Air circulation for heat transfer in materials handling vehicle batteries

Abstract

An industrial battery design for use in a material handling vehicle. The battery includes a metal substrate, a battery container secured to the metal substrate to form a sealed housing for the battery, a row of one or more battery cells disposed over the metal substrate, and a top tray disposed over the row of battery cells. The top tray includes a first fan for blowing in a first direction within the battery container and a second fan for blowing in a second direction within the battery container, where the second direction is opposite to the first direction.

Description

Cross-references to related applications

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 688,186, filed August 28, 2024, the entire contents of which are incorporated herein by reference. Background Technology

[0002] Various types of batteries have been used to power material handling vehicles (MHVs) and other industrial applications. However, there is a general expectation in the industry for improvements in industrial battery design. Summary of the Invention

[0003] This disclosure generally relates to an industrial battery design that includes an air circulation system.

[0004] In one aspect, this disclosure provides a material handling vehicle. The material handling vehicle includes a battery compartment and a battery sealed within a battery container and disposed within the battery compartment. The battery includes a metal substrate, a row of one or more battery cells disposed above the metal substrate, and a top tray disposed above the row of battery cells. The top tray includes a first fan and a second fan, the first fan being used to blow air into the battery container in a first direction, and the second fan being used to blow air into the battery container in a second direction, wherein the second direction is opposite to the first direction.

[0005] In another aspect, this disclosure provides a battery for a material handling vehicle. The battery includes a metal substrate, a battery container fixed to the metal substrate to form a sealed housing for the battery, a row of one or more battery cells disposed above the metal substrate, and a top tray disposed above the row of battery cells. The top tray includes a first fan and a second fan, the first fan for blowing air into the battery container in a first direction, and the second fan for blowing air into the battery container in a second direction, wherein the second direction is opposite to the first direction.

[0006] In another aspect, this disclosure provides another battery for a material handling vehicle. The battery includes a metal substrate, a battery container fixed to the metal substrate to form a sealed housing for the battery, a row of one or more battery cells disposed above the metal substrate, and a top tray disposed above the row of battery cells. The top tray includes a first fan disposed in the upper left quadrant of the top tray for blowing air into the battery container in a first direction; a second fan disposed in the upper right quadrant of the top tray for blowing air into the battery container in a second direction; a third fan disposed in the lower left quadrant of the top tray for blowing air into the battery container in the first direction; and a fourth fan disposed in the lower right quadrant of the top tray for blowing air into the battery container in a second direction, wherein the first direction is away from the metal substrate and the row of battery cells, and the second direction is towards the metal substrate and the row of battery cells.

[0007] The foregoing and other aspects and advantages of this disclosure will become apparent in the description below. In this specification, reference is made to the accompanying drawings, which form a part of this specification, and preferred constructions of this disclosure are shown therein by way of illustration. However, such constructions do not necessarily represent the entire scope of this disclosure, and therefore reference is made to the claims, which are used herein to interpret the scope of this disclosure. Attached Figure Description

[0008] The invention will be better understood when considering the following specific embodiments, and features, aspects, and advantages in addition to those described above will become apparent. This specific embodiment is illustrated in the following figures.

[0009] Figure 1 This is a perspective view of an example material handling vehicle, including a battery compartment for batteries, according to some aspects of this disclosure.

[0010] Figure 2 It is shown that some aspects of this disclosure are compatible with Figure 1 A block diagram of an example battery component used in material handling vehicles.

[0011] Figure 3 It is shown in accordance with some aspects of this disclosure Figure 2 An illustration of an example implementation of the battery.

[0012] Figure 4 It is shown in accordance with some aspects of this disclosure Figure 2 An illustration of an example battery container.

[0013] Figure 5 It is shown in accordance with some aspects of this disclosure Figure 2 An illustration of an example component of the battery's electronic tray.

[0014] Figure 6 It is shown in accordance with some aspects of this disclosure Figure 2 Example schematic diagram of the various components of a battery.

[0015] Figure 7 It is shown, according to some aspects of this disclosure, that it may include as Figure 2 An illustration of an example implementation of a fan that is part of the top tray of the battery.

[0016] Figure 8 It is shown, according to some aspects of this disclosure, that it may include as Figure 2 Another illustration of an example implementation of a fan that is part of the top tray of the battery.

[0017] Figure 9 It is shown in some aspects of this disclosure Figure 2 A diagram illustrating an example temperature distribution on the battery cell during the operation of battery 2.

[0018] Figure 10 It is shown in some aspects of this disclosure Figure 2 A diagram illustrating an example temperature distribution on the battery container during the operation of battery 2.

[0019] Figure 11 It is shown, according to some aspects of this disclosure, that when considering contactor temperature... Figure 2 A diagram illustrating an example temperature distribution on a battery cell during battery operation.

[0020] Figure 12 It is shown, according to some aspects of this disclosure, that when considering contactor temperature... Figure 2 A diagram illustrating an example temperature distribution on the battery container during battery operation.

[0021] Figure 13 It is shown in some aspects of this disclosure Figure 2 A diagram illustrating an example temperature distribution on the electronic tray during battery operation.

[0022] Figure 14 It is shown in some aspects of this disclosure Figure 2 An illustration of the airflow velocity distribution during battery operation.

[0023] Figure 15 It is shown in some aspects of this disclosure Figure 2 Another illustration of the airflow velocity distribution during battery operation.

[0024] Figure 16 It is shown in some aspects of this disclosure Figure 2 A diagram illustrating the pressure distribution during battery operation.

[0025] Figure 17 It is shown in some aspects of this disclosure Figure 2 A flowchart illustrating an example process of providing air circulation within the battery. Detailed Implementation

[0026] Before providing a detailed description of any aspect of the invention, it should be understood that the invention is not limited to its application to the structural details and component arrangements described in the following specification or drawings. The invention can have other aspects and can be practiced or implemented in various ways. Moreover, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The terms “comprising,” “including,” or “having,” and variations thereof, as used herein, are intended to cover the items listed thereafter and their equivalents, as well as any accompanying items. Unless otherwise specified or limited, the terms “mounted,” “connected,” “supported,” and “linked,” and variations thereof, are used broadly and cover direct and indirect mounting, connection, support, and linking. Furthermore, “connection” and “linking” are not limited to physical or mechanical connections or links.

