door 1704 allows access to the battery modules 100 housed within the battery rack housing. The hood 1706 provides space for the fire extinguishing system sprinkler at the top of the battery rack. The exhaust duct 1710 is used to draw air through the battery rack and cool the battery modules. It is also used to direct heat and any gases, such as in the case of battery cell exhaust, to the outside of the container or room where the battery rack is located. In an embodiment, a fan for moving air through the battery rack is positioned in the exhaust duct 1710.

[0116] Fig. 17B is a more detailed diagram of the battery rack 1700. Fig. 17B , the battery modules 100 and the bus bars 1730a to 1730c and cables 1740a to 1740b used to connect the battery modules 100 together to form a battery rack can be more clearly seen.

[0117] Fig.18A 1 to 3 illustrate example battery rack products or units according to embodiments of the present invention. Fig.18A A battery rack 1600 is shown that can be used as part of a battery energy storage system. In an embodiment, this battery rack includes 15 battery modules 100 according to the present invention and forms a nominal 440V battery energy storage system. Fig.18B A battery rack product is shown including one battery rack 1600 and one battery rack 1700 that can be used as part of a battery energy storage system. In an embodiment, this battery rack product includes 33 battery modules 100 according to the present invention and forms a nominal 1000V battery energy storage system. Fig. 18CA battery rack product is shown that includes one battery rack 1600 and two battery racks 1700a to 1700b that can be used as part of a battery energy storage system. In an embodiment, this battery rack product includes 51 battery modules 100 according to the present invention and forms a nominal 1500V battery energy storage system. In practice, a battery energy storage system can be very large and formed by operating many of these battery rack products together in parallel.

[0118] Fig.19 The following further describes an example fire extinguishing system for a battery rack according to an embodiment of the present invention. Fig.19 , the battery rack 1900 has a water fire suppression system with sprinklers 1902 that allow water to cascade down from a commercial fire sprinkler system onto the battery modules 100 within the battery rack housing to provide cooling and fire suppression. The water flows down to the top of the battery module 100 where it is collected / gathered by a plastic top with a berm positioned on top of the battery module. This water flows down through the middle plate and onto the side plates or heat sinks of each of the battery modules or battery cell assemblies and cools the battery cells. As the water leaves the middle plate, it is collected / gathered by another battery module 100 below and may then flow through the middle plate of this battery module and onto the side plates as described herein.

[0119] Fig. 20 An example container system 2000 for housing battery racks forming a battery energy storage system according to the present invention is illustrated. The container system houses a plurality of battery racks and protects the battery racks from environmental influences. In an embodiment, the container system 2000 includes an HVAC unit 2002.

[0120] Fig.21 The battery storage system 2100 is illustrated as a plurality of containers 2102 for accommodating battery racks according to the present invention. In addition to the containers 2102 , the battery storage system 2100 further includes a plurality of bidirectional power converters 2104 for charging and discharging the battery racks accommodated in the containers 2102 .

[0121] Fig. 22 A building 2200 is illustrated for housing a number of battery racks forming a battery energy storage system according to the present invention.

[0122] Fig.23 A battery module 2300 according to an embodiment of the present invention is described. Fig.2323, the battery module 2300 includes a metal battery housing 2302, a plastic side cover 2304, and a plastic top cover 2306. The battery module 2300 has two battery terminals 2308 and 2310 and a connector 2312 that allows connection to conductors of battery cells coupled to the battery module 2300. Also shown are electrical leads 2314 for an optional heating element of the battery module 2300. In an embodiment, the battery module 2300 has 4 battery cells. Other embodiments may have more or less than 4 battery cells.

[0123] Fig.24 Side and top views of a battery module 2300 are illustrated according to an embodiment of the present invention.

[0124] Fig.25 A battery module 2500 according to an embodiment of the present invention is described. The battery module 2500 includes a side plate 2502 having mounting holes 2504a and 2504b. These mounting holes can be used to fix the battery module 2500, for example, when it is referred to below. Figures 52 to 54 When used as part of a larger battery rack or battery system in the applications described.

[0125] Fig.26 Side and top views of a battery module 2500 are illustrated according to an embodiment of the present invention.

[0126] Fig. 27 A battery module 2700 according to an embodiment of the present invention is illustrated. The battery module 2700 includes a base plate 2702 having mounting holes 2704a and 2704b. These mounting holes can be used to fix the battery module 2700, for example, when it is referred to below. Figures 52 to 54 When used as part of a larger battery rack or battery system in the applications described.

[0127] Fig.28 Side and bottom views of a battery module 2700 are illustrated according to an embodiment of the present invention.

