Improved Battery Pack

Abstract

A battery pack comprising one or more battery modules and battery module subassemblies, a battery pack management arrangement for monitoring and / or controlling operation of the battery pack, a battery pack fluid connection assembly for connecting one or more ducts of the battery pack to a source of thermal management fluid, and a battery pack electrical connection arrangement for electrically connecting the battery pack to an external load, the battery pack being modular so as to be adaptable to meet numerous design requirements by adjusting the size, number, location, and / or orientation of one or more battery modules within the battery pack.

Description

[Technical field]

[0001] The present invention relates to an improved battery pack, and in particular to an improved battery pack for use in automotive applications such as electric vehicles, industrial vehicles, and / or factory facility machines. [Background technology]

[0002] Contributing to reducing the amount of greenhouse gases emitted annually into the atmosphere is now a priority in many industries. For example, the automotive industry is undergoing rapid change due to the gradual phase-out of petroleum-based power sources in favor of electricity sources. In the consumer automotive industry, the rate of change has been particularly rapid, leading to an explosion of new battery technologies based on thermally managed lithium-ion batteries. It is becoming clear that in order to meet climate change reduction targets, these changes need to be made in the same way on a much broader scale, i.e. industrial vehicles and factory machines also need to be "electrified" if they are to meet the targets.

[0003] Developing environmentally friendly power solutions for industrial and automotive applications is a costly and time-consuming technical challenge. For example, when trying to replace diesel engines with battery packs in industrial vehicles, it is rare to find an off-the-shelf battery solution that can provide the required power profile and fit completely within the required volume. Such modifications usually require a major redesign of the machine or vehicle structure to be able to accommodate the off-the-shelf battery solution. However, off-the-shelf battery solutions often lack the mechanical strength and reliability typically required for industrial vehicles and factory machines in particular. Summary of the Invention [Problem to be solved by the invention]

[0004] While developing specially designed battery packs and / or structures to accommodate them can be cost-effective for mass production of consumer vehicles, this expense is often prohibitive in lower volume manufacturing settings. Low volume manufacturers of cranes, factory floor machinery, and mining equipment do not enjoy the economies of scale that would justify the expense of an all-electric version. Power solutions are needed that can be integrated into a wide range of machines and easily adapted to meet a range of power, thermal management, strength, reliability, and volume requirements.

[0005] It is an object of the present invention to obviate or mitigate the problems outlined above, and in particular to provide a power solution that can be integrated into a wide range of machines.

[0006] It is another object of the present invention to provide a power solution that can provide the mechanical strength and reliability required by industrial vehicles and plant machinery.

[0007] It is another object of the present invention to provide a power solution that can be easily adapted to meet a range of design, power, and volume requirements.

[0008] It is another object of the present invention to provide a power solution that can be easily adapted to meet a range of safety and thermal management requirements.

[0009] It is another object of the present invention to provide a power solution that is adaptable for incorporation into existing vehicle designs.

[0010] It is another object of the present invention to provide a power solution that can be retrofitted to existing vehicles or machines.

[0011] It is another object of the present invention to provide a battery pack that is more adjustable than prior art battery packs.

[0012] It is another object of the present invention to provide a battery pack which is more reliable and mechanically stronger than prior art batteries. [Means for solving the problem]

[0013] According to an aspect of the present invention, there is provided a battery pack comprising one or more battery modules, battery pack management means for monitoring and / or controlling operation of the battery pack, battery pack fluid connection means for connecting the battery pack to a thermal management fluid, and battery pack electrical connection means for electrically connecting the battery pack to an external load. Advantageously, the battery pack can be adapted to meet a particular set of design requirements by adjusting the size, number, location and / or orientation of the battery modules within the battery pack.

[0014] Ideally, the battery pack comprises a battery pack housing.

[0015] Preferably, the battery pack housing includes a lower container member.

[0016] Preferably, the battery pack housing includes a cover member.

[0017] Preferably, the lower container member is provided with one or more openings.

[0018] Preferably, the lower container member includes a cavity.

[0019] Preferably, the lower container member includes a cavity for receiving one or more battery modules.

[0020] Preferably, the lower container member includes cavities for receiving a plurality of battery modules.

[0021] Preferably, the lower container member includes a cavity for receiving the battery module subassembly.

[0022] Preferably, the cover member is adapted to cover an opening in the lower container member.

[0023] Ideally, the battery pack housing comprises two side walls.

[0024] Preferably, the battery pack comprises two end walls.

[0025] Preferably, the battery pack includes a bottom wall.

[0026] Preferably, the battery pack includes a top wall.

[0027] Preferably, the battery pack is positionable within a predetermined volume.

[0028] Preferably, the battery pack is positionable within a defined volume within a device, such as a mobile or industrial device.

[0029] Preferably, the battery pack is positionable within a volume within a roadworthy vehicle such as a car, truck, lorry, road sweeper, tow truck, or power shovel.

[0030] Preferably, the battery pack is deployable within a defined volume within an industrial facility, such as a factory facility.

[0031] Preferably, the battery pack is adapted to fit within a volume initially adapted to receive an alternative power source, such as a diesel engine.

[0032] Ideally, the battery pack comprises a battery pack management means.

