Structural battery module and battery pack

Abstract

Battery module (106) for constructing a battery pack (102), the battery module (106) comprising: a rectangular housing (108), the housing (108) including a top surface, a bottom surface, a first side surface extending between the top surface and the bottom surface, a second side surface extending between the top surface and the bottom surface, a front open end (111), and a rear open end (113), the housing (108) including a plurality of housing bores (142) extending substantially perpendicularly through the top surface, the bottom surface, the first side surface, and the second side surface proximal to the front open end (111), and a plurality of housing bores (142) extending substantially perpendicularly through the top surface, the bottom surface, the first side surface, and the second side surface proximal to the rear open end (113); a battery (114) disposed in the rectangular housing (108); a backplate (112, 212), the backplate (112, 212) closing the rear open end (113) of the housing (108), the backplate (112, 212) including a plurality of flange surfaces (139) whereby a plurality of backplate bores (141) extend in axial alignment with the plurality of housing bores (142) proximal to the rear open end (113) of the housing (108); and a front plate (110, 210), the front plate (110, 210) closing the front open end (111) of the housing (108), the front plate (110, 210) including a positive terminal (116) and a negative terminal (118) electrically connected to the battery, the battery being sealed within the rectangular housing (108), the back plate (112, 212) and the front plate (110, 210), the front plate (110, 210) including a plurality of flange surfaces (139) whereby a plurality of front plate bores (141) extend in axial alignment with the plurality of housing bores (142) proximal to the front open end (111) of the housing (108), characterized in that the flange surfaces (139) of the back plate (112, 212) and the front plate (110, 210) include a plurality of coupling projections (140) through which the plurality of rear panel bores (141) and the plurality of front panel bores (141) respectively extend,wherein the coupling projections (140) are provided along each of the top edge (230), bottom edge (232) and each of the side edges (234, 236) of the front plate (110, 210) and the back plate (112, 212) such that the battery module (106) can be attached to an adjacent battery module (106) at each of the top, bottom, first side surface and second side surface.

Description

Technical area

[0001] This patent disclosure generally relates to batteries and, more specifically, to a structural battery module to enable various battery pack configurations. background

[0002] Current commercial applications require a wide range of battery sizes and power requirements. For example, battery pack requirements can range from 20 kW to 300 kW and from 48 V to 700 V. Maintaining a wide range of battery sizes generally results in increased inventory and tooling costs, as well as increased research and development investments. Furthermore, reduced capacity or power characteristics of batteries used in a particular application can lead to increased costs and challenges in the disposal or recycling of such batteries.

[0003] To address some of these challenges, manufacturers have developed arrangements where multiple battery modules of varying sizes are assembled to meet the unique requirements of different applications. For example, Absolyte GP has developed a modular steel tray design where multiple individual cell modules can be transported to a desired location and then assembled and connected to a modular steel tray design to provide the required capacity, with a modular steel tray sandwiched between each row of modules.

[0004] CN 1 10 010 807 A discloses a battery with two battery modules arranged one above the other, wherein the battery modules are connected to each other by an external clamping force. US 2008 / 0 057 393 A1 also discloses a secondary battery module with a positive pole and a negative pole, which has an elastic layer to dampen vibrations. Brief description