[0128] Fig.29 A battery module 2900 according to an embodiment of the present invention is described. Fig.29 , battery module 2900 includes side plates 2902a and 2902b, bottom plate 2904, and end plates 2905a and 2905b. Plastic end cap 2907 is shown covering end plate 2905a. Battery module 2900 also includes four battery cells 2908a to 2908d. Pressure assembly 2910 is positioned between battery cells 2908b and 2908c. Two pressure / expansion sensors 2912a and 2912b and mounting holes 2906a and 2906b are also shown.

[0129] In an embodiment, when one or more battery cells 2908a to 2908d expand or their internal pressure increases, pressure is applied to pressure assembly 2910, which is then detected by one or both of expansion / pressure sensors 2912a to 2912b. Various embodiments of pressure assembly 2910 are described below, which can be used with battery module 2900 and other battery modules according to the present invention described herein.

[0130] Fig.30 A battery module 3000 is illustrated according to an embodiment of the invention. The battery module 3000 includes a pressure assembly 3002 and a single expansion / pressure sensor 3004. In an embodiment, when one or more of the battery cells 3006a-3006d expand or their internal pressure increases, pressure is applied to the pressure assembly 3002, which is then detected by the expansion / pressure sensor 3004.

[0131] Fig.31 A battery module 3100 is illustrated according to an embodiment of the invention. The battery module 3100 includes a pressure assembly 3102 and a single expansion / pressure sensor 3104. In an embodiment, when one or more of the battery cells 3106a-3106d expand or their internal pressure increases, pressure is applied to the pressure assembly 3102, which is then detected by the expansion / pressure sensor 3104.

[0132] Fig.32 A battery module 3200 is illustrated according to an embodiment of the invention. The battery module 3200 includes a pressure assembly 3202 and a single expansion / pressure sensor 3204. In an embodiment, when one or more of the battery cells 3206a-3206d expand or their internal pressure increases, pressure is applied to the pressure assembly 3202 and is detected by the expansion / pressure sensor 3204.

[0133] Fig.33 A battery module 3300 is illustrated according to an embodiment of the invention. The battery module 3300 includes a pressure assembly 3302 and one or more expansion / pressure sensors 3304. The expansion / pressure sensors 3304 are positioned within the pressure assembly 3302, such as the following: Fig.39 In an embodiment, when one or more of the battery cells 3306a to 3306d expand or its internal pressure increases, pressure is applied to the pressure assembly 3302, which is then detected by the expansion / pressure sensor 3304.

[0134] Fig.34AAn exploded view of a battery module 3400 according to an embodiment of the invention is illustrated. The battery module 3400 includes a pressure assembly 3402, which includes two plates 3404a and 3404b and mold springs 3406a-3406c. In one embodiment, the pressure assembly 3402 has 4 mold springs 3406. In other embodiments, the pressure assembly 3402 has more or less than 4 mold springs 3406. When pressure is applied to one or both of the plates 3404, the mold springs 3406 allow one or both of the plates 3404 to move. This movement can then be detected using the expansion / pressure sensor described herein.

[0135] like Fig.34A 34, the battery module 3400 also includes two side plates 3408a and 3408b, a bottom plate 3410, and two end plates 3412a and 3412b. As shown, the battery module 3400 includes four battery cells 3414a to 3414d. The battery management circuit board 3420 is coupled to the end plate 3412b. The battery management circuit board 3420 includes the same as described herein, for example, with reference to Figures 10A to 10Q The circuit described is similar to the circuit.

[0136] like Fig.34B , in an embodiment of the invention, a pressure assembly, such as pressure assembly 3402 of battery module 3400, has a plate inhibitor 3440 that inhibits movement of the bottom of the plate while the top of the plate is still movable, thereby causing the plate to tilt and thus amplifying movement of the top of the plate for a given amount of battery expansion. In an embodiment, plate inhibitor 3440 includes two tabs 3440a and 3440b, such as Fig.34B The tabs 3440a-3440b may be formed by cutting, for example, the bottom plate 3410 of the battery module 3400 and bending the metal upward as shown to form the tabs 3440a-3440b. In embodiments, the plate inhibitor 3440 has more or less than two tabs.

[0137] like Fig.34B , in addition to the plate inhibitor 3440, the pressure assembly 3402 also has two plates 3404a-3404b, four mold springs 3406, and an expansion / pressure sensor 3445. When the battery cell expands, it causes the plates 3404a-3404b to apply pressure to the expansion / pressure sensor 3445, which can be detected as described herein.

[0138] Fig.34C The pressure assembly 3402 and the tabs 3440a-3440b of the plate inhibitor 3440 are further illustrated. Fig.34C, it can be seen how the tabs 3440a to 3440b inhibit movement of the bottom of the plates 3404a to 3404b and amplify movement of the top of one or both of the plates 3404a to 3404b.

