Physically and electrically configurable battery pack

Abstract

A battery pack and a method of installing the same. The battery pack has one or more cell stacks, wherein each cell stack has a stack module. The stack module includes a stack interface module, one or more battery modules, and one or more string disconnection modules (SDMs). Each SDM is located in one of the cell stacks, connected to a cell string composed of one or more cell modules connected in series, and configured to selectively connect or disconnect each cell module in the cell string. For any given cell stack, at least one of the SDMs is separated from the cell stack interface module of the cell stack by at least one of the cell modules of the cell stack.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a physically and electrically configurable battery pack. More specifically, the present disclosure relates to a battery pack comprising at least one battery module stack and at least one string disconnect module located in the at least one battery module stack, wherein the at least one string disconnect module is configured to disconnect battery strings comprising series connected battery modules from each other. BACKGROUND

[0002] The rise of electrification in consumer and industrial applications has increased the demand for energy storage, and more specifically, for batteries. Factors such as battery capacity, battery type, battery pack design, and operating conditions can all impact storage capacity and battery performance.

[0003] One factor that can also impact available storage and maximum battery pack voltage or current in certain applications is the volumetric shape of the location in which the battery pack is to be used. If the volume is particularly limited, restrictions in the electrical configuration and physical configuration of the battery pack can limit the number of battery modules that can be physically installed, and / or impede the ability to make proper electrical connections to the installed modules, thereby limiting the energy storage density, maximum voltage, and / or maximum current of the battery pack. SUMMARY

[0004] According to a first aspect, there is provided a battery pack comprising: one or more battery stacks, each battery stack comprising a stack of modules comprising: a battery stack interface module; and one or more battery modules; one or more string disconnect modules (SDMs), wherein each SDM: is located in a battery stack of the one or more battery stacks; is connected to a battery string comprising one or more series connected battery modules of the battery pack; and is configured to selectively connect or disconnect one or more battery modules in the battery string, wherein at least one of the one or more SDMs is separated from the battery stack interface module of the battery stack in which the at least one SDM is located by at least one of the one or more battery modules of the battery stack.

[0005] For at least one battery stack, the battery stack interface module can be located at a bottom of the at least one battery stack, and the one or more battery modules can be located above the battery stack interface module.

[0006] The battery pack can further comprise one or more battery pack controllers configured to control operation of each battery module in the battery pack by communicating with each battery module.

[0007] The one or more battery pack controllers can also be configured to control operation of each battery module and each SDM in the battery pack by communicating with each battery module and each SDM via a battery stack interface module of a battery stack in which the battery module or SDM is located.

[0008] The one or more battery pack controllers can be configured to communicate with each battery module and each SDM by: the one or more battery pack controllers sending a communication to a battery stack interface module of a battery stack in which the battery module or SDM is located; and the battery stack interface module forwarding the communication to the battery module or SDM.

[0009] The one or more battery stacks can include a first battery stack and a second battery stack; at least one of the one or more battery strings can include: one or more first battery modules in the first battery stack; and one or more second battery modules in the second battery stack; and a topmost battery module of the one or more first battery modules can be connected to a bottommost battery module of the one or more second battery modules.

[0010] The topmost battery module of the one or more first battery modules in the first battery stack can not be a topmost battery module of all battery modules in the first battery stack.

[0011] The topmost battery module of the one or more first battery modules can be connected to the bottommost battery module of the one or more second battery modules via a battery stack interface base of the first battery stack and via a battery stack interface base of the second battery stack.

[0012] The topmost battery module of the one or more first battery modules can be connected to the battery stack interface base of the first battery stack using a flexible power connector.

[0013] The one or more battery stacks can include a first battery stack and a second battery stack; and the second battery stack can be: horizontally adjacent to the first battery stack such that a side of the first battery stack is adjacent to a side of the second battery stack; or back-to-back adjacent to the first battery stack such that a back of the first battery stack is adjacent to a back of the second battery stack.

[0014] For at least one battery stack, a topmost battery module of the battery stack can be connected to a battery stack interface module of the battery stack using a flexible power connector.

[0015] The one or more battery stacks can include a first battery stack and an adjacent second battery stack; and a battery stack interface base of the first battery stack can be connected to a battery stack interface base of the second battery stack using a power connector.

[0016] For at least one battery string: the at least one battery string can be entirely contained within a single battery stack of the plurality of battery stacks, wherein the single battery stack can include an SDM connected to the at least one battery string; and the one or more series-connected battery modules of the at least one battery string can consist of: each battery module stacked above the SDM connected to the at least one battery string; and a topmost battery module of the single battery stack.

[0017] For at least one battery string: the at least one battery string can be split into at least a first battery stack and a second battery stack, wherein the first battery stack includes an SDM connected to the at least one battery string and at least one other SDM, and wherein the second battery stack includes at least one SDM; and the one or more series-connected battery modules of the at least one battery string can consist of: in the first battery stack, each battery module stacked above the SDM connected to the at least one battery string and below the at least one other SDM; and in the second battery stack, each battery module below the at least one SDM of the second battery stack.

[0018] Vertically adjacent modules in pairs can be connected using a power connector.

[0019] In each battery stack, each module can include one or more optical communication ports that are optically coupled to one or more optical communication ports of a vertically adjacent module.

[0020] In each battery stack, the battery stack interface module can include one or more digital communication ports that are communicatively coupled to one or more digital communication ports of a battery stack interface module of an adjacent battery stack.

[0021] The one or more digital communication ports can include one or more Ethernet ports.

[0022] The battery pack can further include: one or more battery pack controllers configured to control operation of each battery module in the battery pack by communicating with each battery module, wherein the one or more battery pack controllers can be further configured to control operation of each battery module and each SDM in the battery pack by communicating with each battery module and each SDM via a battery stack interface module of a battery stack in which the battery module or SDM is located, and wherein the one or more battery pack controllers are communicatively connected to each battery stack interface module via the one or more digital communication ports.