[0027] The following arguments are presented to enable those skilled in the art to make and use aspects of this disclosure. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles herein can be applied to other aspects and applications without departing from the aspects of this disclosure. Therefore, the aspects of this disclosure are not intended to be limited to those shown, but are given the widest scope consistent with the principles and features disclosed herein. The following detailed description should be read with reference to the accompanying drawings, in which the same elements in different drawings have the same reference numerals. The drawings, not necessarily drawn to scale, illustrate selected aspects and are not intended to limit the scope of the aspects of this disclosure. Those skilled in the art will recognize that the examples provided herein have many useful alternatives, and that they fall within the scope of the aspects of this disclosure.

[0028] It should also be understood that material handling vehicles (MHVs) are designed in various categories and configurations to perform a wide range of tasks. It will be apparent to those skilled in the art that this disclosure is not limited to any particular MHV, and that various other types of MHV categories and configurations are also provided, including, for example, crane trucks (lift trucks), forklifts, reach trucks, etc. Vehicles, including turret trucks, side-loading trucks, counterbalance forklifts, pallet stacker trucks, picking trucks, transtackers, tractors, and passenger trucks, are commonly found in warehouses, factories, freight yards, and anywhere there is a general need to move pallets, large packages, or stacks of goods from one location to another. The various systems and methods disclosed herein are suitable for any operator-controlled, walk-by-walker-controlled, remotely controlled, and autonomously controlled material handling vehicles. Furthermore, the various systems and methods disclosed herein are applicable to other vehicles such as automobiles, buses, trains, tractor-trailers, agricultural vehicles, factory vehicles, etc.

[0029] See Figure 1According to some aspects of this disclosure, a perspective view of an exemplary material handling vehicle 100 is shown. Figure 1 In the example, the material handling vehicle 100 is a forklift. The material handling vehicle 100 is shown as including a battery compartment 102, a power unit 103, and a joystick 104. The power unit 103 may include any power electronics and other components suitable for operating the material handling vehicle 100. An operator of the material handling vehicle 100 can use the joystick 104 to operate the material handling vehicle 100. The battery compartment 102 is used to install and house industrial batteries that power the material handling vehicle 100, such as the various modular industrial battery configurations described below. The battery compartment 102 in the material handling vehicle 100 may include terminals, ports, wiring, and other components for connecting the industrial batteries to the material handling vehicle 100. It should be understood that, depending on the type and configuration of the material handling vehicle, battery compartments similar to battery compartment 102 may be located in different locations and presented in different configurations.

[0030] See Figure 2 According to some aspects of this disclosure, a block diagram of components of an example battery 200 that can be used with a material handling vehicle 100 is shown. Specifically, the battery 200 may be a sealed battery and may be disposed within the battery compartment 102 of the material handling vehicle 100. Figure 2 As shown, battery 200 may include a top tray 210, a battery cell array 230, and a battery cell array 240. Furthermore, as shown, top tray 210 may include fans 212, 214, 216, and 218, and an electronic tray 220 including a controller 222. Battery cell array 230 may be disposed above battery cell array 240, and top tray 210 may be disposed above battery cell array 230. In some examples, electronic tray 220 may be a component of top tray 210. In some examples, electronic tray 220 may also be separate from top tray 210, wherein electronic tray 220 may be disposed above and fixed to top tray 210.

[0031] Battery cell rows 230 and 240 may include any number of battery cells. Furthermore, in some examples, battery 200 may include only one of battery cell rows 230 or 240, such that battery 200 may include only one or more battery cells in a single row. Additionally, battery 200 may include one or more additional rows of battery cells besides battery cell rows 230 and 240, such that in some examples battery 200 may include three or more rows of battery cells. Battery cell row 230 may include one or more lithium iron phosphate (LFP) battery cells (sometimes referred to as "modules"), and battery cell row 240 may also include one or more LFP battery cells. Specific designs of the air circulation system (e.g., fans 212, 214, 216, and 218 in the top tray 210) may be particularly advantageous in embodiments where battery 200 includes LFP battery cells rather than other types of battery cells. However, in some examples, battery 200 may be implemented with different types of battery cells other than LFP battery cells. Top tray 210, electronic tray 220, fan 212, fan 214, fan 216 and fan 218 will be described in further detail below.

[0032] The controller 222 can be implemented in the battery 200 in various ways, including using one or more separate controller devices. For example, the controller 222 may include various suitable types of processing circuitry (e.g., one or more central processing units (CPUs) and memory (e.g., volatile, non-volatile, random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), etc.). The memory may include one or more non-transitory machine-readable storage media storing instructions that, when executed by the processing circuitry, cause the processing circuitry to perform various operations according to the instructions. The controller 222 may also include various suitable types of communication interfaces for communication via various suitable protocols (e.g., a Controller Area Network (CAN) interface for communication via a CAN bus, an Ethernet interface, a serial communication interface, etc.). The controller 222 can then communicate with various components of the battery 200 (e.g., fans 212, 214, 216, and 218, etc.), the material handling vehicle 100 (e.g., the vehicle controller of the material handling vehicle 100), and / or other computing devices (e.g., servers, personal computing devices, etc.).

[0033] See Figure 3 According to some aspects of this disclosure, illustrations of exemplary embodiments of the battery 200 are shown. Specifically, Figure 3The embodiment of battery 200 shown does indeed include battery cell rows 230 and 240, and each of battery cell rows 230 and 240 includes three LFP battery cells. Specifically, as shown, battery cell row 230 includes battery cells 232, 234, and 236, and battery cell row 240 includes battery cells 242, 244, and 246. The 2x3 cell configuration shown represents only one possible embodiment of battery 200. The design of various components of battery 200, including air circulation systems (e.g., fans 212, 214, 216, and 218 in the top tray 210), can be highly repeatable (and thus efficiently manufactured) for various types of modular battery cell configurations. For example, depending on the desired application (e.g., the type of material handling vehicle, etc.), battery 200 may include, in alternative examples, a 2x2 cell configuration, a 1x1 cell configuration, a 1x2 cell configuration, etc.