[0139] Fig.34D Another plate inhibitor 3460 of a pressure assembly (such as pressure assembly 3402) is illustrated. In one embodiment, as Fig.34D , the plate inhibitor 3460 is a block that restricts the movement of one or more plates 3404a-3404b when the battery cell expands and causes pressure to be applied to one or more plates 3404a-3404b. Specifically, as shown in FIG. Fig.34D , while the top of the plate is still movable, the movement of the bottom of the plate is inhibited, causing the plate to tilt and thus amplifying the movement of the top of the plate for a given amount of battery expansion. In embodiments, other shapes besides squares are used to inhibit movement of the plate, such as, for example, triangular shapes, circular shapes, and rectangular shapes. Plate inhibitor 3460 may be attached to one of plates 3404a-3404b or to the bottom plate 3410 of a battery module such as battery module 3400 (see Fig.34A ).

[0140] Fig.34E The pressure assembly 3402 and the plate suppressor 3460 are further described. Fig.34E , it can be seen how plate inhibitor 3460 inhibits movement of the bottom of plates 3404a to 3404b and amplifies movement of the top of one or both of plates 3404.

[0141] As will be understood by those skilled in the relevant art, Fig.34B Devices and methods other than those shown in FIG. 5E may be used to produce the same effect as plate suppressors 3440 and 3460 .

[0142] Fig.35 An exploded view of a battery module 3500 according to an embodiment of the present invention is illustrated. The battery module 3500 includes a pressure assembly 3502, which includes two plates 3504a and 3504b and leaf springs 3506a to 3506d. In one embodiment, the pressure assembly 3502 has 4 leaf springs 3506. In other embodiments, the pressure assembly 3502 has more or less than 4 leaf springs 3506. When pressure is applied to one or both of the plates 3504, the leaf springs 3506 allow one or both of the plates 3504 to move. This movement can then be detected using the expansion / pressure sensor described herein.

[0143] like Fig.35As described in the specification, the battery module 3500 also includes a battery management circuit board 3520. The battery management circuit board 3520 includes the same as described in the present invention. Figures 10A to 10Q The battery module 3500 may include four battery cells 3508a to 3508d.

[0144] Fig.36 An exploded view of a battery module 3600 is illustrated in accordance with an embodiment of the present invention. The battery module 3600 includes a pressure assembly 3602 that includes two plates 3604a and 3604b and a die spring 3606. In one embodiment, the pressure assembly 3602 has four die springs 3606. In other embodiments, the pressure assembly 3602 has more or less than four die springs 3606. When pressure is applied to one or both of the plates 3604, the die spring 3606 allows one or both of the plates 3604 to move. This movement can then be detected using an expansion / pressure sensor 3612. A battery management circuit board 3620 is also included in the battery module 3600.

[0145] like Fig.36 , in an embodiment, the battery module 3600 includes an optional heating film or pad 3610. Heating the battery module 3600 enables it to be used in cool environments, such as, for example, a forklift in a food storage warehouse.

[0146] Fig.37 An exploded view of a battery module 3700 according to an embodiment of the present invention is illustrated. The battery module 3700 includes a pressure assembly 3702, which includes two plates 3704a and 3704b and a die spring 3706. In one embodiment, the pressure assembly 3702 has four die springs 3706. In other embodiments, the pressure assembly 3702 has more or less than four die springs 3706. When pressure is applied to one or both of the plates 3704, the die spring 3706 allows one or both of the plates 3704 to move. This movement can then be detected using an expansion / pressure sensor 3712 that can be disposed between the plates 3704 and at a location within the perimeter of the plates 3704. A battery management circuit board 3720 is also included in the battery module 3700.

[0147] Fig.38 An exploded view of a battery module 3800 according to an embodiment of the present invention is illustrated. Battery module 3800 is similar to battery module 3700, except that pressure assembly 3702 is relocated from the middle of the four battery cells to one end of battery module 3800. Fig.38 As shown in FIG. 37 , the pressure assembly 3702 includes an expansion / pressure sensor 3712. The battery module 3800 also includes a battery management circuit board 3720.

[0148] Fig.39 An exploded view of a battery module 3900 according to an embodiment of the present invention is illustrated. The battery module 3900 includes a pressure assembly 3902, which includes two plates 3904a and 3904b and leaf springs 3906 (e.g., leaf springs 3906a-3906b). In one embodiment, the pressure assembly 3902 has 4 leaf springs 3906. In other embodiments, the pressure assembly 3902 has more or less than 4 leaf springs 3906. When pressure is applied to one or both of the plates 3904, the leaf springs 3906 allow one or both of the plates 3904 to move. This movement can then be detected using an expansion / pressure sensor described herein. In one embodiment, the expansion / pressure sensor is one or more leaf springs 3906 with a strain gauge 3907.

[0149] like Fig.39 3900, the battery module 3900 also includes two side plates 3908a and 3908b, a bottom plate 3910, and two end plates 3912a and 3912b. As shown, the battery module 3900 includes four battery cells 3914a to 3914d, end plates 3912a to 3912b, and a bottom plate 3910. A battery management circuit board 3920 is coupled to the end plate 3912b. The battery management circuit board 3920 includes the same components as described herein, for example, with reference to Figures 10A to 10Q The circuit described is similar to the circuit.