[0005] The present invention is defined by the independent claims. Advantageous embodiments emerge from the dependent claims, the figures, and the description. The disclosure describes, in one aspect, a battery module for constructing a battery pack. The battery module includes a battery arranged in a rectangular housing, and front and rear panels. The rectangular housing includes a top, a bottom, a first side surface extending between the top and bottom, a second side surface extending between the top and bottom, a front open end, and a rear open end.The housing also includes a plurality of housing bores extending substantially perpendicularly through the top, bottom, first side surface, and second side surface proximal to the front open end, and a plurality of housing bores extending substantially perpendicularly through the top, bottom, first side surface, and second side surface proximal to the rear open end. The back plate closes the rear open end of the housing. The back plate includes a plurality of flange surfaces whereby a plurality of back plate bores extend in axial alignment with the plurality of housing bores proximal to the rear open end of the housing. The front plate closes the front open end of the housing.The front panel includes a plurality of flange surfaces, through which a plurality of front panel holes extend in axial alignment with the plurality of housing holes proximal to the front open end of the housing. The front panel also includes a positive terminal and a negative terminal electrically connected to the battery. The battery is sealed within the rectangular housing, back panel, and front panel.According to the invention, it is further provided that the flange surfaces of the back plate and the front plate include a plurality of coupling projections, whereby the plurality of back plate bores and the plurality of front plate bores each extend, wherein the coupling projections are provided along each of the top edge, bottom edge and each of the side edges of the front plate and the back plate such that the battery module can be fastened to an adjacent battery module at each of the top side, bottom side, first side surface and second side surface.

[0006] In another aspect, the disclosure describes a battery pack including a plurality of battery modules according to the invention and at least two couplers. The at least two couplers together secure at least a first battery module and a second battery module. At least a first one of the couplers is disposed through at least one of the plurality of backplate bores in axial alignment with at least one of the plurality of housing bores proximal to the rear open end of the housing. At least a second one of the couplers is disposed through at least one of the plurality of front plate bores in axial alignment with at least one of the plurality of housing bores proximal to the front open end of the housing.

[0007] In yet another aspect, the disclosure describes a method for constructing the battery pack. The method includes providing a plurality of battery modules according to the invention. The method further includes disposing a rectangular housing of a first battery module of the plurality of battery modules adjacent to a rectangular housing of a second battery module of the plurality of battery modules. The method further includes disposing a first coupler through a backplate bore of the first battery module, a housing bore through the rectangular housing of the first battery module, a housing bore through the rectangular housing of the second battery module, and a backplate bore of the second battery module to secure the first and second battery modules together.The method further includes disposing a second coupler through a front panel hole of the second battery module, a housing hole through the rectangular housing of the second battery module, a housing hole through the rectangular housing of the second battery module, and a front panel hole of the second battery module to secure the second and second battery modules together. Brief description of the drawings Fig. 1 is an isometric view of an exemplary mobile machine in which a battery system according to teachings of this disclosure may be utilized. Fig. 2 is a rear isometric view of an exemplary embodiment of a battery pack according to teachings of this disclosure. Fig. 3 is an isometric front view of the battery pack of Fig. 2. Fig. 4 is an isometric exploded rear view of the battery pack of Fig. 2 and Fig. 3. Fig. 5 is an enlarged front isometric view of a battery module according to teachings of this disclosure. Fig. 6 is a front elevation view of the battery module of Fig. 5. Fig. 7 is a rear elevation view of the battery module of Fig. 5. Fig. 8 is a fragmentary isometric view of an assembly of an alternative embodiment of an exemplary battery pack using the battery module of Fig. 5-7. Fig. 9 is an isometric view of another exemplary battery pack assembly using the battery module of Fig. 8. Detailed description

[0008] This disclosure relates to a battery system 100 that can be used to build battery packs 102 for use in various applications, such as the machine 104 of Fig. 1. While the arrangement is illustrated in connection with a mobile machine, more specifically a front loader, the arrangement disclosed herein has universal applicability in various other types of machines. The term "machine" may refer to any machine that performs some type of operation related to an industry, such as mining, construction, agriculture, transportation, or any other industry known in the art. For example, the machine may be an earthmoving machine, such as a wheel loader, an excavator, a dump truck, a backhoe loader, a motor grader, a loading machine, or the like. Furthermore, a tool may be connected to the machine.Such tools can be used for various tasks including, for example, loading, compacting, lifting, brushing, and include, for example, buckets, compactors, forked lifting devices, brushes, grapples, cutting tools, shears, blades, breakers / hammers, drills and others.