[0023] The one or more battery stacks can include a first battery stack and a second battery stack; and the battery stack interface module of the first battery stack can be in a different horizontal plane than the battery stack interface module of the second battery stack.

[0024] The at least one battery module of the battery pack can include one or more fans for air cooling the battery module.

[0025] The battery pack can further include one or more liquid cooling systems for liquid cooling the at least one battery module of the battery pack.

[0026] In at least some aspects, no battery stack can include more than two SDMs. Alternatively, in at least some aspects, at least one battery stack can include at least two SDMs.

[0027] The at least one battery string can include an electrical safety shutdown path connecting the SDM of the battery string to each battery module in the battery string.

[0028] The stack interface module of at least one of the battery stacks can include: at least one DC bus terminal to receive at least one electrical connector, respectively; and at least one battery side terminal electrically coupled to one or more battery modules of the at least one battery stack. The at least one DC bus terminal can be movable relative to the at least one battery side terminal between an open position and a closed position, such that when in the closed position, the at least one electrical connector, when received by the at least one DC bus terminal, is electrically coupled to the at least one battery side terminal, and when in the open position, the at least one electrical connector, when received by the at least one DC bus terminal, is electrically isolated from the at least one battery side terminal by an air gap.

[0029] The at least one DC bus terminal and the at least one battery side terminal can be axially movable relative to each other, and the stack interface module of the at least one battery stack can further include a screw connected to the at least one DC bus terminal that controls an axial position of the at least one DC terminal relative to the at least one battery side terminal.

[0030] According to another aspect, there is provided a method of installing a battery pack, comprising: installing one or more battery stacks by stacking modules for each battery stack, the modules comprising: a stack interface module; and one or more battery modules; installing one or more string disconnect modules (SDMs) in a battery stack of the one or more battery stacks during installation of the one or more battery stacks by including each SDM in the battery stack of the one or more battery stacks, wherein: each SDM connects to a battery string comprising one or more battery modules of the battery pack; each SDM is configured to selectively connect or disconnect each battery module in the battery string; and at least one of the one or more SDMs is separated from the stack interface module of the battery stack in which the at least one SDM is located by at least one of the one or more battery modules of the battery stack.

[0031] This summary of the invention does not necessarily describe all aspects of the entire scope. Other aspects, features, and advantages will become apparent to those of ordinary skill in the art upon review of the following description of specific BRIEF DESCRIPTION OF DRAWINGS

[0032] In the drawings, which depict one or more exemplary embodiments: Figure 1 is a perspective view of a battery pack according to exemplary embodiments.

[0033] Figure 2 is a perspective view of a battery pack contained within a hull according to exemplary embodiments.

[0034] Figures 3 to 5 depicts a schematic of different battery pack configurations according to exemplary embodiments.

[0035] Figure 6 is a schematic of a battery pack according to exemplary embodiments.

[0036] Figure 7 is a schematic of two battery modules stacked on top of each other according to exemplary embodiments.

[0037] Figure 8 is a schematic of a battery module stacked on top of a battery stack interface module according to exemplary embodiments.

[0038] Figure 9 is a schematic depicting how a battery pack controller communicates with multiple battery stack interface modules according to exemplary embodiments.

[0039] Figures 10A to 10C are perspective, top plan, and cross-sectional views of a first and second battery string port including portions of a battery stack interface module according to exemplary embodiments, respectively. DETAILED DESCRIPTION

[0040] In industrial applications, such as marine applications, the volume available for installation of a battery pack can be irregularly shaped or particularly constrained. For example, in marine applications, the volume available for installation of a battery pack can be adjacent to a hull side that is curved and not designed to efficiently accommodate a rectangular battery module battery stack. This can make it difficult to configure a battery pack physically and electrically to efficiently utilize the available space while meeting power and energy density requirements.

[0041] An exemplary battery pack 100, such as Figure 1The depicted) are designed to be electrically and physically configurable, enabling the provision of required energy density and power requirements within an irregularly shaped physical volume. The battery pack 100 includes first to seventh module stacks 108a-108g (collectively, "module stacks 108") that are electrically connected together. First to seventh stack interface modules 102a-102g (collectively, "stack interface modules 102") are provided at the bottom of the first to seventh battery stacks 108a-108g, respectively. First and second string disconnect modules 104a-104b (both "SDMs," collectively "SDMs 104") are located in the first battery stack 108a, while third to eighth SDMs 104c-104h are located in the second to seventh battery stacks 108b-108g, respectively. The remaining modules of the battery pack 100 are battery modules 106 (including battery cells (not depicted) therein) that are electrically connected in series to one another. Figure 1 Each of the battery modules 106 includes a portion of one of a plurality of different battery strings (not labeled in Figure 1 ).

[0042] As discussed further below with respect to Figures 3 to 6 , the SDMs 104 allow for the construction of one or more battery strings of different maximum voltages using battery stacks 108 of different heights by allowing for the selective connection and disconnection of respective battery strings. For example, a battery string can span multiple battery stacks 108, allowing for the series connection of battery modules 106 to create a battery string with a higher voltage than would be possible if all battery modules 106 of a particular string were limited to a single battery stack 108. Additionally, the SDMs 104 can be used to separate different strings from one another on the same battery stack 108; this allows for a single battery stack 108 to include multiple battery strings, facilitating an increase in the energy density of the pack 100 within a constrained volume. Figure 1 Additionally, the battery stacks 108a-108g of Figures 3 to 6 are horizontally adjacent, with the sides of any of the battery stacks 108 being adjacent to the sides of an adjacent stack.

[0043] Figure 2 is a perspective view of a battery pack 100 contained within a hull 202, in accordance with an example embodiment. Figure 2 The battery pack 100 of Figure 2The battery stacks 108a-d are back-to-back adjacent, with the back of any one of the battery stacks 108a-d adjacent to the back of an adjacent battery stack 108a-d. This facilitates access to the front side of all of the battery stacks 108a-d.