[0150] Fig.40 An exploded view of a battery module 4000 according to an embodiment of the present invention is illustrated. Battery module 4000 is similar to battery module 3900 except that it has two expansion / pressure sensors 4002a and 4002b to detect expansion of battery cells 4004a to 4004d or increased internal pressure of battery cells 4004a to 4004d. Battery module 4000 also includes a battery management circuit board 4020.

[0151] Fig.41 An exploded view of a battery module 4100 according to an embodiment of the present invention is illustrated. The battery module 4100 includes a pressure assembly 4102 at one end of the battery module 4100. As shown, the pressure assembly 4102 includes two plates 4104a and 4104b. It also includes a leaf spring 4106 and an expansion / pressure sensor 4110. A battery management circuit board 4120 is attached to the end plate 4122.

[0152] Fig.42An exploded view of a battery module according to an embodiment of the invention is illustrated. The battery module 4200 includes a pressure assembly 4202 at one end of the battery module 4200. As shown, the pressure assembly 4202 includes two plates 4204a and 4204b. It also includes a leaf spring 4206 and an expansion / pressure sensor 4210. The expansion / pressure sensor 4210 can be disposed between the plates 4204a-4204b at a location within the perimeter of the plates 4204a-4204b. A battery management circuit board 4220 is attached to the end plate 4222.

[0153] Fig.43 An exploded view of a battery module 4300 according to an embodiment of the present invention is illustrated. The battery module 4300 includes a pressure assembly 4302 at one end of the battery module 4300. As shown, the pressure assembly 4302 includes two plates 4304a and 4304b. It also includes leaf springs 4306, such as leaf springs 4306a and 4306b. Leaf spring 4306a includes a strain gauge 4309 attached thereto. In an embodiment, more than one leaf spring 4306 with a strain gauge 4309 is included in the pressure assembly 4302, such as 4 leaf springs. A battery management circuit board 4320 is attached to the end plate 4322.

[0154] Fig.44 A battery module 4400 according to an embodiment of the present invention is described. Fig.44 As shown in FIG. 4 , battery module 4400 includes four battery cells 4402a to 4402d and two pressure assemblies 4404a and 4404b. Pressure assembly 4404 is similar to the pressure assemblies described above with respect to other battery modules according to the present invention. Fig.44 Arranging the battery cells 4402 as shown in FIG. 44 makes the width of the battery module 4400 smaller, making it adaptable to applications where arranging the battery cells differently would make the module too wide.

[0155] Fig.45 4400 according to an embodiment of the present invention. Fig.45 4, the battery module 4400 also includes two side plates 4406a-4406b, two end plates 4408a-4408b, and a bottom plate 4410. In an embodiment, each pressure assembly 4404 includes two plates 4412, a leaf spring 4414, and an expansion / pressure sensor 4416. In other embodiments of the invention, the pressure assemblies use the mold springs described herein and / or other types of expansion / pressure sensors.

[0156] Fig.46A battery management circuit board 4600 according to an embodiment of the present invention is described. In an embodiment, the battery management circuit board 4600 includes a power supply 4603, a microcontroller unit (MCU) 4601, a cell voltage monitor 4602, a cell temperature monitor 4604, a cell pressure monitor 4606, a cell balancing controller 4608, a balancing transformer 4610, and a balancing rectifier 4612. In an embodiment, the MCU 4601 communicates with a higher-level controller using a CANBus communication circuit 4614. The CANBus communication circuit is connected to the higher-level controller using a connector 4616. In an embodiment, the higher-level controller is referred to herein as Fig.47 A battery system controller is described.

[0157] In operation, the power supply 4603 draws power from the grid, the battery cells of the battery module, or both, and converts this power into the AC power and DC voltage required to operate the components of the battery module controller 4600. The AC power output by the power supply 4604 is supplied to the cell balancing transformer 4610 and the balancing rectifier 4612 for balancing the cells 4618. The power supply 4604 generates the DC power required to operate the various components of the battery management circuit board 4600, such as, for example, the MCU 4601, the cell voltage monitor 4602, the cell temperature monitor 4604, the cell pressure monitor 4606, and the cell balancing controller 4608. The MCU 4601 runs firmware and software that controls the operation and functions of the battery management circuit board 4600. These functions include monitoring the voltage, temperature, and pressure of the battery cells that make up the battery module controlled by the battery management circuit board 4600. Functions also include balancing the battery cells of the battery module and communicating data about the battery modules and battery cells to a higher-level controller, such as, for example, the battery system controller described below. The cell voltage monitor 4602, cell temperature monitor 4604, and cell pressure monitor 4606 are the hardware sensors and circuits required to monitor the battery cell voltage, temperature, and pressure. The cell balancing controller 4608 is the hardware required to provide balancing current / power to the individual battery cells 4618 of the battery module controlled by the battery management circuit board 4600. More details on these functions and associated hardware are provided above, for example with reference to Figures 10A to 10Q As will be appreciated by those skilled in the relevant art, hardware other than that described herein may be used to monitor the voltage and temperature of battery cells and balance the battery cells of a battery module according to the present invention.