[0034] like Figure 3 As shown, the battery 200 may also include a metal substrate 270. The metal substrate 270 can be formed using various suitable metals (e.g., steel, aluminum, etc.) and can have different dimensions depending on the intended application of the battery 200. The metal substrate 270 typically provides a structure serving as a base for the battery 200. Additionally, a lower metal tray 260 may be formed on or otherwise disposed above the metal substrate 270. The lower metal tray 260 can also be formed using various suitable metals (e.g., steel, aluminum, etc.) and can have different dimensions depending on the intended application of the battery 200. Then, a battery cell row 240 including battery cells 242, 244, and 246 can be formed on or otherwise disposed above the lower metal tray 260. Furthermore, a middle metal tray can be disposed above the battery cell row 240 including battery cells 242, 244, and 246. The central metal tray 250 can also be formed using various suitable metals (such as steel, aluminum, etc.) and can have different sizes depending on the intended application of the battery 200. Then, a battery cell row 230 including battery cells 232, 234 and 236 can be formed on the central metal tray 250 or otherwise disposed above the central metal tray 250.

[0035] Then, as Figure 3As shown, the top tray 210 can be positioned above the battery cell row 230, which includes battery cells 232, 234, and 236. The top tray 210 can also be formed from various suitable metals (e.g., steel, aluminum, etc.) and can have different dimensions depending on the intended application of the battery 200. Finally, an electronic tray 220 can be formed on or otherwise positioned above the top tray 210. The electronic tray 220 can include various electronic and / or mechanical components for the battery 200, as will be further detailed below. As previously mentioned, the electronic tray 220 can be an integral part of the top tray 210, or it can be detached from the top tray 210. In the example where the electronic tray 220 is detached from the top tray 210, the electronic tray 220 can be secured to the top tray 210 in various suitable ways (e.g., using various types of fasteners, etc.).

[0036] See Figure 4 According to some aspects of this disclosure, illustrations of example embodiments of a battery container 280 for a battery 200 are shown. Together with a metal substrate 270, the battery container 280 can be used to provide a sealed housing that protects internal components of the battery 200 (e.g., battery cell rows 230, 240, electronic tray 220, etc.) from environmental factors. For example, the sealed housing formed by the battery container 280 and the metal substrate 270 can protect the internal components of the battery 200 from the intrusion of dust, liquids, chemicals, and other potential contaminants. The battery container 280 can be formed using various suitable materials (e.g., bent steel sheet, bent aluminum sheet, etc.) and can be, for example, bolted to the metal substrate 270 to form the sealed housing. The battery container 280 and / or the metal substrate 270 may include components that help form the sealed housing, such as gaskets, compression restrainers, etc. In some examples, the metal substrate 270 may be considered part of the battery container 280 itself. Depending on the specific modular configuration of the battery 200, the battery container 280 may have different dimensions for a given application. Since the battery 200 may be sealed inside the battery container 280 and located in the battery compartment 102 of the material handling vehicle 100, it may be difficult to remove heat from the battery cells (e.g., battery cells 232, 234, 236, 242, 244 and 246) during operation of the battery 200 without an air circulation system.

[0037] Typically, thermal management (e.g., removing heat from battery cells 232, 234, 236, 242, 244, and 246) is required within battery 200 because battery 200 can be sealed not only within battery container 200 but also further disposed within battery compartment 102 of material handling vehicle 100. Without fans (e.g., fans 212, 214, 216, and / or 218) in battery 200, approximately 90% of the heat transfer resistance may exist between the walls of the battery cells (e.g., battery cells 232, 234, 236, 242, 244, and 246) and the walls of battery container 280. In contrast, without fans in battery 200, only about 10% of the heat transfer resistance may exist between battery container 280 and ambient air. However, using fans 212, 214, 216, and / or 218 in battery 200 may be advantageous because their use allows more heat to be transferred from the walls of the battery cell to the walls of battery container 280. The air circulation provided within battery 200 by fans 212, 214, 216, and / or 218 can provide convection within battery 200 by providing a thermal connection between the battery cell and battery container 280. Furthermore, the specific design of fans 212, 214, 216, and / or 218 included in the top tray 210 can provide effective heat dissipation from the top of battery container 280.

[0038] Battery 200 can be divided into discrete hot zones, the boundaries of which can follow an empirically mapped heat loss gradient of the sealed casing of battery 200 (e.g., battery container 280 and metal substrate 270). The hot zones of battery 200 can be equipped with dedicated temperature sensors or temperature sensing systems (e.g., thermistor pairs, resistance temperature detector (RTD) strings, etc.). Controller 222 can then use the temperature data associated with the different hot zones of battery 200 for various purposes. For example, controller 222 can use the temperature data associated with the different hot zones of battery 200 to adjust heater power (e.g., by controlling heater relay 352, etc., as detailed below) or adjust the duty cycle of fans 212, 214, 216, and / or 218, as well as other possible types of control functions associated with battery 200. Controller 222 can implement control strategies to provide a larger or faster rate of heating circuit circulation for hot zones with higher conduction or convection losses, while maintaining hot zones with lower conduction or convection losses in a low-power sustaining state. Therefore, dividing the battery 200 into hot zones allows the controller 222 to dynamically redistribute power as the environmental conditions (and its heat loss curve) of the material handling vehicle 100 change over time.