[0044] Figure 6 A schematic diagram of an example battery pack 100 is depicted in accordance with example embodiments. Figure 6 The pack 100 includes first through third battery stacks 108a-c at their bottoms are first through third battery stack interface bases 102a-c, respectively. The battery pack 100 also includes first through fifth battery strings 302a-e that are electrically connected or disconnected from the rest of the battery pack 100 via first through fifth SDMs 104a-e, respectively. The first SDM 104a is placed directly on the first battery stack interface base 102a; the second SDM 104b is the sixth module on the first battery stack interface base 102a; the third SDM 104c is the fourth module on the second battery stack interface base 102b; the fourth SDM 104d is the sixth module on the second battery stack interface base 102b; and the fifth SDM 104e is the sixth module on the third battery stack interface base 102c. The modules in the battery pack 100 that are not SDMs 104a-e or battery stack interface bases 102a-c are battery modules 106 that include battery cells (i.e., power sources).

[0045] Each of the battery modules 106 is electrically modeled to include a first terminal and a second terminal, with the battery cells 602 and the fuse 604 electrically connected in series between the first terminal and the second terminal. While a single fuse 604 is schematically depicted in each of the battery modules 106, Figure 6 While a single fuse 604 is schematically depicted in each of the battery modules 106, in various embodiments, each of the modules 106 can include: a single fuse for all of the cells 602; multiple fuses 604 for each of the cells 602 (e.g., one fuse 604 per cell 602); and / or different overcurrent protection devices in place of the fuses 604, such as circuit breakers. Additionally, in at least some other embodiments (not depicted), any one or more of the battery modules 106 can not include any overcurrent protection devices.

[0046] Each of SDMs 104a to 104e is a two-port network, wherein a first port includes a first terminal and a third terminal, and a second port includes a second terminal and a fourth terminal. A first fuse 610a and a first switch 612a are connected in series between the first and third terminals, wherein a DC power supply 614 models the DC current conducted from the third terminal to the first terminal (which is drawn from the battery module 106 electrically connected to the SDM 104). A second fuse 610b and a second switch 612b are connected in series electrically between the second and fourth terminals in a similar manner. As described above with respect to fuse 604 of battery module 106, in at least some exemplary embodiments, one or both of fuses 610a and 610b of SDM 104 may be replaced by or completely omitted from the list of overcurrent protection devices of different types.

[0047] The first battery stack interface modules 102a to the third battery stack interface modules 102c collectively include first battery string ports 606a to fifth battery string ports 606e, which output electrical energy from the first battery strings 302a to the fifth battery strings 302e, respectively. Each of the first battery string ports 606a to the fifth battery string ports 606e includes a pair of positive and negative terminals, wherein one of the terminals is electrically connected to a first module 106 that includes a portion of the corresponding battery strings 302a to 302e, and the other of the terminals is electrically connected to a last module 106 that includes a portion of the corresponding battery strings 302a to 302e. The battery string ports 606a to 606e are typically electrically connected to a DC power bus (not shown) to provide access to the DC power generated by the battery pack 100.

[0048] The first SDM 104a also includes a pre-charge circuit, which is connected in parallel with the second fuse 610b and the second switch 612b. The pre-charge circuit includes a resistor 618 connected in series with the pre-charge switch 612c and the pre-charge fuse 610c. The resistor 618 may include, for example, a separate resistor or some other type of resistive element. The pre-charge circuit is used to reduce the voltage difference between the first battery string 302a and the DC bus connected to the first battery string 302a via the first battery string port 606a, thereby reducing the inrush current from the first battery string 302a to the DC bus during initial connection. Although in Figure 6Only the first SDM 104a is shown as having a pre-charge circuit, but in at least some other embodiments, none of the SDMs 104 in the battery pack 100 can include a pre-charge circuit, or each of two or more SDMs 104 of the battery pack 100 can include a pre-charge circuit. Further, as described above with respect to the first and second fuses 610a, 610b of the SDM 104, in at least some example embodiments, a different overcurrent protection device than the pre-charge fuse 610c can be used in the pre-charge circuit, or the pre-charge circuit can not include an overcurrent protection device at all.

[0049] All of the modules 104b, 106 including the second battery string 302b are located in the first battery stack 108a (i.e., the second SDM 104b is the sixth module 108a on the battery stack interface module 102a, and the remaining seven modules 106 of the second battery string 302b are located on top of the second SDM 104b). The seven modules 106 are electrically coupled in series with one another, with the first (positive) terminal of the first module stacked on the second SDM 104b, and the second (negative) terminal of the topmost module stacked on the second SDM 104b, which terminal is coupled to the second port of the second SDM 104b (i.e., the second and fourth terminals) via the return conductor 616. The electrical connections between the modules 106, the SDMs 104a-104e, and the battery stack interface modules 102a-102e (including the return conductor 616) can be flexible (e.g., electrical cables) or rigid (e.g., busbars) power connectors. The first port of the second SDM 104b (i.e., the first and third terminals) is electrically coupled to the second battery string port 606b. The second battery string port 606b accordingly provides access to power for the modules 106 including the second battery string 302b connected in series.

[0050] The fourth and fifth battery strings 302d, 302e are constructed in a similar manner to the second battery string 302b, with the difference being that they include portions of the second and third battery stacks 108b, 108c (rather than the first battery stack 108a), respectively. The fourth and fifth battery string ports 606d, 606e accordingly provide access to power for the modules 106 including the fourth and fifth battery strings 302d, 302e connected in series, respectively.