[0009] The battery system 100 includes a plurality of battery modules 106 that can be coupled in various configurations to provide various battery packs 102 with desired power output and voltage output. An exemplary battery module 106 is shown in Fig. 5-7 illustrates and includes a rectangular housing 108, a front panel 110, and a back panel 112. The housing 108 has a channel structure including a top surface 300, a bottom surface 302, and first and second side surfaces 304, 306 extending between the top and bottom surfaces 300, 302. The front panel 110 closes the front open end 111 of the housing 108, and the back panel 112 closes the rear open end 113 of the housing 108 to form a sealed structure.

[0010] The housing 108 and the front and back panels 110, 112 may be manufactured by any suitable method and from any suitable materials. For example, the housing 108 may be 3D printed, stamped, otherwise formed, molded, or extruded from a filled or unfilled polymer material. Similarly, the front and back panels 110, 112 may be 3D printed, molded, or otherwise formed from a filled or unfilled polymer material.

[0011] Each battery module 106 houses a battery 114, which may have any configuration as understood by those skilled in the art. Positive and negative terminals 116, 118 may be provided along the front panel 110. Once the battery 114 is sealed within the battery module 106, the battery module 106 may be transported and handled for further construction of a desired battery pack 102. Returning to Fig. 2-4, to electrically couple the battery modules, any suitable electrical couplers, such as the plurality of cables 102, may be provided.

[0012] In at least one embodiment, the battery pack 102 further includes a base 122 upon which a plurality of battery modules 106 may be supported and coupled together. While the base 122 may not be required in all embodiments, the base 122 may provide additional support for the assembled battery pack 102 and may facilitate further handling, particularly with larger battery packs 102. As shown in Fig. 4, the base 122 may have a rectangular construction and may include structural elements, such as a rectangular frame 124 with cross members 126, which may enhance strength and stability while minimizing weight. The base 122 may further include structure to enhance the adhesion of a battery module 106. For example, the frame 124 may include a plurality of protrusions 128 that may be internally threaded for engagement with corresponding couplers, such as bolts or screws, the importance of which will be discussed below. The illustrated base 122 is sized to support two battery modules 106. However, it is recognized that the battery system 100 may include a variety of sizes of bases, such as bases sized to support one battery module 106, as well as three, four, or more battery modules 106 side by side.

[0013] The battery pack 102 may optionally further include a distribution unit 132 if desired. The battery modules 106 may be electrically connected to the distribution unit 132, here by cables 120. The distribution unit 132 may serve as a controller to allow distribution of power to one or more loads of a machine 104. For example, in an electric machine, power may be provided to a drive system and / or individual components of the machine.

[0014] According to one aspect of this disclosure, the battery modules 106 may be secured together to provide a battery pack 102 that is structurally stable without the need for an external frame between stacked battery modules 106. To secure the battery modules 106 to one another, each battery module 106 includes a plurality of coupling assemblies on opposing plates 110, 112 of the battery module 106. More specifically, the front and rear plates 110, 112 include flange surfaces 139 including a plurality of coupling projections 140 through which a plurality of plate bores 141 extend, while the housing 108 includes a plurality of housing bores 142 arranged in alignment with the plate bores 141 of the coupling projections 140.Furthermore, while the front and rear plates 110, 112 have been illustrated with coupling projections 140, it is recognized that the flange surfaces 139 themselves may include the plate bores 141. A plurality of couplers 130, such as bolts or rivets, are provided for placement through the coupling projections 140 to couple the battery modules 106 together.

[0015] According to one aspect of this disclosure, the plate holes 141 and housing holes 142 may extend substantially perpendicular to the housing 108. In this manner, couplers 130 may be easily mounted through the plate holes 141 and housing holes 142 of adjacently disposed battery modules 106. Those skilled in the art will appreciate that the coupling arrangement may provide improved stability for the battery module 106 by having couplers 130 extend through both the plate holes 141 and housing holes 142, further stabilizing the relationship between the front and rear plates 110, 112 and the housing 108.