[0039] See Figure 5 According to some aspects of this disclosure, illustrations of example components of the electronic tray 220 are shown. Specifically, Figure 5 A top view and a bottom view of the electronic tray 220 are shown. As shown, the electronic tray 220 may include a main controller 322, a sub-controller 324, an interface board 332, a communication board 334, a communication port 326, a main contactor 342, a series contactor 344, a heater relay 352, a system fuse 354, a shunt 356, and a Hall effect sensor 358. Each of these components of the electronic tray 220 can be formed on the metal substrate 310 of the electronic tray 220, such as... Figure 5 As shown. Figure 2 The controller 222 shown can be implemented in various ways. For example, the controller 222 may include a main controller 322 and a sub-controller 324, or the controller 222 may include only the main controller 322, and other possible implementations.

[0040] The metal substrate 310 of the electronic tray 220 can be formed using various suitable metals (e.g., steel, aluminum, etc.) and can have different dimensions depending on the intended application of the battery 200. The metal substrate 310 typically provides a structure serving as the base for the electronic tray 220. The main controller 322 and the sub-controller 324 can be implemented using various suitable types of electronic controller components. The main controller 322 and the sub-controller 324 can each include various types of processing circuitry and various types of memory storing non-transitory machine-readable instructions, which, when executed by the processing circuitry of the main controller 322 and the sub-controller 324 respectively, cause the main controller 322 and the sub-controller 324 to operate according to the machine-readable instructions. The main controller 322 can interact with the sub-controller 324, such that the main controller 322 acts as the primary initiator of control transactions, and the sub-controller 324 responds to communications received from the main controller 322. The main controller 322 and the sub-controller 324 can operate as separate modules as part of the battery management system (BMS) of the battery 200.

[0041] Both interface board 332 and communication board 334 can be implemented as printed circuit boards (PCBs), among other possible implementations. Interface board 332 may include circuitry for providing various electronic interfaces between components of battery 200. For example, interface board 332 may include circuitry to provide an electronic interface between main controller 322 and sub-controller 324, and to provide an interface between controller 222 and various sensors included as part of battery 200 (e.g., to communicatively connect controller 222 to sensors). Communication board 334 may include circuitry to provide communication between battery 200 and material handling vehicle 100 (e.g., an interface between battery 200 and one or more controllers on material handling vehicle 100). Communication port 336 may be communicatively coupled to interface board 332 and / or communication board 334 and may be used to form various electrical connections between battery 200 and external components and devices (e.g., wiring battery 200 to one or more controllers on material handling vehicle 100, etc.).

[0042] The main contactor 342 may include any suitable number of main contactors for protecting the battery (e.g., interrupting current in the circuit under certain operating conditions). Similarly, the series contactor 344 may include any suitable number of contactors for protecting the battery (e.g., interrupting current in the circuit under certain operating conditions). The main contactor 342 can be universal for all modular configurations of the battery 200 (e.g., 1x1 unit configuration, 2x2 unit configuration, etc.), while the series contactor 344 can vary depending on the specific modular configuration of the battery 200 (e.g., the series contactor 344 may include two contactors for smaller battery sizes and four contactors for larger battery sizes). Both the main contactor 342 and the series contactor 344 can be implemented using a variety of suitable types and configurations of contactors. Furthermore, in some applications, the main contactor 342 and the series contactor 344 may be implemented using other suitable components (e.g., different types of switches, relays, etc.).

[0043] Heater relay 352 is typically used to control the operation of one or more heaters to provide heat to battery cell rows 230 and 240. For example, the ability to provide heat to battery cell rows 230 and 240 via one or more heaters when battery 200 is powered on can help battery 200 achieve a steady-state operating condition that might not be achievable without these heaters. Heater relay 352 can be implemented using various suitable types and configurations of relays, and heaters can be implemented using various suitable types and configurations of heaters. Furthermore, in some applications, heater relay 352 can be implemented using other suitable components (e.g., different types of switches, contactors, etc.). For example, battery 200 may include one of heater relays 352 and a connected heater for each row of battery cells used in battery 200 (e.g., a first heater and first heater relay for battery cell row 230, and a second heater and second heater relay for battery cell row 240).

[0044] A system fuse 354 can be used in the battery 200 to provide overcurrent protection for the battery 200 by interrupting the current flowing through it. The system fuse 354 can be implemented using different types and configurations of fuses depending on the application of the battery 200. Similarly, a shunt 356 can be used in the battery 200 to provide further overcurrent protection for the battery 200 by diverting current within it. The shunt 356 can also be implemented using different types and configurations of shunts depending on the application of the battery 200. A Hall effect sensor 358 can be used in the battery 200 to provide current sensing and / or other types of sensing functions. The Hall effect sensor 358 can be implemented using different types and configurations of Hall effect sensors depending on the application of the battery 200.

[0045] See Figure 6 According to some aspects of this disclosure, example schematic diagrams of various components of the battery 200 are shown. Figure 6 The schematic diagram shows various example components of the electronic tray 220, including heater relay 352, system fuse 354, shunt 356, and Hall effect sensor 358. Fans 212, 214, 216, and 218 are also visible. Figure 6The schematic diagram also illustrates various attached example components, including charger guide circuit interface 362, proximity sensor 364, charger guide circuit interface 367, proximity sensor 368, charger disconnector 372, parallel series disconnector 374, truck disconnector 376, redundancy disconnector 378, terminal circuit 382, ​​truck control interface 384, truck wake-up interface 386, truck control interface 388, fan disconnector 390, first charger connector port 392, second charger connector port 394, and truck connector port 396. Figure 6 The schematic diagram shown represents only one possible implementation of various aspects of the battery 200 disclosed herein; other implementations are also conceivable and possible.