[0051] In comparison to the second 302b, fourth 302d, and fifth 302e battery strings, the first battery string 302a includes a first SDM 104a, four modules 106 electrically connected in series in a first battery stack 108a and stacked between the first 104a and second 104b SDMs, and three modules 106 electrically connected in series in a second battery stack 108b and stacked between the battery stack interface module 102b and third SDM 104c. A first cross-stack port 608a in the first battery stack 108a and a second cross-stack port 608b in the second battery stack are used to electrically connect the modules 106 of the first battery string 302a together in the first 108a and second 108b battery stacks. Each of the cross-stack ports 608a, 608b includes a pair of terminals. As described above with respect to the second battery string 302b, a first terminal of the first SDM 104a is connected to one of the terminals of the first battery string port 606a. However, the topmost module 106 of the first battery string 302a is not connected directly to the first SDM 104a, but rather to one terminal of the first cross-stack port 608a. That terminal is connected to a corresponding terminal of the second cross-stack port 608b, which in turn is connected to a first terminal of the bottommost module 106 of the first battery string 302a in the second battery stack 108b. A second terminal of the topmost module of the first battery string 302a in the second battery stack 108b is connected to the remaining terminal in the second cross-stack port 608b, which in turn is connected to the remaining terminal in the first cross-stack port 608a, which itself is connected to the remaining terminal in the first battery string port 606a. Then, from an electrical perspective, the topmost module 106 of the first battery string 302a in the second battery stack 108b is similar to the topmost module 106 of the second battery string 302b in the first battery stack 108a, with the first 608a and second 608b cross-stack ports used to electrically connect the topmost module 106 of the first battery string 302a in the first battery stack 108a and the bottommost module 106 in the second battery stack 108b together in series.

[0052] Like the first battery string 302a, the third battery string 302c also spans two battery stacks 108b, 108c. In the second battery stack 108b, the third battery string 302c includes the third SDM 104c and one module 106 stacked directly thereon, and the first six modules 106 on the third stack interface module 102c of the third battery stack 108c. The third cross-stack port 608c and the fourth cross-stack port 608d function similarly to the first cross-stack port 608a and the second cross-stack port 608b to connect the modules 106 of the third battery string 302c in the second battery stack 108b with the bottom-most module 106 of the third battery string 302c in the third battery stack 108c. The first port of the third SDM 104c is connected to the third battery string port 606c to provide access to power from the third battery string 302c.

[0053] Referring now to Figures 10A to 10C , perspective, top plan, and cross-sectional views of a port assembly 1000 including the first battery string port 606a and the second battery string port 606b are depicted, respectively. Figure 10C The cross-sectional view of Figure 10A is taken along line 10C-10C in Figures 10A to 10C Although only the first battery string port 606a and the second battery string port 606b are depicted in

[0054] Figures 10A to 10C Each of the battery string ports 606a, 606b depicted in comprise: first and second DC bus terminals 1002a, 1002b for connection to power conductors, such as cables, that are electrically coupled to a DC bus (not shown); and first and second battery-side terminals 1002c, 1002d that are electrically connected to battery modules 106 via bus bars and / or cables. This allows power to be drawn from the battery modules 106 and delivered to the DC bus, or power delivered along the DC bus to be delivered to the modules 106 for charging. The first DC bus terminal 1002a and the first battery-side terminal 1002c and the second DC bus terminal 1002b and the second battery-side terminal 1002d are located at opposite ends of the cylindrical housing 1010 and are axially aligned with one another.

[0055] Each of the first and second DC bus terminals 1002a, 1002b includes a portion of a sliding portion 1004 that is axially slidable between an open position and a closed position. In the closed position, the DC bus terminals 1002a, 1002b and the battery-side terminals 1002c, 1002d are respectively electrically connected together; and in the open position, the DC bus terminals 1002a, 1002b and the battery-side terminals 1002c, 1002d are respectively electrically disconnected. Figures 10A to 10C In the example embodiment depicted in FIG. 6, the first battery string port 606a is shown in the closed position and the second battery string port 606b is shown in the open position. Figure 10C The cross-sectional view of FIG. 10 specifically shows that within the housing 1010 of the first and second DC bus terminals 1002a, 1002b are respectively first and second electrical contacts 1006a, 1006b. When the DC bus terminals 1002a, 1002b are in the closed position, the front surfaces of the terminals 1002a, 1002b and the contacts 1006a, 1006b are close enough that an electrical connector inserted into the terminals 1002a, 1002b contacts and makes electrical conduction with the contacts 1006a, 1006b. In contrast, when the DC bus terminals 1002a, 1002b are in the open position, the air gap between the front surfaces of the terminals 1002a, 1002b and the contacts 1006a, 1006b is large enough that a connector inserted into the terminals 1002a, 1002b remains electrically isolated from the battery-side terminals 1002c, 1002d.

[0056] An actuator in the form of a screw 1008 is used to fix the DC bus terminals 1002a, 1002b in the open and closed positions. As shown in FIG. 6, the screw 1008 for each of the battery string ports 606a, 606b is fixed to and extends through a plate that is fixed to a movable portion of the first and second DC bus terminals 1002a, 1002b. Rotating the screw accordingly causes the DC bus terminals 1002a, 1002b to move axially closer to or further away from the battery-side terminals 1002c, 1002d. Figures 10A to 10C

[0057] While Figures 10A to 10C While the example embodiment is depicted in which the DC bus terminals 1002a, 1002b are axially movable relative to the battery-side terminals 1002c, 1002d via a screw, different implementations are possible in at least some other embodiments. For example, the DC bus terminals 1002a, 1002b can be pivoted or slid relative to the battery-side terminals 1002c, 1002d, and a different fixation device (e.g., a lock or a clamp) than a screw can be used to fix the DC bus terminals 1002a, 1002b in the open or closed position. ​

[0058] Figures 3 to 6 Schematic diagrams depicting different battery pack configurations according to exemplary embodiments. Figure 3 A battery pack 100 is depicted that includes identical first and second arrays 306a, 306b. Each of the arrays 306a, 306b includes first through third battery stack interface modules 102a-c, the bases of which include first through third battery stacks 108a-c, respectively. A first SDM 104a is placed directly on the first battery stack interface module 102a, and a second SDM 104b is the third module on the second interface module 102b. A first battery string 302a includes six modules 106 on top of the first SDM 104a and two modules 106 between the second battery stack interface module 102b and the second SDM 104b. A second battery string 302b includes three modules 106 stacked on top of the second SDM 104b and all five modules 106 stacked on top of the third battery stack interface base 102c. Each array 306a, 306b includes two battery strings 302a, 302b, respectively, each including six modules 106 connected in series.