[0158] Fig.47A battery system controller 4700 according to an embodiment of the present invention is illustrated. The battery system controller includes a power supply 4701, an MCU 4702, CANBus communication 4704, and wireless communication 4708. In an embodiment, the MCU 4702 uses the CANBus communication 4704 to exchange messages and data with one or more battery modules described herein. In an embodiment, this data is communicated with Fig.13 1300. The battery module CANBus communications are coupled to the CANBus communications 4704 of the battery system controller using connector 4706. The MCU 4702 uses wireless communications 4708 to talk to higher level software (e.g., a monitoring or control computer). In an embodiment, the wireless communications use TCP / IP. The battery system controller 4700 also includes an optional USB 4710 that can be used to connect to a laptop computer, for example, during maintenance and / or testing or when programming the MCU 4702 or when changing software and / or firmware settings.

[0159] In an embodiment, the battery system controller 4700 also includes a current measurement circuit 4712, a voltage measurement circuit 4713, a contactor 4714, and a fuse 4716. The current measurement circuit is used to monitor the charging and discharging current of the controlled battery module. The voltage measurement circuit 4713 is used to monitor the voltage of the battery module controlled by the battery system controller 4700. The contactor controlled by the MCU 4702 can be closed to allow the connected battery module to be charged and discharged, or disconnected to prevent the connected battery module from being charged and discharged. The fuse is used for short circuit protection and disconnects the battery module if the contactor is not disconnected during a short circuit. In an embodiment, if there is an overcurrent event, an overvoltage time, or an undervoltage event, the MCU 4702 disconnects the contactor 4714. The outputs of the current measurement circuit 4712 and the voltage measurement circuit 4713 can be multiplied together to obtain power, and power is also monitored in an embodiment of the present invention.

[0160] In an embodiment, the battery management circuit boards of the various battery modules described herein send warning messages and alarm messages to the battery system controller 4700, and when these warnings and alarms are received, the battery system controller 4700 will take action to respond to the warnings and alarms, such as, for example, sending a message to the connected charger to stop charging or disconnecting the contactor 4714 to prevent the connected battery module from overcharging or over-discharging.

[0161] Fig.48 A 12 volt battery system 4800 is illustrated according to an embodiment of the present invention. The battery system 4800 includes one or more battery modules 4802. If there is more than one battery module 4802, the battery modules are connected in parallel.

[0162] Fig.49 A 24 volt battery system 4900 according to an embodiment of the present invention is illustrated. The battery system 4900 includes at least two battery modules 4902a and 4902b. The two battery modules are connected in series. In an embodiment, the battery system 4900 includes an additional set of 2 battery modules 4902 connected in parallel. Fig.49 Two battery modules are shown in Figure 1.

[0163] Fig.50 A 36 volt battery system 5000 according to an embodiment of the present invention is illustrated. The battery system 5000 includes at least three battery modules 5002a, 5002b, and 5002c. The three battery modules are connected in series. In an embodiment, the battery system 5000 includes an additional set of three battery modules 5002 connected in parallel. Fig.50 The three battery modules are shown in Figure 1.

[0164] Fig.51 A 48 volt battery system 5100 according to an embodiment of the present invention is described. The battery system 5100 includes at least four battery modules 5102a, 5102b, 5102c, and 5102d. The four battery modules are connected in series. In an embodiment, the battery system 5100 includes an additional group of four battery modules 5102 connected in parallel. Fig.51 The four battery modules are shown in Figure 1.

[0165] Additional battery systems may be implemented using the battery modules according to the present invention. Those skilled in the relevant art will understand how to configure and arrange these battery modules to achieve a desired battery system voltage and a desired energy storage capacity.

[0166] Fig.52 Various example vehicles that can be powered by battery module 5200 according to the present invention are illustrated. In an embodiment, battery module 5200 is one of the battery modules described herein. These battery modules can be combined in series and / or in parallel to form a battery system for powering the illustrated vehicle and others that are not illustrated. Fig.52 , the vehicles that can be powered include an electric counterbalanced forklift 5202, a snowmobile 5204, an electric pallet truck 5206, an electric golf cart 5208, and an electric recreational vehicle 5210. In view of the description herein, those skilled in the relevant art will understand other vehicles that can be powered.