[0046] The main contactor 342 may include, for example, a charger disconnect contactor 372, a truck disconnect contactor 376, and / or a redundant disconnect contactor 378, such as Figure 6 As shown. Charger disconnect contactor 372 can be used to disconnect components of battery 200 (e.g., disconnect from power supply) in an overcurrent condition that may result from one or more charger devices (e.g., via first charger connector port 392 and second charger connector port 394) connected to battery 200. For example, controller 222 may receive current data from Hall effect sensor 358 and / or other sensors included in battery 200, and open charger disconnect contactor 372 in response to determining that the current data exceeds one or more thresholds. Truck disconnect contactor 376 can be used to disconnect components of battery 200 and / or material handling vehicle 100 when an overcurrent condition may occur within battery 200 and / or material handling vehicle 100. For example, controller 222 may receive data from Hall effect sensor 358 and / or other sensors included in battery 200, and open truck disconnect contactor 376 in response to determining that the sensor data exceeds one or more thresholds. The redundant disconnect contactor 378 can also be used to disconnect components of the battery 200 and / or the material handling vehicle 100 in the event of an overcurrent condition that may occur within the battery 200 and / or the material handling vehicle 100. For example, the controller 222 may receive data from the Hall effect sensor 358 and / or other sensors included in the battery 200, and open the redundant disconnect contactor 378 in response to determining that the sensor data exceeds one or more thresholds.

[0047] The series contactor 344 may include, for example, the series disconnect contactor 374, such as... Figure 6 As shown. The series disconnect contactor 374 can be used to cut off the current flowing to and / or from the battery cells of battery 200, in order to disconnect the battery 200 and / or components of the material handling vehicle 100 in the event of an overcurrent condition that may occur within battery 200. For example... Figure 6As illustrated in the schematic diagram, the series disconnect contactor 374 may include a first contactor connected to a first row of battery cells (e.g., battery cell row 230) and a second contactor connected in parallel with the first contactor to a second row of battery cells (e.g., battery cell row 240). For example, the controller 222 may receive data from the Hall effect sensor 358 and / or other sensors included in the battery 200, and open one or more series disconnect contactors 374 in response to determining that the sensor data exceeds one or more thresholds.

[0048] The first charger connector port 392 is used to connect a first charger device to the battery 200, and the second charger connector port 394 is used to connect a second charger device to the battery 200. The truck connector port 396 is used to connect the battery 200 to the material handling vehicle 100 (e.g., to a controller on the material handling vehicle 100). The charger guide circuit interface 362 may include circuitry for providing a charging interface between the first charger device and the battery 200, and the charger guide circuit interface 367 may include circuitry for providing a charging interface between the second charger device and the battery 200. The proximity sensor 364 provides proximity sensing functionality, enabling the controller 222 to detect the presence of a connection between the first charger device and the battery 200, and the proximity sensor 368 provides proximity sensing functionality, enabling the controller 222 to detect the presence of a connection between the second charger device and the battery 200.

[0049] Terminal circuitry 382 may be included in battery 200 to provide an endpoint (terminal) of a communication bus (e.g., CAN bus) for battery 200. Truck control interface 384 may be included in battery 200 to provide a control interface between battery 200 and material handling vehicle 100. Truck wake-up interface 386 may be used to transmit a wake-up signal (e.g., a power-on signal) to battery 200 via material handling vehicle 100 (e.g., when material handling vehicle 100 is powered on). Truck control interface 388 may also be included in battery 200 to provide a control interface between battery 200 and material handling vehicle 100. Specifically, truck control interface 384 may provide a common standard interface (PSI) option, while truck control interface 388 may provide a power limiting (PSL) interface option for battery 200. Fan disconnector 390 may be controlled by controller 222 to supply or disconnect power to fans 212, 214, 216, and 218.

[0050] See Figure 7 According to some aspects of this disclosure, an illustration shows an example embodiment of a fan 212 included as part of a top tray 210 of a battery 200. Again, in Figure 7In the illustrated embodiment of battery 200, battery 200 includes two rows of three battery cells each (2x3 cell configuration). Specifically, battery 200 includes battery cell row 230 and battery cell row 240. Battery cell row 230 includes battery cells 232, 234, and 236, and battery cell row 240 includes battery cells 242, 244, and 246. Additionally, a top tray 210 is disposed above battery cell row 230. Figure 7 In the embodiment of the battery 200 shown, the fan 212 is located in the upper left corner of the top tray 210.

[0051] See Figure 8 According to some aspects of this disclosure, it is shown that Figure 7 Another perspective view of an example implementation of the battery 200. Figure 8 The illustration provided is a perspective view of the top tray 210 when viewed downwards along the z-axis. Figure 8 In the diagram, the top tray 210 is divided into four quadrants: upper left quadrant 810, upper right quadrant 820, lower left quadrant 830, and lower right quadrant 840. As shown, these quadrants can be roughly divided along the x and y axes. Again, fan 212 is located in the upper left quadrant 810 of the top tray 210, typically in the upper left corner. Then, as shown, fan 218 can be located in the upper right quadrant 820, fan 214 in the lower left quadrant 830, and fan 216 in the lower right quadrant 840. More generally, fans 212 and 214 may be located in the left half of the top tray 210, wherein the left half of the top tray 210 includes the upper left quadrant 810 and the lower left quadrant 830 of the top tray 210. Similarly, fans 216 and 218 may more generally be located in the right half of the top tray 210, wherein the right half of the top tray 210 includes the upper right quadrant 820 and the lower right quadrant 840 of the top tray 210.

[0052] Fans 212, 214, 216, and 218 can be implemented using different suitable types and configurations of fans depending on the intended application of battery 200. For example, fans 212, 214, 216, and 218 can each be implemented as 60x60x25 mm fans disposed in top tray 210, among other possible examples. The operation of fans 212, 214, 216, and 218 is typically controlled by controller 222. For example, controller 222 can control fan 212 such that it blows air in a first direction within battery container 280, and controller 222 can control fan 218 such that it blows air in a second direction opposite to the first direction within battery container 280. Controller 222 can also control fan 214 such that it blows air in the first direction within battery container 280, and controller 222 can control fan 216 such that it blows air in a second direction opposite to the first direction within battery container 280. The first direction can be an upward direction (e.g., away from the metal substrate 270 along the z-axis), and the second direction can be a downward direction (e.g., towards the metal substrate 270 along the z-axis).