[0016] During assembly, a first battery module 150 may optionally be positioned on a base 122 sized to support a desired number of battery modules 106 in a horizontal configuration. Upon positioning the first battery module 150, the housing holes through the housing 151 and the aligned plate holes through the coupling projections 152, 153 on the bottom edge 154 of the back plate 159 of the first battery module 150 are arranged in alignment with the projections 128 of the base 122. Couplers 130 are then inserted into and secured in the coupling projections 152, 153 of the back plate 159 of the first battery module 150 and the projections 128 of the base 122 to attach the first battery module 150 to the base 122.While this process has been explained in detail with respect to a back plate 159 of the first battery module 150, this same process is performed with respect to a front plate 158 of the first battery module 150, wherein couplers 130 are inserted into plate holes along the front plate bottom edge of the first battery module 150, the housing holes through housing 151, and projections 128 of the base 122.

[0017] A second battery module 160 may be positioned on a top surface of the first battery module 150; similarly, the housing holes through the housing 161 and the plate holes through coupling projections 162, 163 along the bottom edge 164 of the backplate 169 of the second battery module 160 are positioned in alignment with the housing holes through the housing 151 and plate holes through the coupling projections 155, 156 of the backplate 159 along the top edge 157 of the first battery module 150. Couplers 130 are then inserted into the housing bores of the housings 151, 161 and secured in the plate bores by the coupling projections 162, 163 of the second battery module 160 and the plate bores by the coupling projections 155, 156 of the first battery module 150 to attach the second battery module 160 to the first battery module 150.As with attaching the first battery module 150 to the base 122, this same operation is performed with respect to the front panels 158, 168 of the first and second battery modules 150, 160.

[0018] This process can be continued with a third battery module 170 being secured to plate holes by coupling projections 172, 173, to plate holes by coupling projections 165, 166 along the top edge 167 of the second battery module 160 on both front and rear plates 168, 169. The process continues until a desired number of battery modules 106 are secured together.

[0019] According to another aspect of this disclosure, additional battery modules 106 may be coupled to the side surfaces 180, 181 of the first battery module 150 and subsequently coupled battery modules 160, 170. In the embodiments of Fig. 2-4, for example, a fourth battery module 190 is positioned laterally of the first battery module 150. That is, the housing 191 of the fourth battery module 190 is positioned on the base 122 and adjacent the side surface 181 of the first battery module 150. In positioning the fourth battery module 190, the housing bore through the housing 191 and the plate bore through the coupling projection 192 along the side edge 193 of the fourth battery module 190 are positioned in axial alignment with the housing bore through the housing 151 and the plate bore of the coupling projection 182 along the side edge 183 of the first battery module 150, and the plate bores through the housing 191 and the plate bores of coupling projections 194, 195 along the bottom edge 196 of the fourth battery module 190 are positioned in axial alignment with projections 128 of the base 122.A mating coupler 130 then engages the coupling protrusion 192 of the fourth battery module 190 and the coupling protrusion 182 of the first battery module 150, and couplers 130 engage coupling protrusions 194, 195 of the fourth battery module 190 and protrusions 128 of the base 122.

[0020] As with the assembly of the first, second, and third battery modules 150, 160, 170, while this process was explained in detail with respect to a back plate 198 of the fourth battery module 190, this same process is performed with respect to a front plate 197 of the fourth battery module 190, with couplers 130 being inserted into bores of the coupling bosses along the front plate side and bottom edges of the fourth battery module 190 and the first battery module 150 and bosses 128 of the base 122. Similarly, a fifth battery module 185 can be attached to a side surface 186 of the second battery module 160 and a top surface 199 of the fourth battery module 190. Again, this process can continue with a sixth battery module 187 and any additional battery modules 106 being added until a desired battery pack 102 has been constructed.

[0021] When used once all desired battery modules 106 have been coupled together, the distribution unit 132 can be attached to the battery pack 102. While the distribution unit 132 is attached to the top 134 of the coupled battery pack 102 in an embodiment shown in Fig. 2-4, a distribution unit may alternatively be attached to a side surface 136 of the battery pack 102, if appropriate for the particular application. Once interconnected, the battery modules 106 may be electrically connected to each other and to the distribution unit 132, if deployed, by cables 120 or the like.