[0033] Ideally, the battery pack comprises a battery pack management means for monitoring and / or controlling the operation of the battery pack.

[0034] Preferably the battery pack comprises a battery pack fluid connection means.

[0035] Preferably, the battery pack fluid connection means comprises a battery pack fluid inlet and a battery pack fluid outlet.

[0036] Preferably, the thermal management means of the or each battery module within the battery pack is in fluid communication with the battery pack fluid connection means.

[0037] Preferably, the battery pack comprises a battery pack fluid connection means for connecting the battery pack to a source of thermal management fluid.

[0038] Preferably, the inlet side fluid distribution means of each battery module is in fluid communication with the inlet side fluid distribution means of at least one other battery module.

[0039] Preferably, the outlet side fluid distribution means of each battery module is in fluid communication with the outlet side fluid distribution means of at least one other battery module.

[0040] Preferably, the battery pack comprises a battery pack fluid connection means for connecting the battery pack to an external source of thermal management fluid.

[0041] Preferably, the thermal management fluid is water and / or a water glycol mixture.

[0042] Preferably, the battery pack fluid connection means is adapted to allow the battery pack to be operably connected to a thermal management system.

[0043] Preferably, the thermal management system comprises a source of thermal management fluid.

[0044] Preferably, the thermal management system comprises a reservoir for containing a thermal management fluid.

[0045] Preferably, the thermal management system comprises a heat exchanger and a pump.

[0046] Preferably, the heat exchange system comprises a coolant loop.

[0047] Preferably, the heat exchange system comprises a pressure sensor.

[0048] Ideally, the pressure sensor is adapted to monitor the pressure within the thermal management system, and in particular within the coolant loop.

[0049] Preferably, the battery pack fluid connection means comprises a battery pack fluid inlet.

[0050] Preferably, the battery pack fluid inlet provides a fluid intake means, i.e., a path for fluid to enter the battery pack.

[0051] Preferably, the battery pack fluid inlet comprises an inlet adapter.

[0052] Preferably, the battery pack fluid inlet comprises an inlet conduit.

[0053] Preferably, fluid can enter the battery pack through an inlet adapter and an inlet conduit.

[0054] Preferably, fluid is able to enter the battery pack through an opening in an end wall of the battery pack housing.

[0055] Preferably, the battery pack fluid connection means comprises a battery pack fluid outlet.

[0056] Preferably, the battery pack fluid outlet provides a means for fluid evacuation, i.e. a path for fluid to exit the battery pack.

[0057] Ideally, the battery pack fluid outlet is provided with an outlet adaptor.

[0058] Preferably, the battery pack fluid outlet comprises a vent conduit.

[0059] Preferably, fluid is allowed to exit the battery pack through the outlet adapter and the outlet conduit.

[0060] Preferably, fluid is able to exit the battery pack through an opening in an end wall of the battery pack housing.

[0061] Preferably, the battery pack fluid inlet and the battery pack fluid outlet are in fluid communication with each other.

[0062] Ideally, the battery pack fluid inlet and the battery pack fluid outlet are in fluid communication with each other through the or each battery module.

[0063] Ideally, the battery pack fluid inlet and the battery pack fluid outlet are in fluid communication with each other through the battery module subassembly.

[0064] Ideally, the inlet conduit and / or the outlet conduit are curved.

[0065] Preferably, the inlet conduit comprises a first end and a second end.

[0066] Preferably, the outlet conduit includes a first end and a second end.

[0067] Preferably, the first end of the inlet conduit and / or the first end of the outlet conduit are connectable to one or more battery modules.

[0068] Preferably, the second end of the inlet conduit and / or the second end of the outlet conduit is substantially flat.

[0069] Preferably, the second end of the inlet conduit and / or the second end of the outlet conduit comprises a generally square shaped arrangement.

[0070] Preferably the locating member is locatable within the maintaining means.

[0071] Preferably the maintaining means is located inside the battery pack housing.Advantageously, the positioning means is reliably and accurately positioned during manufacture of the battery pack.

[0072] Preferably the retaining means is located inside the cavity of the lower container member.

[0073] Preferably the retaining means is attachable to an end wall or a side wall of the lower container member.

[0074] Ideally, the inlet conduit is operatively connected to the primary fluid inlets of one or more battery modules.

[0075] Preferably, the outlet conduit is operatively connected to the primary fluid outlet of one or more battery modules.

[0076] Preferably the battery pack comprises electrical connection means.

[0077] Preferably, the battery pack comprises electrical connection means for electrically connecting the battery pack to an external load.

[0078] Preferably, the battery pack electrical connection means is adapted to allow the battery pack to be electrically connected to an external load, such as a motor or other electrical component of a vehicle, machine, or piece of industrial equipment.

[0079] Preferably, the electrical connection means comprises a positive battery pack terminal and a negative battery pack terminal.

[0080] Preferably, the electrical connection means comprises an electrical adapter.

[0081] Preferably, the positive and negative terminals are provided by an electrical adapter.

[0082] Preferably, the battery pack includes an end enclosure.

[0083] Preferably, the end closure is attachable to an end wall of the battery pack.

[0084] Preferably, the adapter is located within the end enclosure.

[0085] Preferably, the adapter passes through the wall of the end enclosure.