[0059] Figure 3 A battery pack controller 304 is also included that is communicatively coupled to the battery stack interface modules 102a-c of the first and second arrays 306a, 306b. Control signals from the battery pack controller 304 are transmitted to the third battery stack interface module 102c of the second array 306b and propagate to the second battery stack interface module 102b of the second array 306b, to the first battery stack interface module 102a of the second array 306b, to the third battery stack interface module 102c of the first array 306a, to the second battery stack interface module 102b of the first array 306a, and then to the first battery stack interface module 102a of the first array 306a. The control signals can modulate the switches 612a, 612b (not shown) of the SDMs 104a, 104b of both arrays 306a, 306b, thereby allowing any of the battery strings 302a, 302b of either array 306a, 306b to be selectively added to or removed from the battery pack 100. Figure 3 The circuitry used to implement the control signals is described in more detail below with respect to Figures 7 to 9 .

[0060] Figure 4 Another battery pack 100 is depicted that is constructed in a similar manner to the pack 100 of Figure 3 and Figure 6 . More specifically, Figure 4The battery pack 100 includes five battery strings 302a-302e distributed over three battery stacks 108a-108c, with first battery stack interface modules 102a-102c located at the bases of the battery stacks 108a-108c, respectively. The first SDM 104a- fifth SDM 104e can electrically connect and disconnect the first battery string 302a- fifth battery string 302e to and from the battery pack 100, respectively.

[0061] Figure 5 The battery pack 100 is shown including a first battery string 302a and a second battery string 302b, which can be controlled using a first SDM 104a and a second SDM 104b, respectively, distributed over first battery stack 108a- third battery stack 108c, with first battery stack interface modules 102a- third battery stack interface modules 102c at the bases of the battery stacks, respectively. The battery stack interface modules 102a-102c are electrically connected to each other to allow the first battery string 302a and the second battery string 302b to span the battery stacks 108a-108c, and to allow control signals from a battery pack controller (not shown) to propagate across the battery stacks 108a-108c, as described above with respect to Figure 5 Figure 4 Figure 5 Three battery stack interface modules 102a-102c are shown at different levels, emphasizing that the bases of the battery stacks 108a-108c can be at different heights to accommodate different shaped volumes in which the battery pack 100 can be installed. In this embodiment, flexible power and communication connectors are used to electrically and communicatively connect the battery stack interface modules 102a-102c to each other, respectively.

[0062] Figure 7 is a schematic diagram of a second battery module 106b stacked on top of a first battery module 106a, according to an example embodiment. The battery modules 106a, 106b are identical, each including: battery cells 602 and fuses 604; a module control board 706 to receive and process optical and electrical signals; a fan 710 for cooling; and a voltage / temperature acquisition board 714 to measure cell voltage and temperature during operation. Each of the modules 106a, 106b also includes a first terminal 712a and a second terminal 712b electrically coupled in series with the cells 602; the second terminal 712b of the first module 106a is connected to the first terminal 712a of the second module 106b, thereby electrically coupling the modules 106a, 106b in series. Conductors 616 are also depicted as being routed through the modules 106a, 106b to electrically connect the modules 106a, 106b to each other and to the battery pack 100. Figure 7 ​​The extension extends through modules 106a and 106b, terminating at either the battery string port 606 or the cross-stacking port 608. Each of modules 106a and 106b also includes an input optical terminal 702a and an output optical terminal 702b, which facilitate the transmission of optical signals to and from the module control board 706, and also includes an input fan terminal 708a and an output fan terminal 708b, which control whether and how fast the fan 710 rotates, thereby controlling the air cooling of modules 106a and 106b. Although not depicted, in at least some other embodiments, modules 106a and 106b may use liquid cooling as an alternative to or supplement to air cooling.

[0063] Module control board 706 monitors the cell voltage and temperature acquired via voltage / temperature acquisition board 714 and determines whether one or both of the voltage and temperature measurements indicate that modules 106a and 106b are in a fault state (e.g., due to the measured temperature exceeding a temperature fault threshold or the measured voltage exceeding a measured voltage threshold). If either module 106a or 106b is in a fault state, the module control board 706 of that module 106a or 106b sends an electrical safety shutdown signal down along the battery stack 108 to SDM 104, and as described below... Figure 8 Further discussion reveals that SDM 104, in response to this signal, disconnects the battery string including modules 106a and 106b by disconnecting one or both of the first switch 612a and the second switch 612b.

[0064] Alternatively or concurrently, in at least some embodiments, the module control board 706 of modules 106a, 106b that enter a fault state sends an electrical safety shutdown signal that propagates upward and downward along the battery stack 108, so that all modules 106 in the battery stack 108 are aware of the fault state and can respond accordingly without requiring input from SDM 104. For example, in at least some embodiments, if a second module 106b enters a fault state, it sends a safety shutdown signal upward and downward along the battery stack 108 via safety shutdown terminals 704a, 704b. The first module 106a and all other modules 106 in the battery stack 108 can then disconnect their cells 602 for safety purposes without waiting for a message from SDM 104.