[0053] See Figure 9 According to some aspects of this disclosure, an illustration of an example temperature distribution on battery cells 232, 234, 236, 242, 244, and 246 is shown during operation of battery 200. As shown, downstream battery cells including battery cells 232 and 234 (e.g., downstream where fan 218 blows air downward toward metal substrate 270) may be hotter than upstream battery cells including battery cells 236 and 246 (e.g., upstream where fan 218 blows air downward toward metal substrate 270) during operation of battery 200. Additionally, during operation of battery 200, the top row of battery cells (battery cell row 230) including battery cells 232, 234, and 236 may be on average about 2.2 degrees Celsius hotter (warmer) than the bottom row of battery cells (battery cell row 240) including battery cells 242, 244, and 246. Furthermore, during battery 200 operation, the left battery cell, including battery cells 232 and 242, can be on average about 1.9 degrees Celsius hotter than the right battery cell, including battery cells 236 and 246.

[0054] See Figure 10According to some aspects of this disclosure, an illustration of an example temperature distribution on the battery container 280 during operation of the battery 200 is shown. As shown, the temperature distribution on the battery container 280 can be fairly uniform during operation of the battery 200. However, during operation of the battery 200, the temperature distribution on the battery container 280 may be hotter where return air (e.g., air blown upwards by fans 212 and / or 214) impacts the top of the battery container 280, and cooler where air is locally circulated (e.g., air ultimately blown downwards by fans 216 and / or 218). During operation of the battery 200, the battery container 280 is on average about 7.7 degrees Celsius warmer than ambient air.

[0055] See Figure 11 According to some aspects of this disclosure, illustrations of example temperature distributions on battery cells 232, 234, 236, 242, 244, and 246 during operation of battery 200 are shown, including the effect of heat generated by the contactors of battery 200. In the components of battery 200, contactors (e.g., main contactor 342, series contactor 344) can be a significant source of heat generation within battery container 280 during operation of battery 200. Figure 11 As shown, when considering the heat generated by the contactor, the upstream battery cell including battery cells 236 and 246 (e.g., the upstream where fan 218 blows air downward toward metal substrate 270) may actually be hotter during battery 200 operation than the downstream battery cell including battery cells 232 and 242 (e.g., the downstream where fan 218 blows air downward toward metal substrate 270).

[0056] When considering the heat generated by the contactor of battery 200, the average temperature of the battery cells including battery cells 232, 234, 236, 242, 244, and 246 can be approximately 43.4 degrees Celsius, compared to approximately 31.8 degrees Celsius without considering the heat generated by the contactor. When considering the heat generated by the contactor, the top row of battery cells (battery cell row 230) including battery cells 232, 234, and 236 can be on average about 4.0 degrees Celsius hotter than the bottom row of battery cells (battery cell row 240) including battery cells 242, 244, and 246 during battery 200 operation. Furthermore, when considering the heat generated by the contactor, the left-side battery cells including battery cells 232 and 242 can be on average about 1.6 degrees Celsius cooler than the right-side battery cells including battery cells 236 and 246 during battery 200 operation.

[0057] See Figure 12According to some aspects of this disclosure, a diagram illustrating an example temperature distribution on battery container 280 during operation of battery 200 is shown, including the effect of heat generated by the contactors. As shown, when heat generated by the contactors is also taken into account, the temperature distribution on battery container 280 during operation of battery 200 can be fairly uniform. However, in this case, when heat generated by the contactors is taken into account, the temperature distribution on battery container 280 during operation of battery 200 may be hottest near the downstream contactor (e.g., truck disconnector 376) and hotter at the bottom of battery container 28 (e.g., below battery cell row 240) without external convection. On average, when heat generated by the contactors is taken into account, battery container 280 can be about 16.8 degrees Celsius hotter than ambient air during operation of battery 200.

[0058] See Figure 13 According to some aspects of this disclosure, a diagram illustrating example temperature distributions on various components of the electronic tray 220 during operation of the battery 200 is shown. Specifically, Figure 13 The illustration shows an example temperature distribution on example contactors 1310, 1312, 1320, and 1322 of the electronic tray 220. For example, Figure 13 The contactors 1310 and 1320 shown can be Figure 5 Two of the main contactors 342 are shown. Busbars 1320 and 1322 can be implemented in various configurations using various suitable types of busbars to form different electrical connections within the battery 200 (e.g., between battery cell rows 230 and 240 of the battery 200). As shown, contactors 1310, 1312, busbars 1320 and 1322 may become particularly hot during battery 200 operation. In particular, downstream contactors and busbars (e.g., downstream of the fan 212 blowing air upwards) may become hot during battery 200 operation.

[0059] See Figure 14 According to some aspects of this disclosure, an illustration of an example airflow velocity distribution that may occur within the battery container 280 during operation of the battery 200 is shown. Specifically, Figure 14The airflow velocity distribution shown can be generated using at least two of fans 212, 214, 216, and / or 218. As shown, fans 212, 214, 216, and / or 218 can generate the highest intensity airflow within the battery container 280 in the region between battery cell rows 230 and 240. Additionally, fans 212, 214, 216, and / or 218 can generate significant airflow within the battery container 280 in the regions near fans 212, 214, 216, and / or 218, as well as on the periphery of battery cell rows 230 and 240.

[0060] See Figure 15 According to some aspects of this disclosure, an illustration is shown of another example airflow velocity distribution that may occur within the battery container 280 during operation of the battery 200. Figure 15 The airflow velocity distribution shown can be generated again using at least two of fans 212, 214, 216, and / or 218. Specifically, Figure 15 The airflow velocity distribution shown illustrates the flow from the center plane of battery 200 (e.g., along...). Figure 8 The figure shows an example airflow velocity distribution within the battery container 280 from the perspective of a cross-section taken along the y-axis. As shown, fans 212, 214, 216, and / or 218 can again generate the highest intensity airflow within the battery container 280 in the region 1510 between the battery cell rows 230 and 240.