[0086] Preferably, the end closure includes a housing member and a lid member.

[0087] Preferably the end closure is provided with a status indicating means.

[0088] Preferably, the status indicating means is an indicator light.

[0089] Preferably the indicator light is visible through an opening in the lid member.

[0090] Preferably, the indication means is adapted to display a coded signal indicative of the operating status of the battery, for example a flashing light signal and / or a coloured light signal.

[0091] Preferably, the end enclosure further comprises one or more electrical adaptors.

[0092] Preferably, the electrical adapter provides electrical terminals for the battery.

[0093] Preferably, the end enclosure further comprises one or more communication ports.

[0094] Preferably, the communications port allows, for example, an external computer to be connected to the battery, for example for monitoring and / or diagnostic purposes.

[0095] Preferably, the end enclosure further comprises one or more internal electrical connectors.

[0096] Preferably, the internal electrical connector is adapted to pass through the battery pack housing and connect the end closures, and in particular the circuitry carried within the end closures, to the terminals of the battery module subassembly / battery module.

[0097] Preferably, the battery pack includes a bus bar.

[0098] Preferably, the battery pack includes a plurality of bus bars.

[0099] According to another aspect of the present invention, there is provided a battery module subassembly comprising one or more battery modules, the battery module subassembly advantageously allowing multiple battery modules to be assembled into a battery pack and maintained as a single replaceable unit within the battery pack.

[0100] According to another aspect of the present invention, a battery pack is provided that includes a battery module subassembly.

[0101] Ideally, the battery pack comprises a battery module subassembly.

[0102] Ideally, a battery module subassembly comprises one or more battery modules.

[0103] Preferably, the battery module subassembly comprises a plurality of battery modules.

[0104] Preferably, a battery module subassembly comprises one or more identical battery modules.

[0105] Preferably, the battery module subassembly comprises six identical battery modules.

[0106] Preferably, two or more of the battery modules within a battery module subassembly are fluidly interconnected.

[0107] Preferably, fluid connections are provided between the battery modules within a battery module subassembly.

[0108] Preferably, a coolant fluid is allowed to flow through the battery module subassemblies.

[0109] Preferably, the battery module subassembly includes a primary fluid inlet.

[0110] Preferably, the battery module subassembly includes a primary fluid outlet.

[0111] Preferably, the battery module subassembly includes one or more multi-port fluid connectors.

[0112] Preferably, the battery module subassembly includes two multi-port fluid connectors.

[0113] Preferably, the battery module subassembly includes an inlet side multi-port fluid connector.

[0114] Preferably, the battery module subassembly includes an outlet side multi-port fluid connector.

[0115] Preferably, coolant fluid is allowed to flow through the battery module subassemblies via the primary fluid inlet, the battery modules, and the primary fluid outlet.

[0116] Preferably, coolant fluid is allowed to flow through the battery module subassembly via the inlet side multiport fluid connector, the battery modules, and the outlet side multiport fluid connector.

[0117] Preferably, at least some or all of the fluid connections between the battery modules are parallel fluid connections.

[0118] Preferably, fluid is allowed to flow in parallel through each of the battery modules.

[0119] Optionally, at least some or all of the fluid connections are series fluid connections.

[0120] Preferably, the fluid is allowed to flow sequentially through two or more battery modules.

[0121] Preferably, two or more of the battery modules within a battery module subassembly are electrically interconnected.

[0122] Preferably, two or more of the battery modules in a battery module subassembly are electrically connected in parallel.

[0123] Preferably, two or more of the battery modules in a battery module subassembly are electrically connected in series.

[0124] Preferably, electrical connections are provided between the battery modules within a battery module subassembly.

[0125] Ideally, electrical current is allowed to flow through the battery module subassembly.

[0126] Preferably, electrical current is allowed to flow through the battery module subassembly via the negative terminal bus bar, the battery modules, and the positive terminal bus bar.

[0127] Preferably, the battery modules are connected in series.

[0128] Preferably, during use, the battery modules are discharged in series.

[0129] Optionally, the battery modules are connected in parallel.

[0130] Optionally, during use, the battery modules are discharged in parallel.

[0131] Preferably, the positive side of at least one battery module is connectable to the negative side of an adjacent battery module.

[0132] Preferably, the battery module subassembly includes one or more inter-module bus bars.

[0133] Preferably, the two or more battery modules are connected via inter-module bus bars.

[0134] Ideally, the positive side of at least one battery module is connectable to the negative side of an adjacent battery module via one or more inter-module bus bars.

[0135] Preferably the or each inter-module busbar is a planar conductive member.

[0136] Preferably, the or each inter-module busbar is adapted to provide an electrical connection between two adjacent or proximate battery modules.

[0137] Preferably, a battery module subassembly comprises one or more peripheral battery modules.

[0138] Ideally, the battery pack comprises two peripheral battery modules.

[0139] Ideally, each peripheral battery module is located on an outer peripheral edge of a battery module subassembly.

[0140] Preferably, the battery module subassembly includes a terminal bus bar.

[0141] Preferably, the battery module subassembly includes a positive terminal bus bar and a negative terminal bus bar.

[0142] Preferably, the peripheral battery module is connectable to the positive battery pack terminal and the negative battery pack terminal.