[0065] Figure 8 This is a schematic diagram of an SDM 104 stacked on top of a battery stack interface module 102 according to an exemplary embodiment. The SDM 104 includes a first fuse 610a and a second fuse 610b, a first switch 612a and a second switch 612b, and as described above regarding... Figure 6 The described DC power supply 614. SDM 104 also includes information about...Figure 6 the pre-charge circuit described above with respect to the first SDM 104a. In Figure 8 conductor 616 is also depicted as extending through the SDM 104, terminating in either of the battery string ports 606 or the cross stack port 608.

[0066] The SDM 104 also includes an SDM control board 812, an AC / DC converter 814, a high voltage board 816, and a noise filter 818. The noise filter 818 filters the power delivered to the battery string ports 606. Similar to the modules 106a, 106b of Figure 7 the SDM 104 also includes input optical terminals 806a and output optical terminals 806b, as well as safety shutdown terminals 810a, 810b, which facilitate the transmission of optical signals and safety shutdown signals to and from the SDM control board 812, respectively. Input fan terminals 820a and output fan terminals 820b transmit signals to the modules 106 to control the fans 710. More specifically, the output optical terminals 806b, safety shutdown terminals 810b, and output fan terminals 820b are coupled to the input optical terminals 702a, safety shutdown terminals 704a, and input fan terminals 708a, respectively, of the modules 106 that are directly stacked on the SDM 104.

[0067] Figure 8 The battery stack interface module 102 of the battery stack 300 includes the battery string ports 606 to provide access to the power provided by one of the battery strings 302, and the battery stack interface module 102 also includes output optical terminals 804 and safety shutdown terminals 822 that communicate with the input optical terminals 806a and safety shutdown terminals 810a, respectively, of the SDM 104 that is directly stacked on top of the battery stack interface module 102. Figure 8 The battery stack interface module 102 of the battery stack 300 also includes input communication ports 802a and output communication ports 802b for communicating with the battery pack controller 304, as described above with respect to the battery stack 200 and in more detail below with respect to the battery stack 400. In the depicted embodiment, the communication ports 802a, 802b are Ethernet ports, but in different embodiments the communication ports 802a, 802b can be configured to communicate using, for example, any suitable optical or electrical communication protocol. Figure 3 Figure 9

[0068] ​​The combination of horizontally extending communication ports 802a, 802b and vertically extending optical terminals 702a, 702b, 804, 806a, 806b, 810a, 810b allows the battery pack controller 302 to send commands to the battery stack interface module 102, and the battery stack interface module 102 subsequently propagates these commands up the battery stack 108 via the SDM 104 and the battery modules 106. Specifically, electrical communication signals from the battery pack controller 302 to the battery stack interface module 102 can be used to communicate away from the battery modules 106 where there is relatively less electrical noise, and optical signals are used to transmit up the battery stack 108 closer to the battery modules 106 where electrical noise is more of a concern.

[0069] If any of the modules 106 in the battery stack 108 fails and performs a safe shutdown, as described above, the safe shutdown signal propagates up the battery stack 108 starting from the failed module 106. The safe shutdown signal eventually reaches the SDM control board 812 of the SDM 104, in response to which the SDM control board 812 opens the first switch 610a and the second switch 610b to disconnect the battery string including the failed module or modules 106. The safe shutdown signal continues to propagate down the battery stack until it reaches the battery stack interface module 102. In embodiments where the battery stack interface module 102 is one of a plurality of battery stack interface modules 102 connected together, such as depicted in Figures 1 to 6 the safe shutdown signal is first received by the battery stack interface module 102 forwards this signal vertically horizontally via the safe shutdown terminals 824 to the other battery stack interface modules 102. Upon receiving the safe shutdown signal, the other battery stack interface modules 102 can send optical signals via their respective optical terminals 804 to shut down the modules 106 in their respective battery stacks 108. The battery stack interface module 102 that first receives the safe shutdown signal can also send an electrical message to the battery pack controller 304 via the communication ports 802a, 802b to inform the battery pack controller 304 of the failure.

[0070] Figure 9 is a schematic diagram depicting how the battery pack controller 302 communicates with a plurality of battery stack interface modules 102a-102n according to an exemplary embodiment. Figure 9A battery pack controller 302 is depicted connected to each of the battery stack interface modules 102a-102n in a ring network. More specifically, the battery pack controller 302 includes a first communication port 902a and a second communication port 902b, with a communication line extending from the second communication port 902b of the battery pack controller 302 to the input communication port 802a of the nth battery stack interface module 102n. The nth battery stack interface module then relays the communication signal along the row of battery stack interface modules 102a-102n via its output communication port 802b until it reaches the input communication port 802a of the third battery stack interface module 102c. The signal continues to propagate in this manner until it reaches the first battery stack interface module 102a. The output communication port 802b of the first battery stack interface module 102a is connected to the first communication port 902a of the battery pack controller 302 via a return loop; while the return loop is not necessary, it can be useful for redundancy purposes. While the depicted embodiment shows the communication ports 902a, 902b, 802a, 802b, 810a, 810b, 822, 704a, 704b as being digital communication ports, in at least some alternative embodiments (not depicted) they can be configured for analog communication. Figure 9 While the depicted embodiment shows the communication ports 902a, 902b, 802a, 802b, 810a, 810b, 822, 704a, 704b as being digital communication ports, in at least some alternative embodiments (not depicted) they can be configured for analog communication. Figure 9 While the depicted embodiment shows the communication ports 902a, 902b, 802a, 802b, 810a, 810b, 822, 704a, 704b as being digital communication ports, in at least some alternative embodiments (not depicted) they can be configured for analog communication. Figure 9 While the depicted embodiment shows the communication ports 902a, 902b, 802a, 802b, 810a, 810b, 822, 704a, 704b as being digital communication ports, in at least some alternative embodiments (not depicted) they can be configured for analog communication.