[0167] Fig.53 Various example vehicles with auxiliary power systems that can be powered by battery module 5300 according to the present invention are described. In an embodiment, battery module 5300 is one of the battery modules described herein. These battery modules can be combined in series and / or in parallel to form a battery system such as the auxiliary power system included in the vehicle shown and others not shown. Fig.53 5 , vehicles having auxiliary power systems that can be powered using battery modules according to the present invention include tractor trailers 5302, campers or recreational vehicles 5304, work trucks 5306, food trucks 5308, and buses 5310. In view of the description herein, those skilled in the relevant art will appreciate other vehicles having auxiliary power systems that can be powered by battery modules according to the present invention.

[0168] Fig.54 Various example equipment that can be powered by battery module 5400 according to the present invention are illustrated. In an embodiment, battery module 5400 is one of the battery modules described herein. These battery modules can be combined in series and / or in parallel to form a battery system for the equipment shown and other equipment not shown. Fig.54 5402, a residential battery energy storage unit 5404, and construction signs 5406 and 5408. In view of the description herein, those skilled in the relevant art will understand other equipment that can be powered by the battery module according to the present invention.

[0169] In an embodiment, a battery module may include: a plurality of battery cells, wherein at least one of the battery cells is in contact with a movable plate; and a sensor coupled to the movable plate, the sensor configured to detect expansion of at least one of the plurality of battery cells.

[0170] In some further embodiments, the sensor comprises a first flexible section having a circular or elliptical shape, and wherein a first strain gauge is attached to the first flexible section.

[0171] In some further embodiments, the first flexible section comprises at least one of metal or plastic.

[0172] In some further embodiments, the sensor includes a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge is electrically connected in series with the second strain gauge.

[0173] In some further embodiments, the battery module may include a tray in contact with the battery module, the tray configured to collect water and direct the water toward at least one of the plurality of plates.

[0174] In some further embodiments, the battery module may include an inner plate in contact with one of the plurality of battery cells and extending at least partially into the battery module, wherein the tray is configured to direct water to the inner plate to cool the battery module.

[0175] In some additional embodiments, the battery module may include a controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal from the sensor, wherein the control signal is configured to cause the battery module to stop charging and discharging at least one of the plurality of battery cells of the battery module.

[0176] In some further embodiments, the battery module may include a controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal from the sensor, wherein the control signal is configured to cause the battery module to be electrically disconnected from an electrical bus.

[0177] In some additional embodiments, the controller includes a power supply configured to generate an electrical output having an AC frequency greater than 40,000 Hz and less than 280,000 Hz, and wherein the electrical output from the power supply is provided to a balancing circuit configured to balance the electrical input of at least two of the plurality of battery cells.

[0178] In some further embodiments, the power supply is coupled to the plurality of battery cells using at least one isolation transformer.

[0179] In some additional embodiments, the battery module includes: a plurality of battery assemblies, each battery assembly including a first battery cell and a second battery cell; an internal plate between the first battery cell and the second battery cell; a first side plate in contact with the first battery cell; a second side plate in contact with the second battery cell; and a sensor coupled to at least one of the first side plate or the second side plate, wherein the sensor is configured to detect movement of at least one of the first side plate or the second side plate, wherein the movement is due to expansion of at least one of the first battery cell or the second battery cell.

[0180] In some further embodiments, the sensor comprises a first flexible section having a circular or elliptical shape, and wherein a first strain gauge is attached to the first flexible section.

[0181] In some further embodiments, the first flexible section comprises metal or plastic.

[0182] In some further embodiments, the sensor includes a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge is electrically connected in series with the second strain gauge.

[0183] In some further embodiments, the battery module may include a tray in contact with the battery module, the tray being configured to collect water and direct the water to the first side plate and the second side plate.

[0184] In some further embodiments, the battery module may include a tray in contact with the battery module, the tray configured to collect water and direct the water to the inner plate.

[0185] In some additional embodiments, the battery module may include a controller configured to receive at least one output signal from the sensor and generate a control signal in response to the at least one output signal, wherein the control signal is configured to cause the battery module to stop charging and discharging at least one of the plurality of battery cells of the battery module.

[0186] In some further embodiments, the battery module may include a controller configured to receive at least one output signal from the sensor and generate a control signal in response to the at least one output signal, wherein the control signal is configured to cause the battery module to be electrically disconnected from an electrical bus.

[0187] In some additional embodiments, the controller includes a power supply configured to generate an electrical output having an AC frequency greater than 40,000 Hz and less than 280,000 Hz, and wherein the electrical output from the power supply is provided to a balancing circuit configured to balance the electrical input of at least two of the multiple battery cells of the multiple battery assemblies.

[0188] In some further embodiments, the power supply is coupled to the battery cells of the battery assembly using at least one isolation transformer.