[0143] Preferably, the peripheral battery modules are connectable to the positive and negative battery pack terminals via positive and negative terminal bus bars.

[0144] Preferably, the positive terminal of the battery pack is electrically connected to the first peripheral battery module via a positive terminal bus bar.

[0145] Preferably, the positive terminal bus bar is electrically connected to the positive side of the first peripheral battery module.

[0146] Preferably, the negative terminal of the battery pack is electrically connected to the peripheral battery module via a negative terminal bus bar.

[0147] Preferably, the negative terminal bus bar is electrically connected to the negative side of the second peripheral battery module.

[0148] Preferably the battery pack is provided with a manual disconnect means.

[0149] Ideally, the manual disconnect means is a manual service disconnect.

[0150] Ideally the manual disconnect means comprises a switch.

[0151] Preferably, the switch is located inside the end enclosure.

[0152] Preferably, the switch is operatively connected to the central battery module.

[0153] Preferably, the manual disconnect means is configured to electrically disconnect two groups of battery modules within the battery pack.

[0154] Preferably, the groups of battery modules comprise the same number of battery modules or alternative numbers of battery modules.

[0155] Preferably, the manual disconnect means is configured to disconnect the terminals of the battery pack.

[0156] Preferably, the manual disconnect means is activated to electrically disconnect the terminals of the first and second groups of battery modules.

[0157] Preferably, the first and second groups of battery modules are disconnected by opening the switch.

[0158] Preferably, the manual disconnect means is operably connected to one or more of the central battery modules.

[0159] Preferably, the manual disconnect means is operatively connected to the central battery module or modules via a disconnect busbar.

[0160] Ideally, the battery module subassembly comprises at least one central battery module.

[0161] Preferably, the battery module subassembly comprises two central battery modules.

[0162] Preferably, the central battery module is connected to the manual disconnect means via a disconnect busbar.

[0163] Preferably, the battery pack comprises a support means.

[0164] Preferably the battery module subassembly comprises a support means.

[0165] Preferably, the battery module subassembly comprises support means for supporting and / or mechanically connecting one or more battery modules.

[0166] Preferably, two or more of the battery modules within a battery module subassembly are mechanically connected to each other.

[0167] Ideally, the battery modules within a battery module subassembly are mechanically coupled to one another via support means.

[0168] Preferably the support means comprises one or more end support members.

[0169] Preferably, the support means comprises two end support members located at the peripheral edges of the battery module subassembly.

[0170] Ideally the support means comprises elongate corner support members.

[0171] Ideally the support means comprises four elongate corner support members.

[0172] Preferably the or each corner support member is an L-shaped joint.

[0173] Preferably, the or each corner support member is adapted to receive a corner of a plurality of battery modules.

[0174] Preferably, the or each elongate corner support member is attachable to the or each battery module.

[0175] Preferably the or each end support member is connected to the or each corner support member.

[0176] Preferably the support means comprises one or more retaining means.

[0177] Preferably, the support means comprises one or more retention means for mounting and securing the multi-port fluid connector to the battery module subassembly.

[0178] Preferably, the support means comprises one or more retention means for mounting and fixing the multi-port fluid connector. Advantageously, the retention means can be used to maintain and hold the multi-port fluid connector within the battery module subassembly such that the branch ports are in fluid communication with the first and second fluid connection conduits of the peripheral fluid delivery array.

[0179] Preferably the retaining means comprises a major planar portion.

[0180] Preferably, the major planar portion is adapted to engage and bear against the multi-port fluid connector, particularly the first body member, in use.

[0181] Preferably, the major planar portion includes a port opening.

[0182] Preferably, the primary port passes through a port opening in the major planar portion.

[0183] Preferably the retaining means comprises one or more attachment portions.

[0184] Preferably, the retaining means comprises three attachment portions.

[0185] Preferably the or each mounting portion extends from the main planar portion.

[0186] Preferably, the or each mounting portion comprises a plurality of apertures for receiving fastening arrangements such as screws or bolts for fastening the retainer plate to another component, such as a fluid delivery arrangement.

[0187] According to another aspect of the present invention there is provided a battery pack comprising a housing, a battery module subassembly and at least one mounting means for the battery module subassembly. Advantageously the mounting means is adapted to support the weight of the battery module subassembly.

[0188] According to another aspect of the present invention, there is provided a battery pack comprising a housing and a battery module subassembly, the battery module subassembly being at least partially located inside the housing and mechanically connected to at least one mounting means, advantageously capable of transferring the weight of the battery module subassembly to another component, such as an external chassis or support structure.

[0189] Preferably, the battery module subassembly is mechanically connected to at least one mounting means.

[0190] Preferably, the or each mounting means is accessible through the battery pack housing.

[0191] Preferably the or each mounting means provides a mechanical connection point external to the battery pack.

[0192] Preferably, the mounting means is accessible from the exterior of the battery pack housing.

[0193] Preferably, the mounting means is adapted to transfer the weight of the battery module subassembly to a component external to the housing. Advantageously, the mounting means allows the weight of the battery module subassembly to be transferred directly to a support structure, such as an external chassis, rather than to the support structure via a connection to the battery pack housing and one or more external brackets.