[0022] While the embodiment described in Fig. 2-4, includes a battery pack 102 constructed from two columns of seven battery modules 106, it is recognized that battery packs with alternative voltage and power delivery, as well as different geometries, may be constructed from the battery modules 106. That is, with reference to Fig. 8, the front and rear plates 210, 212 of the battery module 214 are provided according to the invention with coupling projections 220, 221, 222, 223, 224, 225 along each of the upper edge 230, lower edge 232 and side edges 234, 236 with corresponding plate holes (not visible in Fig. 8) and the housing 216 is provided with axially aligned respective housing bores (not visible with respect to battery module 214 in Fig. 8). In this way, additional battery modules 240, 242, 244, 246 can be attached to each of the top, bottom, and side surfaces of the housing 216 of the battery module 214. Additional battery modules can be attached to battery modules 240, 242, 244, 246 that are attached to the battery module 214, thereby enabling the construction of various sizes and geometric shapes of battery packs, as further described in Fig. 9 illustrates.

[0023] In at least one embodiment, the protrusions 128 of the base 122 and the plate bores 141 of the coupling protrusions 140 of the battery module 106 are internally threaded. In at least one embodiment, a portion of the protrusions 128 of the base 122 and the plate bores 141 of the coupling protrusions 140 of the battery module 106 are internally threaded, while the remaining protrusions 128 of the base 122 and the plate bores 141 of the coupling protrusions 140 of the battery module 106 are unthreaded; instead, the remaining protrusions 128 of the base 122 and the plate bores 141 of the coupling protrusions 140 of the battery module 106 are unthreaded. In this way, the assembly of a battery pack 102 can be simplified.It is noted, however, that if the projections 128 of the base 122 and / or the bores 141 of the coupling projections 140 of the battery module 106 include unthreaded bores, the couplers 130 are first inserted through the unthreaded bore and then screwed into the threaded bore.

[0024] Only exemplary, in the embodiment shown in Fig.2-4, the protrusions 128 of the base may be internally threaded, while the coupling protrusions 152, 153 of the first battery module 150 may include unthreaded plate bores. In this manner, couplers 130 may be inserted through the unthreaded plate bores of the coupling protrusions 152, 153 of the first battery module 150 and then secured in the threaded bores of the protrusions 128 of the base 122. Similarly, the coupling projections 155, 156 of the first battery module 150 may include threaded plate holes, while the coupling projections 162, 163 of the second battery module 160 may include unthreaded plate holes, such that couplers 130 inserted through the unthreaded plate holes of the coupling projections 162, 163 of the second battery module 160 are secured in the threaded plate holes of the coupling projections 155, 156 of the first battery module 150.Similarly, the coupling boss 192 of the fourth battery module 190 may include an unthreaded plate bore, while the coupling boss 182 of the first battery module 150 may include a threaded plate bore. In this way, a mating coupler 130 may be inserted through the unthreaded plate bore of the coupling boss 192 of the fourth battery module 190 and secured in the threaded plate bores of the coupling boss 182 of the first battery module 150.

[0025] Those skilled in the art will therefore appreciate that the construction of a battery module 106 may be standardized. For example, the coupling protrusions located along the bottom edge of a face may include unthreaded plate holes, while the coupling protrusions along the opposite top edge may include threaded plate holes; similarly, the coupling protrusion along one side edge of a face may include an unthreaded plate hole, while the coupling protrusion along the opposite side edge may include a threaded plate hole. Industrial applicability

[0026] The present disclosure is applicable to battery packs used in various machines and applications. The battery system may include a variety of battery modules, including batteries with different power output and voltage output values, optionally bases of different sizes, and couplers such as bolts or rivets, from which various sizes and configurations of battery packs can be constructed. Consequently, the battery system can provide customized battery packs with desired power output and voltage output based on the configuration.