[0189] In an embodiment, a battery rack includes: a plurality of battery modules, wherein each battery module includes a plurality of battery cells, each battery cell being in contact with a side plate; a sensor coupled to the side plate and configured to detect movement of the side plate due to expansion of the battery cells; and a battery module controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal, wherein the control signal is configured to cause the battery module to stop charging and discharging the plurality of battery cells of the battery module; and a battery rack controller having a contactor, wherein the battery rack controller receives the control signal and sufficiently disconnects the contactor to stop charging and discharging the battery module having the battery module controller generating the control signal.

[0190] In some further embodiments, any of the battery rack or the battery module may further include a tray in contact with the battery module, the tray being configured to collect water and direct the water to the side plates of the battery module.

[0191] In some further embodiments, the sensor comprises a flexible section having a circular or elliptical shape, and wherein the strain gauge is attached to the flexible section.

[0192] In some further embodiments, the flexible section comprises at least one of metal or plastic.

[0193] In some additional embodiments, the battery module controller includes a power supply configured to generate an electrical output, and wherein the electrical output from the power supply is provided to a balancing circuit configured to balance the electrical input of at least two of the battery cells of the battery module.

[0194] In some further embodiments, the power supply is coupled to the battery cells of the battery module using at least one isolation transformer.

[0195] In some further embodiments, the battery rack may include a water spray system configured to spray water onto the battery modules.

[0196] In some further embodiments, the sprinkler system is configured to connect to a fire protection system of a building.

[0197] In some further embodiments, the water sprinkler system is configured to connect to pipes configured to allow water to be pumped into the battery rack.

[0198] In some further embodiments, the battery rack may include a hood connected to an exhaust duct, wherein the exhaust duct is configured to remove gases released by the battery cells of the battery rack.

[0199] In some further embodiments, the battery rack may further include: a first housing including the battery rack controller and a first plurality of battery modules; and a second housing coupled to the first housing, the second housing including a second plurality of battery modules.

[0200] In some further embodiments, the battery rack may include a third housing coupled to the first housing, the third housing including a third plurality of battery modules.

[0201] In some additional embodiments, a battery rack may include: a plurality of battery modules, each battery module including a plurality of battery cells, each battery cell in contact with a side plate; a sensor coupled to the side plate and configured to detect movement of the side plate due to expansion of the battery cells; a tray in contact with the battery module, the tray configured to collect water and direct the water to the side plate of the battery module; and a battery module controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal, wherein the control signal is configured to cause the battery module to stop charging and discharging the battery module; a battery rack controller including a contactor, wherein the battery rack controller receives the control signal and sufficiently disconnects the contactor to stop charging and discharging the battery module having the battery module controller generating the control signal; and a water sprinkler system configured to spray water on the battery module.

[0202] In some further embodiments, the sprinkler system is configured to connect to a fire protection system of a building.

[0203] In some further embodiments, the water sprinkler system is configured to connect to pipes configured to allow water to be pumped into the battery rack.

[0204] In some further embodiments, the battery rack further includes a hood connected to an exhaust duct, wherein the exhaust duct is configured to remove gases released by the battery cells of the battery rack.

[0205] In some further embodiments, the sensor comprises a flexible section having a circular or elliptical shape, and wherein the strain gauge is attached to the flexible section.

[0206] In some further embodiments, the flexible section comprises at least one of metal or plastic.

[0207] In some further embodiments, the battery module controller includes a power supply configured to generate an electrical output, and wherein the electrical output from the power supply is provided to a balancing circuit configured to balance the electrical input of at least two of the battery cells of the battery module.

[0208] In some further embodiments, the power supply is coupled to the battery cells of the battery module using at least one isolation transformer.

[0209] In an embodiment, a battery module may include a sensor configured to detect swelling of a battery cell.

[0210] In some further embodiments, the output of the sensor is configured to stop operation of a battery system containing the battery module.

[0211] In some further embodiments, the output of the sensor is configured to stop charging and discharging of the battery module.

[0212] In some further embodiments, the battery module may include a cell balancing circuit that uses an AC to AC power supply to provide audio frequency power to balance the battery cells of the battery module.

[0213] In some further embodiments, the AC to AC power supply provides an electrical output having an AC frequency greater than 5,000 Hz.

[0214] In some further embodiments, the AC to AC power supply provides electrical power having an AC frequency greater than 5,000 Hz but less than 20,000 Hz.

[0215] In some further embodiments, the battery module may include a pressure sensing assembly for detecting expansion of a battery cell of the battery module.

[0216] In some additional embodiments, the battery modules are further configured to allow water to flow through tubing configured to direct the water to a predetermined location within the battery rack.

[0217] In some further embodiments, the fire suppression system is configured to be connected to a fire protection system of a building.

[0218] In some further embodiments, the battery module or the fire suppression system is further configured to connect to a pipe configured to allow water to be pumped into the battery rack.