[0194] Preferably, the battery pack comprises a number of mounting means. Advantageously, the mounting means allow the battery pack to be mounted to another structure, such as a vehicle chassis.

[0195] Preferably, the battery pack comprises eight mounting means.

[0196] Preferably, the mounting means provides a plurality of locations on the battery pack housing where the battery pack can be fixedly mounted to a vehicle chassis or other structure.

[0197] Preferably, during use, the battery pack is mounted to a supporting structure, such as a chassis.

[0198] Preferably, during use, the battery pack is mounted to a supporting structure, such as a chassis, via mounting means.

[0199] Preferably, the mounting means is accessible through an opening in a cover member of the battery pack housing.

[0200] Preferably the mounting means is accessible through a cover member of the upper mounting arrangement.

[0201] Preferably, the upper mounting arrangement comprises a mounting member directly accessible through the battery pack housing.

[0202] Preferably, the other mounting means is located on the bottom wall of the battery pack housing.

[0203] Preferably, the other mounting means located on the bottom wall of the battery pack housing is a lower mounting arrangement.

[0204] Preferably the lower mounting arrangement is covered by a leg covering.

[0205] Preferably the or each mounting means comprises a mounting member.

[0206] Preferably, the mounting member is a mounting block having a body.

[0207] Preferably, the mounting member includes a first interface portion.

[0208] Preferably, the first interface portion is adjacent to the battery pack housing.

[0209] Preferably, the mounting member includes a second interface portion.

[0210] Preferably, the second interface portion is adjacent the battery module subassembly.

[0211] Preferably, the second interface portion is similar to the first interface portion.

[0212] Preferably, the first interface portion includes an annular recess for receiving a seal, such as an O-ring. Advantageously, the seal can be used to seal the interface between the mounting member and an adjacent component, such as a cover of a battery pack housing.

[0213] Preferably the or each interface portion is provided with receiving means.

[0214] Preferably, the receiving means comprises a tubular member having a threaded bore.

[0215] Preferably, the receiving means is adapted to receive fastening means, such as screws and / or bolts, which can be used to attach the mounting member to an external support or chassis or the like.

[0216] Preferably the or each interface portion is provided with further receiving means.

[0217] Preferably, the or each interface portion is provided with two further receiving means.

[0218] Preferably, the further receiving means comprises a threaded hole.

[0219] Preferably, the other receiving means is adapted to receive fastening means, such as screws and / or bolts, that can be used to attach the mounting member to the battery pack housing.

[0220] Preferably, each mounting member is attached to the battery module subassembly and the battery pack housing via another receiving arrangement.

[0221] Preferably, the mounting member is a spacer that defines a gap between the battery module subassembly and the battery pack housing.

[0222] Preferably, the mounting member is adapted to transfer the weight of the battery module subassembly to the exterior of the battery pack housing, for example to a support structure or chassis.

[0223] Preferably, the mounting member is directly accessible on the outside of the battery pack housing, for example through an opening.

[0224] According to another aspect of the invention, there is provided a battery module comprising one or more cells and thermal management means for thermally managing the one or more cells, the thermal management means comprising at least one thermal management duct, an inlet side fluid delivery means and an outlet side fluid delivery means, the inlet side fluid delivery means being in fluid communication with the outlet side fluid delivery means via the at least one thermal management duct. Advantageously, an adjustable number of such battery modules can be assembled into a battery pack to be able to meet any particular volumetric and / or electrical requirements.

[0225] According to another aspect of the present invention, there is provided a battery module comprising a battery module housing, one or more cells located within the battery module housing, thermal management means for thermally managing the one or more cells, and battery module electrical connection means for providing electrical connection between the battery module and other battery modules and / or an external load. Advantageously, the one or more battery modules can be assembled into a battery pack in a variety of orientations and locations such that any particular volumetric and / or electrical requirements can be met.

[0226] According to another aspect of the present invention, a battery pack is provided that includes one or more battery modules.

[0227] Preferably, the battery module is disposable within a battery pack.

[0228] Preferably, the battery pack comprises at least one battery module.

[0229] Preferably, the battery pack includes a plurality of battery modules.

[0230] Preferably, the battery pack comprises at least three battery modules.

[0231] Preferably, the battery module is connectable to one or more other identical battery modules.

[0232] Ideally, the battery module comprises a battery module housing.

[0233] Ideally, the battery module housing includes an upper housing member.

[0234] Preferably, the battery module housing includes a lower housing member.

[0235] Preferably, the upper and lower housing members are substantially identical.

[0236] Preferably, the upper and lower housing members each include a substantially planar base.

[0237] Preferably, each of the upper and lower housing members includes two side walls.

[0238] Preferably, each of the upper and lower housing members includes two end walls.

[0239] Preferably, the corresponding side walls and end walls extend in a direction substantially perpendicular to each base.

[0240] Preferably, the side walls of the upper and lower housing members include one or more recesses.

[0241] Preferably, the end walls of the upper and lower housing members include one or more recesses.

[0242] Preferably, the battery module housing includes two opposing side walls.

[0243] Ideally, the sidewall recess forms an opening in the sidewall of the battery module housing.

[0244] Ideally, electrical connections can be made to the battery module terminals through the sidewall recesses / openings.