[0061] See Figure 16 According to some aspects of this disclosure, an illustration of an example pressure distribution that may occur within the battery container 280 during operation of the battery 200 is shown. Specifically, Figure 16 The pressure distribution shown can be generated using at least two of fans 212, 214, 216 and / or 218. Figure 16 The pressure distribution shown illustrates the pressure distribution from the plane of symmetry of battery 200 (e.g., along the plane of symmetry). Figure 8 The figure shows an example pressure distribution within battery container 280 from the perspective of a cross-section taken along the x-axis. As shown, the design of battery 200 in this example could contain a pressure rise of approximately 40 Pascals (Pa) or 0.16 inches of water column to drive a fan airflow of 30 cubic feet per minute (CFM) from fans 212, 214, 216, and / or 218.

[0062] See Figure 17According to some aspects of this disclosure, a flowchart of an example process 1700 for providing air circulation within battery 200 is shown. For example, process 1700 may be performed by controller 222 and at least two of fans 212, 214, 216, and / or 218. Process 1700 typically includes receiving temperature data associated with battery 200 and controlling the operation of fans 212, 214, 216, and / or 218 based on the temperature data. By implementing process 1700 within battery 200, fans 212, 214, 216, and / or 218 can provide heat transfer from cells of battery 200 and / or other components of battery 200 (e.g., main contactor 342, etc.) to walls of battery 200 (e.g., battery container 280). Therefore, fans 212, 214, 216 and / or 218 can provide thermal connections between the battery container and battery cells 232, 234, 236, 242, 244 and 246 to provide convection within the battery 200 and to dissipate heat through the top of the battery 200 (e.g. through a portion of the battery container 200 disposed above the top tray 210).

[0063] At step 1710, process 1700 may include receiving temperature data indicating the temperature of the battery cells of battery 200. For example, at step 1710, controller 222 may receive temperature data indicating the temperature of each of battery cells 232, 234, 236, 242, 244, and 246. Controller 222 may receive the temperature data indicating the temperature of the battery cells of battery 200 in a variety of suitable manner. For example, battery 200 may include temperature sensors of various suitable types and configurations, which may be included in battery 200 to generate and provide temperature data indicating the temperature of the battery cells to controller 222.

[0064] At step 1720, process 1700 may include receiving temperature data indicating the temperature of one or more other components in battery 200 besides the battery cells. For example, at step 1720, controller 222 may receive temperature data indicating the temperature of any component of electronic tray 220, such as main contactor 342 and / or series contactor 344. Controller 222 may receive temperature data indicating the temperature of one or more busbars of battery 200, temperature data indicating the ambient temperature at different locations within battery 200, and temperature data indicating the temperature of charging connector ports of battery 200 (e.g., ...). Figure 6Temperature data of the temperature of the charging connector port shown in the example schematic diagram, and / or temperature data indicating any other temperature related to battery 200. Controller 222 may again receive temperature data at step 1720 in a variety of suitable manners. For example, battery 200 may include various suitable types and configurations of temperature sensors that may be included within battery 200 to generate and provide temperature data to controller 222 at step 1720.

[0065] At step 1730, process 1700 may include determining whether the temperature of any battery cell of battery 200 exceeds a threshold temperature level. For example, at step 1730, controller 222 may evaluate the temperature data by comparing the temperature data received at step 1710 with one or more suitable threshold temperature levels. Different threshold temperature levels may be used in step 1730 depending on various factors related to the design of battery 200. For example, the threshold temperature level used in step 1730 may depend on the specific type of battery cell (e.g., capacity, weight, energy density, rated voltage, nominal energy, size characteristics (e.g., high speed, length, width, etc.)) and / or the specific location of the relevant battery cell within battery 200 (e.g., top row, bottom row, left side, right side, etc.). Furthermore, the threshold temperature level used in step 1730 may vary depending on the modular cell configuration of battery 200 (e.g., 2x3 cell configuration, 2x2 cell configuration, 1x1 cell configuration, 1x2 configuration, etc.). Additionally, the threshold temperature level used in step 1730 may vary depending on the number, type, and / or location of the fans (e.g., fans 212, 214, 216, and / or 218) included in the battery 200. At step 1730, the controller 222 may use the same threshold temperature level for each of the battery cells included in the battery 200, or the controller 222 may use at least one different threshold for the battery cells included in the battery 200.

[0066] At step 1740, process 1700 may include determining whether the temperature of any component of battery 200 exceeds a threshold temperature level. For example, controller 222 may evaluate the temperature data by comparing the temperature data received at step 1720 with one or more suitable threshold temperature levels. The threshold temperature level used by controller 222 at step 1740 may again vary depending on a variety of factors. For example, controller 222 may use a first threshold temperature level for one or more busbars of battery 200 and a second threshold temperature level for main contactor 342. The threshold temperature level used in step 1740 may again depend on the specific type of battery cell used within battery 200, the modular battery configuration of battery 200, and / or the number, type, and location of fans included in battery 200. Step 1740 may also include determining whether the temperature associated with any hot areas of battery 200 exceeds a threshold temperature level.

[0067] At step 1750, if, based on the evaluation at step 1730 or step 1740, any temperature data received at step 1710 or 1720 exceeds a corresponding threshold temperature level, process 1700 may include operating one or more fans of battery 200. For example, if controller 222 determines, based on the temperature data received at step 1710 or 1720, that any temperature threshold level evaluated at step 1730 or 1740 has been exceeded, controller 222 may send one or more appropriate control signals to operate fan 212, fan 214, fan 216, and / or fan 218. The control signals can operate fans 212, 214, 216, and / or 218 by turning fans 212, 214, 216, and / or 218 on or off, controlling the speed of fans 212, 214, 216, and / or 218, controlling the duty cycle of fans 212, 214, 216, and / or 218, and / or controlling the rotation direction of fans 212, 214, 216, and / or 218.

[0068] It should be noted that, although in Figure 17 The steps of process 1700 are shown in a specific order, but process 1700 may not include all the steps shown, may include additional steps, or may include steps in a different order.

[0069] Although various spatial and directional terms, such as top, bottom, lower, middle, side, horizontal, vertical, front, etc., may be used to describe examples of this disclosure, it should be understood that these terms are used only in relation to the orientation shown in the accompanying drawings. Orientation may be reversed, rotated, or otherwise changed such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and so on.