[0219] In some further embodiments, the sensor may be further configured to detect movement of a plate in contact with the battery module.

[0220] In some further embodiments, the sensor may include a metal strip with at least one strain gauge attached to the metal strip.

[0221] In some further embodiments, the sensor may be made of plastic and have at least one strain gauge attached to the plastic.

[0222] In some further embodiments, the sensor may include a flexible section having a circular or elliptical shape, and wherein a strain gauge is attached to the flexible section.

[0223] In some further embodiments, the battery module may further include a tray in contact with the battery module, configured to direct water to the plates of the battery module.

[0224] In an embodiment, a battery module may include a sensor configured to detect movement of a plate in contact with the battery module, wherein the movement is caused by expansion of a battery cell within the battery module.

[0225] In some further embodiments, the sensor may include a load cell.

[0226] In some further embodiments, the sensor may include a metal strip with at least one strain gauge attached to the metal strip.

[0227] In some further embodiments, the sensor may be made of plastic and have at least one strain gauge attached to the plastic.

[0228] In some further embodiments, the sensor may include a flexible section having a circular or elliptical shape, and wherein a strain gauge is attached to the flexible section.

[0229] In another embodiment, a pressure assembly for a battery module may include: a spring for applying force; a bolt that contacts the spring; a nut that couples to the bolt; and a metal bracket that transfers force from the spring to a pressure plate of the battery module.

[0230] In some further embodiments, the spring is one of a leaf spring and a die spring.

[0231] In some further embodiments, the pressure applying assembly may include a sensor that detects expansion of a battery cell of the battery module.

[0232] In an embodiment, a battery rack may be configured to accommodate a battery module and allow water to be sprayed from a fire extinguishing system onto a plurality of battery cells of the battery module.

[0233] It will be readily apparent to those skilled in the relevant art that various adaptations and modifications of the exemplary embodiments described above may be implemented without departing from the scope and spirit of the present disclosure. Therefore, it should be understood that within the scope of the appended claims, the teachings of the present disclosure may be practiced other than as explicitly described herein.

Claims

1. A battery module, comprising: a plurality of battery cells; a pressure assembly in contact with at least one of the plurality of battery cells, the pressure assembly comprising a surface configured to move due to expansion of one of the plurality of battery cells; and A sensor is configured to detect the swelling of the at least one of the plurality of battery cells. 2 . The battery module of claim 1 , wherein the sensor includes a first flexible section having one of a circular and an elliptical shape, and wherein a first strain gauge is attached to the first flexible section. The battery module of claim 2 , wherein the first flexible section comprises plastic. 4 . The battery module of claim 2 , wherein the sensor comprises a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge is electrically connected in series with the second strain gauge.

5. The battery module of claim 1, wherein the pressure assembly further comprises: First board; Second board; and A plurality of springs are in contact with the first plate and the second plate, the springs being configured to apply a force to the first plate and the second plate. The battery module according to claim 5 , wherein the plurality of springs are one of mold springs and leaf springs. 7 . The battery module of claim 6 , wherein the sensor is at least one leaf spring having a strain gauge attached to a surface of the leaf spring.

8. The battery module of claim 5, wherein the sensor is coupled to the first plate of the pressure assembly.

9. The battery module according to claim 1, further comprising: A battery management circuit board is coupled to the sensor, the battery management circuit board being configured to receive an output from the sensor in response to the expansion of the at least one of the plurality of battery cells.

10. The battery module of claim 10, wherein the battery management circuit board is configured to generate a digital value of the output from the sensor.

11. The battery module of claim 1, wherein the pressure assembly further comprises a plate restrainer.

12. A battery module, comprising: a planar surface in contact with one of the plurality of battery cells, the planar surface configured to move due to expansion of the one of the plurality of battery cells; a sensor configured to detect movement of the planar surface due to expansion of one of the plurality of battery cells; and A battery management circuit board is coupled to the sensor, the battery management circuit board being configured to receive an output from the sensor. 13 . The battery module of claim 12 , wherein the sensor includes a first flexible section having one of a circular and an elliptical shape, and wherein a first strain gauge is attached to the first flexible section. The battery module of claim 13 , wherein the first flexible section comprises plastic. 15 . The battery module of claim 14 , wherein the sensor comprises a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge is electrically connected in series with the second strain gauge.

16. The battery module of claim 12, wherein the sensor is at least one leaf spring having a strain gauge attached to a surface of the leaf spring.

17. The battery module of claim 12, wherein the planar surface is a surface of a plate, and the sensor is coupled to the plate.

18. The battery module according to claim 17, further comprising: A plate inhibitor is configured to cause tilting of the plate.

19. The battery module according to claim 12, further comprising: A second sensor is configured to detect swelling of one of the plurality of battery cells.

20. The battery module of claim 12, wherein the battery management circuit board is further configured to generate a digital value of the output from the sensor.

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