[0245] Preferably, the end wall recess defines an opening in the end wall of the battery module housing.

[0246] Preferably, electrical and / or fluid connections can be made to the battery module terminals through the end wall recesses / openings.

[0247] Preferably, the battery module comprises an upper surface and a lower surface. Preferably, the battery module comprises one or more side surfaces.

[0248] Preferably, the battery module comprises one or more end faces.

[0249] Preferably, the upper surface is formed by the base of the upper housing member.

[0250] Preferably, the lower surface is formed by a base of the lower housing member.

[0251] Preferably, the side surfaces are formed by side walls of the upper and lower housing members and the terminal bus bars of the battery module.

[0252] Ideally, the end faces are formed by the end walls of the upper and lower housing members, the bus bars of the battery modules, and the fluid distribution means.

[0253] Preferably, the battery module comprises at least one cell.

[0254] Preferably, the battery module comprises one or more cells.

[0255] Preferably, the battery module comprises a plurality of cells.

[0256] Preferably the or each cell is electrically connected to a busbar.

[0257] Preferably, the battery module comprises one or more cylindrical cells.

[0258] Preferably, the battery module comprises an array of cylindrical cells.

[0259] Preferably, the battery module comprises a predetermined number of cells arranged in a regular array.

[0260] Preferably, the battery module comprises a multiple of 6 or 12 cells.

[0261] Preferably, the cells are in a close-packed hexagonal array.

[0262] Preferably, the battery module comprises a close-packed hexagonal array of cylindrical cells.

[0263] Preferably, the or each battery module comprises at least one cell arrangement means.

[0264] Preferably, the cell arrangement means is a plate.

[0265] Ideally, the cell alignment means is for supporting and positioning a plurality of cells.

[0266] Preferably, the cell alignment means is for supporting and arranging a plurality of cells in an array.

[0267] Preferably, the cell alignment means comprises a substantially planar body.

[0268] Ideally, the cell alignment means comprises one or more receiving structures.

[0269] Preferably, the cell alignment means comprises a plurality of receiving structures.

[0270] Ideally, the or each receiving structure is formed within the body.

[0271] Preferably, the or each receiving structure is adapted to receive and locate an end of a cell.

[0272] Preferably, the receiving structures are arranged in a close-packed hexagonal or honeycomb pattern.

[0273] Preferably the minimum separation between the cells is 2 mm.

[0274] Preferably, the battery module comprises one or more cells located within a battery module housing.

[0275] Preferably, the battery module comprises one or more sensing means.

[0276] Preferably, a sensing means is used to measure the temperature of the cell.

[0277] Preferably the sensing means is located on the flexible carrier.

[0278] Preferably, the flexible carrier is a flexible PCB.

[0279] Preferably the flexible carrier is attachable to a duct.

[0280] Preferably, the sensing means is located between the thermal management duct and the cell or cells.

[0281] Preferably the sensing means comprises one or more sensors.

[0282] Preferably, the sensors comprise pressure sensors, temperature sensors, voltage sensors and / or liquid / moisture sensors.

[0283] Preferably, the sensors are mounted in an array.

[0284] Preferably, the sensors are mounted in an array on a flexible carrier. Advantageously, mounting the sensors in an array not only allows the performance and physical characteristics of the battery pack to be mapped, but also allows the determination of quantity differences throughout the pack, for example the rate of change of fluid flow rate and temperature to be inferred / predicted.

[0285] Preferably, the sensors are mounted in a linear array.

[0286] Optionally, the sensors are mounted in the form of a polarized array.

[0287] Preferably, the carrier comprises conductive traces which advantageously allow sensors on the carrier to be operatively connected to, for example, a daughter board of a battery module, for communicating, for example, cell temperatures to, for example, battery pack management means for analysis by, the battery pack management means.

[0288] Preferably, the battery module comprises a battery module electrical connection means.

[0289] Preferably, the battery module comprises battery module electrical connection means for providing electrical connections between the battery module and components such as other battery modules, bus bars, interconnects, and / or external loads.

[0290] Preferably, the battery module electrical connection means comprises one or more bus bars.

[0291] Preferably, the battery module electrical connection means comprises a positive terminal and a negative terminal.

[0292] Preferably, the positive and negative terminals are located on opposite side walls of the housing.

[0293] According to another aspect of the invention there is provided a busbar for a battery module and / or battery pack, the busbar comprising electrical connections and at least one structural support means. Advantageously the busbar serves a dual function in that it not only provides a means by which electrical connections can be made within the battery module and / or battery pack, but also provides additional structural support and mechanical strength to the battery module and / or battery pack.

[0294] According to another aspect of the invention, there is provided a busbar for a battery module and / or battery pack, the busbar comprising cell connection portions and external connection portions, the cell connection portions being arranged at an angle relative to the external connection portions. Advantageously, the busbar is constructed to enable electrical contact to be made between one or more cells within the battery pack or battery module and an external component.

[0295] According to another aspect of the present invention, there is provided a battery module comprising at least one bus bar.

[0296] Preferably, a busbar is used to electrically interconnect one or more cells.

[0297] Ideally, bus bars may be used within the battery modules and / or battery packs to provide electrical connections to the cells within the battery packs and / or battery modules.