[0027] The battery system can utilize a standard size of battery modules to address the design requirements of various applications. If battery packs can be assembled to meet the requirements of an application, the battery system can facilitate the construction of battery packs to meet the battery requirements and volumes of both low-volume and high-volume applications.

[0028] This use of standardized sizes and performance can lead to reduced costs and investments in inventory and warehousing as well as investments in validation.

[0029] In at least some applications, the battery system can facilitate the construction of battery packs to meet not only the power and voltage output requirements, but also the physical constraints of the application. That is, in at least some applications, a battery pack can be built to fit into a specific geometric space, such as that provided by a machine.

[0030] Battery packs constructed according to the teachings of this disclosure may not require an external frame or external scaffolding to support the individual modules. This practical design can simplify battery pack construction and minimize the manufacturing costs of such a construction, particularly in low-volume applications.

[0031] It is recognized that the assembly and electrical connection of at least some embodiments may be performed partially or entirely at a manufacturing facility or on-site, thereby allowing flexibility in the construction and shipping of such battery packs.

[0032] As battery modules are used in various applications, their power output and voltage output may decrease over time. Accordingly, a battery system according to the teachings of this disclosure may be employed to reuse battery modules for a second life in different battery packs. This reuse may reduce the volume of batteries that are scraped or disassembled for recycling of internal metals. Therefore, this reuse may result in an environmentally friendly arrangement by minimizing the amount of batteries sent to landfills.

[0033] It is understood that the foregoing description provides examples of the disclosed system and technology. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to refer to the specific example being discussed at that time and are not intended to imply a limitation on the scope of the disclosure generally. Any language of distinction or disparagement with respect to particular features is intended to indicate a lack of preference for those features, but not to exclude them entirely from the scope of the disclosure, unless otherwise noted.

[0034] Reference to ranges of values herein is merely a shorthand for individually referring to each value falling within the range, unless otherwise stated herein, and each value is incorporated into the specification as if individually recited herein. All methods described herein may be performed in any suitable order, unless otherwise stated herein or clearly contradicted by context.

[0035] The use of the terms "a," "an," "the," "at least one," and similar references in the context of describing the invention (particularly in the context of the following claims) is to be construed to include both the singular and the plural, unless otherwise stated herein or clearly contradicted by the context. The use of the term "at least one" followed by a list of one or more items (e.g., "at least one of A and B") is to be construed to mean one item selected from the listed items (A or B), or a combination of two or more of the listed items (A and B), unless otherwise stated herein or clearly contradicted by the context.

[0036] Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the appended claims, to the extent permitted by applicable law. Furthermore, any combination of the elements described above, in all possible variations thereof, is included in the disclosure, unless otherwise stated herein or clearly contradicted by context.