[0071] While the depicted embodiment shows the communication ports 902a, 902b, 802a, 802b, 810a, 810b, 822, 704a, 704b as being digital communication ports, in at least some alternative embodiments (not depicted) they can be configured for analog communication. Figure 9 While the depicted embodiment shows the communication ports 902a, 902b, 802a, 802b, 810a, 810b, 822, 704a, 704b as being digital communication ports, in at least some alternative embodiments (not depicted) they can be configured for analog communication.

[0072] At least some embodiments include a method of installing the above-described battery pack 100. One or more battery stacks 108 can be installed, and as Figures 1 to 5As depicted, the battery stacks 108 can have different heights to accommodate installation in different shaped volumes. Each battery stack 108 is installed by stacking battery modules including the battery stack interface module 102 and one or more battery modules 106. During installation of the one or more battery stacks 108, one or more SDMs 108 are also included in at least one of the battery stacks 108. Each of the SDMs 108 is connected to a battery string 302 including one or more battery modules 106; is configured to selectively connect or disconnect the one or more battery modules 106 of the battery string 302 from the battery pack 100; and at least one of the SDMs 108 is separated from the battery stack interface module 102 located in at least one of the SDMs 108 by at least one or more of the battery modules 106 of that battery stack 108.

[0073] Embodiments have been described above with reference to flowchart illustrations, sequence diagrams, and block diagrams of methods, apparatus, systems, and computer program products. In this regard, the flowchart illustrations, sequence diagrams, and block diagrams have illustrated the architecture, functionality, and operation of implementations of various embodiments. For example, each block in the flowchart illustrations, sequence diagrams, and block diagrams, and operations in sequence diagrams, can represent a module, segment, or portion of code, which comprises one or more executable instructions implementing the specified logic. In some alternative embodiments, the actions recited in the blocks or operations can occur in a different order than those illustrated in the figures. For example, in some embodiments, two blocks or operations that are in succession can be executed concurrently or the blocks or operations can sometimes be executed in reverse order, depending on the functionality involved. Some specific examples have been recorded above, but these recorded examples are not necessarily exhaustive. Each block in the flowchart illustrations, sequence diagrams, and block diagrams, and operations in sequence diagrams, and combinations of these blocks and operations, can be implemented by a special purpose hardware-based system, or a combination of special purpose hardware and computer instructions.

[0074] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and groups thereof. Directional terms as used in describing the present disclosure (such as "top," "bottom," "up," "down," "vertically," and "horizontally") are used for ease of description to provide relative references only and do not imply any limitations on how any of the described products are to be positioned or installed in assemblies or relative to an environment during use. Additionally, the term "connected" and variations thereof, as used in the present specification are intended to include both indirect and direct connections unless otherwise indicated. For example, if a first device is connected to a second device, that coupling can be through a direct connection or through an indirect connection via other devices and connections. Similarly, if a first device is communicatively connected to a second device, the communication can be through a direct connection or through an indirect connection via other devices and connections. As used herein, the terms "and / or," "at least one of," and "one or more of" are used to associate together alternatively related items, such as elements connected by a disjunctive connective. For example, each of "A, B, and / or C," "at least one of A and C," and "one or more of A and C," means A, B, C, A and B, A and C, B and C, or A and B and C.

[0075] Any reference to a processor or controller used herein can include, for example, a processing unit (such as a processor, microprocessor, or programmable logic controller) communicatively coupled to a non-transitory computer readable medium having program code stored thereon for execution by the processing unit; a microcontroller (which includes a processing unit and a non-transitory computer readable medium); a field programmable gate array (FPGA); a system on a chip (SoC); an application specific integrated circuit (ASIC); and an artificial intelligence accelerator. Examples of computer readable media are non-transitory and include: disc-based media such as CD-ROM and DVD; magnetic media such as hard disks drives and other forms of disk storage; semiconductor-based media such as flash memory media, random access memory (including DRAM and SRAM), and read only memory.

[0076] It is contemplated that any portion of any aspect or embodiment discussed in this specification can be implemented or combined with any portion of any other aspect or embodiment discussed in this specification.

[0077] One or more example embodiments have been described by way of illustration, not limitation. This description is presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the form of the disclosure to the precise form disclosed. Many modifications and variations are possible in light of this disclosure.

Claims

1. A battery pack, comprising: One or more battery stacks, each battery stack including a stacking module, the stacking module comprising: Battery stack interface module; and One or more battery modules; One or more battery string disconnect modules (SDMs), wherein each battery string disconnect module: Located in the battery stacks of the one or more battery stacks; Connected to a battery string, the battery string comprising one or more battery modules connected in series with the battery pack; and It is configured to selectively connect or disconnect one or more battery modules in the battery string. Specifically, at least one of the one or more battery modules in the battery stack is separated from the battery stack interface module of the battery stack in which the at least one battery string disconnect module is located.

2. The battery pack according to claim 1, wherein, For at least one battery stack, the battery stack interface module is located at the bottom of the at least one battery stack, and the one or more battery modules are located above the battery stack interface module.

3. The battery pack of claim 1, further comprising one or more battery pack controllers configured to control the operation of each battery module in the battery pack by communicating with each battery module.

4. The battery pack according to claim 3, wherein, The one or more battery pack controllers are further configured to communicate with each battery module and each battery string disconnect module via a battery pack interface module of the battery pack in which the battery module or battery string disconnect module is located, thereby controlling the operation of each battery module and each battery string disconnect module in the battery pack.

5. The battery pack according to claim 4, wherein, The one or more battery pack controllers are configured to communicate with each battery module and each battery string disconnect module in the following manner: The one or more battery pack controllers send communication to the battery stack interface module of the battery stack where the battery module or the battery string disconnect module is located; and The battery stack interface module forwards the communication to the battery module or the battery string disconnect module.

6. The battery pack according to claim 1, wherein: The one or more battery stacks include a first battery stack and a second battery stack; At least one of the one or more battery strings includes: One or more first battery modules in the first battery stack; and One or more second battery modules in the second battery stack; and The topmost battery module of the one or more first battery modules is connected to the bottommost battery module of the one or more second battery modules.