[0298] Preferably, the busbar is a terminal of the battery module.

[0299] Preferably, the busbar is a positive or negative terminal of the battery module.

[0300] Ideally, the busbars are adapted to receive the edges of the array of cells.

[0301] Preferably, the busbar comprises an electrical connection portion.

[0302] Preferably, the electrical connection portion is adapted to electrically interconnect one or more cells with one or more other components, such as other bus bars, terminals, interconnects, and / or an external load.

[0303] Preferably, the electrical connection portion comprises an external connection portion.

[0304] Preferably, the electrical connection is at least partially made from an electrically conductive material.

[0305] Preferably, the electrical connection is at least partially made from aluminium or steel.

[0306] Preferably, the electrical connection portion is generally non-planar.

[0307] Preferably, the electrical connection portion comprises a plurality of portions.

[0308] Preferably, the electrical connection comprises a cell connection.

[0309] Preferably, the electrical connection portion comprises a cell connection portion adapted for electrical connection to a terminal of one or more cells, for example via wire bonding.

[0310] Preferably, the cell connection portion is substantially perpendicular to the primary external connection portion.

[0311] Preferably, the cell connection portion is adapted to be connectable to the terminals and / or casings of one or more cells.

[0312] Preferably, the cell connecting portion is generally planar.

[0313] Ideally, the cell connection portion comprises one or more cell connection openings.

[0314] Ideally, the cell connection portion comprises a plurality of cell connection openings.

[0315] Preferably, the cell connection portion comprises at least two rows of cell connection openings.

[0316] Preferably, the or each connecting opening is generally rectangular.

[0317] Preferably, the or each connection aperture is adapted to allow the complete passage of a wire bond therethrough.

[0318] Preferably, the or each connecting aperture is arranged in a close-packed hexagonal or honeycomb pattern.

[0319] Preferably, the electrical connection portion comprises at least one external connection portion.

[0320] Preferably, the external connection portion is a terminal portion adapted for connection to an external load.

[0321] Preferably, the external connection portion is adapted to provide an electrical connection to other components, such as other bus bars, terminals, interconnects, or an external load.

[0322] Preferably, the cell connection portion is substantially perpendicular to the external connection portion.

[0323] Preferably, the external connection portion comprises a major planar portion.

[0324] Preferably, the major planar portion is generally planar.

[0325] Preferably, the external connection portion comprises one or more protrusions.

[0326] Ideally, the external connection portion comprises a plurality of protrusions.

[0327] Ideally, the external connection portion comprises four prongs.

[0328] Preferably, the generally planar portion includes one or more protrusions.

[0329] Preferably, the or each protrusion is adapted to provide an electrical connection to other components, such as other bus bars, terminals, interconnects, or an external load.

[0330] Preferably, the or each projection is generally planar.

[0331] Preferably the or each projection is raised above a major plane of the primary external connection portion.

[0332] Preferably, the or each protrusion is adapted to be accessible through the housing of the battery module.

[0333] Preferably, the or each projection is adapted to pass through an opening in the housing of the battery module.

[0334] Preferably, the or each projection is integrally formed within the external connection portion.

[0335] Preferably the or each protrusion is formed via compression moulding.

[0336] Ideally, the or each projection comprises a planar portion surrounded by a curved peripheral portion.

[0337] Preferably the or each protrusion is provided with a retaining means.

[0338] Preferably the or each retaining means comprises a threaded hole.

[0339] Preferably, the or each retaining means is adapted to retain a fastening means such as a bolt. Advantageously, the presence of the retaining means allows for example for rigid attachment of the inter-module busbars to the connection surfaces of the busbars.

[0340] Preferably, the or each electrical connection is accessible from outside the battery module. Advantageously, the accessibility of the primary and secondary electrical connections allows the battery module to be electrically connected to other components in multiple locations and / or orientations.

[0341] Preferably, the or each cell in the battery module is electrically connected to at least one busbar.

[0342] Preferably, the or each cell in the battery module is electrically connected to at least one busbar via one or more wire bonds.

[0343] Preferably, the or each cell in the battery module is electrically connected to at least one bus bar via wire bonds that are fusible and / or frangible electrical connections.

[0344] Preferably, the or each wirebond electrical connection to the busbar is made using ultrasonic bonding, laser welding, ultrasonic welding, or resistance welding.

[0345] Preferably the or each wire bond is an aluminium wire bond.

[0346] Preferably the busbar comprises at least one structural support means.

[0347] Preferably the busbar comprises two structural support means.

[0348] Preferably, the or each structural support means is adapted to maintain electrical connections in place within the battery module and / or to provide structural support to the battery module. Advantageously, the structural support means allows multiple battery modules to be stacked in alignment.

[0349] Preferably, the or each structural support means is locatable at a peripheral edge of the electrical connection portion.

[0350] Preferably the or each structural support means comprises a body portion.

[0351] The body portion is preferably made from a non-conductive material, preferably plastic.

[0352] Preferably the or each structural support means is rigidly attachable to the electrical connections.

[0353] Preferably the or each structural support means is overmolded onto the electrical connections.

[0354] Preferably the or each structural support means comprises an end portion.