[0070] In this specification, various aspects are described in a manner that allows for clear and precise description, but it is intended and will be understood that these aspects can be combined or separated in various ways without departing from the disclosure. For example, it should be understood that all preferred features described herein can be applied to all aspects of the disclosed technology described herein.

[0071] Therefore, although the disclosed technology has been described in conjunction with specific aspects and examples, the disclosed technology is not necessarily limited in this way, and various other aspects, examples, uses, modifications and changes to aspects, examples, and uses are included in the appended claims. The full disclosure of each patent and publication cited herein is incorporated by reference as if each patent or publication were individually incorporated by reference herein.

[0072] The various features and advantages of this disclosure are set forth in the following claims.

Claims

1. A materials handling vehicle comprising: a battery compartment; and a battery sealed within a battery container and disposed within the battery compartment, the battery comprising: a metal base plate; a row of one or more battery cells disposed above the metal base plate; and a top tray disposed above the row of battery cells, the top tray comprising: a first fan for blowing air within the battery container in a first direction; and a second fan for blowing air within the battery container in a second direction opposite the first direction.

2. The materials handling vehicle of claim 1, wherein: the first direction is away from the metal base plate and the row of battery cells; and the second direction is toward the metal base plate and the row of battery cells.

3. The materials handling vehicle of claim 1, wherein, the top tray of the battery comprises: a third fan for blowing air within the battery container in the first direction; and a fourth fan for blowing air within the battery container in the second direction.

4. The materials handling vehicle of claim 1, wherein: the first fan is disposed in an upper left quadrant of the top tray; and the second fan is disposed in an upper right quadrant of the top tray.

5. The materials handling vehicle of claim 3, wherein: the first fan is disposed in an upper left quadrant of the top tray; the second fan is disposed in an upper right quadrant of the top tray; the third fan is disposed in a lower left quadrant of the top tray; and the fourth fan is disposed in a lower right quadrant of the top tray.

6. The material handling vehicle of claim 1, wherein, the battery comprises an electronics tray disposed on the top tray, the electronics tray comprising a controller and a contactor for the battery.

7. The materials handling vehicle of claim 6, wherein, the controller comprises circuitry configured to operate the first fan and the second fan in response to determining that a temperature of at least one battery cell of the row of battery cells exceeds a threshold value.

8. The material handling vehicle of claim 1, wherein, a second row of one or more battery cells disposed between the row of battery cells and the top tray.

9. A battery for a materials handling vehicle, the battery comprising: a metal base plate; a battery container secured to the metal base plate to form a sealed housing for the battery; a row of one or more battery cells disposed above the metal base plate; and a top tray disposed above the row of battery cells, the top tray comprising: a first fan for blowing air within the battery container in a first direction; and a second fan for blowing air within the battery container in a second direction opposite the first direction.

10. The battery of claim 9, wherein: the first direction is away from the metal base plate and the row of battery cells; and the second direction is toward the metal base plate and the row of battery cells. the top tray of the battery comprises: a third fan for blowing air within the battery container in the first direction; and 11. The battery of claim 9, wherein the cathode comprises a lithium metal oxide. a fourth fan for blowing air within the battery container in the second direction.

12. The battery of claim 11, wherein: the first fan is disposed in an upper left quadrant of the top tray; the second fan is disposed in an upper right quadrant of the top tray; ​ ​ the third fan is disposed in a lower left quadrant of the top tray; and the fourth fan is disposed in a lower right quadrant of the top tray.

13. The battery of claim 9, wherein the cathode comprises a lithium metal oxide. the battery includes an electronics tray disposed on the top tray, the electronics tray including a controller and contactors for the battery.

14. The battery of claim 13, wherein the cathode comprises a lithium metal oxide. the controller includes circuitry configured to operate the first fan and the second fan in response to determining that a temperature of at least one battery cell of the row of battery cells exceeds a threshold value.

15. The battery of claim 14, wherein the cathode comprises a lithium metal oxide. the circuitry of the controller is configured to operate the first fan and the second fan by turning on the first fan and the second fan in response to determining that the temperature of at least one battery cell of the row of battery cells exceeds the threshold value.

16. A battery for a material handling vehicle, the battery comprising: a metal base plate; a battery container secured to the metal base plate to form a sealed housing for the battery; a row of one or more battery cells disposed above the metal base plate; and a top tray disposed above the row of battery cells, the top tray comprising: a first fan disposed in an upper left quadrant of the top tray for blowing air in a first direction within the battery container, the first direction being away from the metal base plate and the row of battery cells; a second fan disposed in an upper right quadrant of the top tray for blowing air in a second direction within the battery container, the second direction being toward the metal base plate and the row of battery cells; a third fan disposed in a lower left quadrant of the top tray for blowing air in the first direction within the battery container; and a fourth fan disposed in a lower right quadrant of the top tray for blowing air in the second direction within the battery container. the battery includes an electronics tray disposed on the top tray, the electronics tray including a controller and contactors for the battery.

17. The battery of claim 16, wherein the cathode comprises a lithium metal oxide. the controller includes circuitry configured to operate at least one of the first fan or the third fan and at least one of the second fan or the fourth fan in response to determining that a temperature of at least one battery cell of the row of battery cells exceeds a threshold value.

18. The battery of claim 17, wherein the cathode comprises a lithium metal oxide. the circuitry of the controller is configured to operate at least one of the first fan or the third fan and at least one of the second fan or the fourth fan by turning on at least one of the first fan or the third fan and at least one of the second fan or the fourth fan in response to determining that the temperature of at least one battery cell of the row of battery cells exceeds the threshold value.

19. The battery of claim 18, wherein the cathode comprises a lithium metal oxide. the circuitry of the controller is configured to operate at least one of the first fan or the third fan and at least one of the second fan or the fourth fan by controlling a speed of at least one of the first fan or the third fan and at least one of the second fan or the fourth fan in response to determining that the temperature of at least one battery cell of the row of battery cells exceeds the threshold value.

20. The battery of claim 18, wherein the cathode comprises a lithium metal oxide. ​

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