Claims

[1] Battery module (106) for constructing a battery pack (102), the battery module (106) comprising: a rectangular housing (108), the housing (108) including a top surface, a bottom surface, a first side surface extending between the top surface and the bottom surface, a second side surface extending between the top surface and the bottom surface, a front open end (111), and a rear open end (113), the housing (108) including a plurality of housing bores (142) extending substantially perpendicularly through the top surface, the bottom surface, the first side surface, and the second side surface proximal to the front open end (111), and a plurality of housing bores (142) extending substantially perpendicularly through the top surface, the bottom surface, the first side surface, and the second side surface proximal to the rear open end (113); a battery (114) disposed in the rectangular housing (108); a backplate (112, 212), the backplate (112, 212) closing the rear open end (113) of the housing (108), the backplate (112, 212) including a plurality of flange surfaces (139) whereby a plurality of backplate bores (141) extend in axial alignment with the plurality of housing bores (142) proximal to the rear open end (113) of the housing (108); and a front plate (110, 210), the front plate (110, 210) closing the front open end (111) of the housing (108), the front plate (110, 210) including a positive terminal (116) and a negative terminal (118) electrically connected to the battery, the battery being sealed within the rectangular housing (108), the back plate (112, 212), and the front plate (110, 210), the front plate (110, 210) including a plurality of flange surfaces (139) whereby a plurality of front plate bores (141) extend in axial alignment with the plurality of housing bores (142) proximal to the front open end (111) of the housing (108), characterized byin that the flange surfaces (139) of the back plate (112, 212) and the front plate (110, 210) include a plurality of coupling projections (140) through which the plurality of back plate bores (141) and the plurality of front plate bores (141) respectively extend, the coupling projections (140) being provided along each of the top edge (230), bottom edge (232) and each of the side edges (234, 236) of the front plate (110, 210) and the back plate (112, 212) such that the battery module (106) can be fastened to an adjacent battery module (106) at each of the top side, bottom side, first side surface and second side surface. [2] The battery module (106) of claim 1, wherein the flange surfaces (139) of the back plate (112, 212) are disposed substantially adjacent to the rear open end (113) of the housing (108) and wherein the flange surfaces (139) of the front plate (110) are disposed substantially adjacent to the front open end (111) of the housing (108). [3] The battery module (106) of claim 2, wherein at least one of the back plate (112, 212) is disposed substantially in the rear open end (113) of the housing (108), and the front plate (110, 210) is disposed substantially in the front open end (111) of the housing (108). [4] The battery module (106) of claim 1, wherein at least a portion of the back plate bores (141) is internally threaded and at least a portion of the front plate bores (141) is internally threaded. [5] Battery pack (102) according to, comprising: a plurality of battery modules (106) according to any one of claims 1-4; and at least two couplers (130) securing at least a first battery module (150) and a second battery module (160) together, wherein at least a first of the couplers (130) is disposed through at least one of the plurality of back plate bores (141) in axial alignment with at least one of the plurality of housing bores (142) proximate the rear open end (113) of the housing (108), and wherein at least a second of the couplers (130) is disposed through at least one of the plurality of front plate bores (141) in axial alignment with at least one of the plurality of housing bores (142) proximate the front open end (111) of the housing (108). [6] The battery pack (102) of claim 5, further including a plurality of electrical couplers (130) electrically coupling the terminals (116, 118) of the at least one first battery module (150) and a second battery module (160). [7] Battery pack (102) according to claim 5, further comprising at least one of a base (122), wherein the at least one first battery module (150) is connected to the base (122); and a distribution unit (132), wherein the distribution unit (132) is connected to at least one of the plurality of battery modules (106). [8] A method for building a battery pack (102) according to any one of claims 5-7, the method comprising: Arranging a rectangular housing (151) of the first battery module (150) of the plurality of battery modules (106) adjacent to a rectangular housing (161) of the second battery module (160) of the plurality of battery modules (106); Arranging the first of the couplers (130) through a backplate bore (141) of the first battery module (150), a housing bore (142) through the rectangular housing (151) of the first battery module (150), a housing bore (142) through the rectangular housing (161) of the second battery module (160), and a backplate bore (141) of the second battery module (160) to secure the first and second battery modules (150, 160) together; and Disposing the second of the couplers (130) through a front panel hole (141) of the first battery module (150), a housing hole (142) through the rectangular housing (151) of the first battery module (150), a housing hole (142) through the rectangular housing (161) of the second battery module (160), and a front panel hole (141) of the second battery module (160) to secure the first and second battery modules (150, 160) together. [9] Method according to claim 8, wherein disposing the first of the couplers (130) includes disposing the first of the couplers (130) through an unthreaded backplate bore (141) of the first battery module (150), a housing bore (142) through the rectangular housing (151) of the first battery module (150), a housing bore (142) through the rectangular housing (161) of the second battery module (160), and a threaded backplate bore (141) of the second battery module (160) to secure the first and second battery modules (150, 160) together; and disposing the second of the couplers (130) includes disposing the second of the couplers (130) through an unthreaded backplate bore (141) of the first battery module (150), a housing bore (142) through the rectangular housing (151) of the first battery module (150), a housing bore (142) through the rectangular housing (161) of the second battery module (160), and a threaded backplate bore (141) of the second battery module (160) to secure the first and second battery modules (150, 160) together.

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