7. The battery pack according to claim 6, wherein, The topmost battery module in one or more first battery modules in the first battery stack is not the topmost battery module among all battery modules in the first battery stack.

8. The battery pack according to claim 6, wherein, The topmost battery module of the one or more first battery modules is connected to the bottommost battery module of the one or more second battery modules via the battery stack interface base of the first battery stack and via the battery stack interface base of the second battery stack.

9. The battery pack according to claim 8, wherein, The topmost battery module of the one or more first battery modules is connected to the battery stack interface base of the first battery stack using a flexible power connector.

10. The battery pack according to claim 1, wherein: The one or more battery stacks include a first battery stack and a second battery stack; and Second battery stack: Horizontally adjacent to the first battery stack, such that the side of the first battery stack is adjacent to the side of the second battery stack; or It is positioned back-to-back with the first battery stack, such that the rear of the first battery stack is adjacent to the rear of the second battery stack.

11. The battery pack according to claim 1, wherein, For at least one battery stack, the topmost battery module of the battery stack is connected to the battery stack interface module of the battery stack using a flexible power connector.

12. The battery pack according to claim 1, wherein: The one or more battery stacks include a first battery stack and an adjacent second battery stack; and The battery stack interface base of the first battery stack is connected to the battery stack interface base of the second battery stack using a power connector.

13. The battery pack according to claim 1, wherein, For at least one battery string: The at least one battery string is entirely contained within a single battery stack of the plurality of battery stacks, wherein the single battery stack includes a battery string disconnect module connected to the at least one battery string; and The at least one battery string and one or more series-connected battery modules consist of the following: Each battery module stacked above a battery string disconnect module connected to the at least one battery string; and The topmost battery module of the single battery stack.

14. The battery pack according to claim 1, wherein, For at least one battery string: The at least one battery string is divided into at least a first battery stack and a second battery stack, wherein the first battery stack includes a battery string disconnect module connected to the at least one battery string and at least one other battery string disconnect module, and wherein the second battery stack includes at least one battery string disconnect module; and The at least one battery string and one or more series-connected battery modules consist of the following: In the first battery stack, each battery module is stacked above a battery string disconnect module connected to the at least one battery string and below the at least one other battery string disconnect module; and In the second battery stack, each battery module is located below at least one battery string disconnect module of the second battery stack.

15. The battery pack according to claim 1, wherein, Pairs of vertically adjacent modules are connected using one or more busbars.

16. The battery pack according to claim 1, wherein, In each battery stack, each module includes one or more optical communication ports, which are optically coupled to one or more optical communication ports of the vertically adjacent module.

17. The battery pack according to claim 1, wherein, In each battery stack, the battery stack interface module includes one or more digital communication ports that are communicatively coupled to one or more digital communication ports of the battery stack interface modules of adjacent battery stacks.

18. The battery pack according to claim 17, wherein, The one or more digital communication ports include one or more Ethernet ports.

19. The battery pack according to claim 17, further comprising: One or more battery pack controllers are configured to control the operation of each battery module in the battery pack by communicating with each battery module. The one or more battery pack controllers are further configured to communicate with each battery module and each battery string disconnect module via a battery pack interface module of the battery pack containing the battery module or battery string disconnect module, thereby controlling the operation of each battery module and each battery string disconnect module in the battery pack. The one or more battery pack controllers are communicatively connected to each battery stack interface module via the one or more digital communication ports.

20. The battery pack according to claim 1, wherein: The one or more battery stacks include a first battery stack and a second battery stack; and The battery stack interface module of the first battery stack and the battery stack interface module of the second battery stack are located on different horizontal planes.

21. The battery pack according to claim 1, wherein, At least one battery module of the battery pack includes one or more fans for air cooling of the battery module.

22. The battery pack of claim 1, further comprising one or more liquid cooling systems for liquid cooling of at least one battery module of the battery pack.

23. The battery pack according to claim 1, wherein, No battery stack includes more than two disconnected battery strings.

24. The battery pack according to claim 1, wherein, At least one battery stack includes at least two battery string disconnect modules.

25. The battery pack according to claim 1, wherein, At least one battery string includes an electrical safety shutdown path that connects a battery string disconnect module of the battery string to each battery module in the battery string.

26. The battery pack according to claim 1, wherein, The battery stack interface module in the at least one battery stack includes: At least one DC bus terminal for receiving at least one electrical connector; and At least one battery-side terminal is electrically coupled to one or more battery modules in the at least one battery stack, wherein the at least one DC bus terminal is movable relative to the at least one battery-side terminal between an open position and a closed position, such that when in the closed position, the at least one electrical connector is electrically coupled to the at least one battery-side terminal when received by the at least one DC bus terminal, and when in the open position, an air gap electrically isolates the at least one electrical connector from the at least one battery-side terminal when the at least one electrical connector is received by the at least one DC bus terminal.

27. The battery pack according to claim 26, wherein, The at least one DC bus terminal and the at least one battery-side terminal are axially movable relative to each other, and wherein the battery stack interface module in the at least one battery stack further includes a screw connected to the at least one DC bus terminal, the screw controlling the axial position of the at least one DC terminal relative to the at least one battery-side terminal.

28. A method for installing a battery pack, comprising: For each battery stack, one or more battery stacks are installed by stacking modules, including: Battery stack interface module; and One or more battery modules; During the installation of the one or more battery stacks, one or more battery string disconnect modules are installed by including each battery string disconnect module (SDM) in the battery stack of the one or more battery stacks, wherein: Each battery string disconnect module is connected to a battery string that includes one or more battery modules of the battery pack; Each battery string disconnect module is configured to selectively connect or disconnect one or more battery modules in the battery string; and At least one of the one or more battery modules in the battery stack is separated from the battery stack interface module of the battery stack in which the at least one battery string disconnect module is located.

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