[0355] Preferably the or each structural support means comprises an upper portion.

[0356] Preferably the or each structural support means comprises a lower portion.

[0357] Preferably the or each structural support means comprises a side portion.

[0358] Preferably, the outer surfaces of the upper and lower portions are substantially parallel.

[0359] Preferably the outer surfaces of the end and side portions are substantially perpendicular to each other. By "outer surface" it is meant the surface which is outermost in use and which is opposite the inner surface.

[0360] Preferably, the outer surfaces of the end and side portions are substantially perpendicular to the outer surfaces of the top and bottom portions.

[0361] Preferably the or each structural support means is attached to the electrical connection portion via fasteners which pass through apertures at a peripheral edge of the external connection portion.

[0362] Preferably a side portion of the or each structural support means is attached to the external connection portion.

[0363] Preferably, peripheral ends of the external connection portions of the busbars are received within the or each structural support means.

[0364] Preferably the or each structural support means comprises a first and a second receiving arrangement for receiving fastening means such as screws and / or bolts.

[0365] Preferably, the first receiving arrangement and the second receiving arrangement include threaded openings.

[0366] Preferably, the first receptor sequence is located within the end portion.

[0367] Preferably, the second receiving sequence is located within the side portion.

[0368] Preferably, the receiving arrangement is adapted to allow the elongated corner support members of the support arrangement to be attached to the busbars via fixing means such as screws and / or bolts.

[0369] Preferably, the at least one opening is located in the external connection portion.

[0370] In accordance with another aspect of the present invention, a thermal management means is provided for thermally managing one or more cells within a battery pack, battery module subassembly, or battery module.

[0371] According to another aspect of the present invention, there is provided a battery pack, battery module subassembly, or battery module including a thermal management means.

[0372] Preferably the or each battery module is provided with thermal management means.

[0373] Preferably, the or each battery module comprises thermal management means for thermally managing one or more cells.

[0374] Preferably, the thermal management means is configured to allow fluid connections to be made to the battery module in multiple locations and / or orientations.

[0375] Ideally, the or each thermal management means is adapted to thermally manage one or more cells.

[0376] Ideally, the or each thermal management means is adapted to heat and / or cool one or more cells.

[0377] Preferably the thermal management means comprises an inlet side fluid delivery means.

[0378] Preferably the thermal management means comprises an outlet side fluid delivery means.

[0379] Preferably the inlet side fluid delivery means and the outlet side fluid delivery means are substantially identical.

[0380] Preferably the thermal management means comprises one or more thermal management ducts.

[0381] Preferably the thermal management means comprises a plurality of thermal management ducts.

[0382] Preferably the thermal management means comprises one or more substantially parallel thermal management ducts.

[0383] Preferably the thermal management means comprises one or more manifold ducts.

[0384] Preferably the thermal management means comprises one or more serpentine ducts.

[0385] Preferably the or each thermal management duct is a flexible duct.

[0386] Preferably, the or each thermal management duct is flexible and / or expandable.

[0387] Preferably, the or each thermal management duct is made from an expandable plastic material, which is advantageous as it is inherently electrically insulating, lightweight and does not corrode or chemically interact with coolants such as glycol water mixtures.

[0388] Ideally, the or each thermal management duct is made from polyethylene (PE).

[0389] Preferably, the or each thermal management duct is made from low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), or high-density polyethylene (HDPE).

[0390] Preferably, the or each thermal management duct comprises one or more thermally conductive additives, which provide the advantage that the thermal conductivity of the duct material can be improved.

[0391] Preferably, the thermally conductive additive may comprise a thermally conductive filler.

[0392] Preferably, the thermally conductive additive may comprise particles of a thermally conductive filler material.

[0393] Preferably, the particle has a diameter of 1 nm to 10 nm.

[0394] Preferably the particles have a diameter of <5 μm.

[0395] Preferably, the thermally conductive filler is incorporated into the expandable plastic material.

[0396] Ideally, the or each thermal management duct comprises a matrix material and a thermally conductive filler.

[0397] Preferably, the matrix material comprises an expandable plastic material such as polyethylene (PE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), or high density polyethylene (HDPE).

[0398] Preferably, the thermally conductive filler comprises a carbon-based filler.

[0399] Preferably, the thermally conductive filler comprises carbon, carbon black, graphite, graphene, multi-walled carbon nanotubes, or single-walled carbon nanotubes.

[0400] Optionally, the thermally conductive filler comprises an inorganic filler.

[0401] Optionally, the thermally conductive filler comprises a ceramic filler.

[0402] Optionally, the thermally conductive filler comprises aluminum oxide, silicon carbide, boron nitride, silicon nitrate, alumina, aluminum nitride, or zinc oxide.

[0403] Preferably, the thermally conductive filler comprises a mixture of different types of particles.

[0404] Preferably, the thermally conductive filler comprises a mixture of at least two different types of particles.

[0405] Ideally the or each duct comprises polyethylene, a carbon based filler and a ceramic based filler.

[0406] Preferably the or each duct comprises polyethylene, graphite particles and boron nitride particles.

[0407] Preferably the, or each, duct comprises up to 30% additive.

[0408] Preferably, the ratio of the carbon-based filler to the ceramic-based filler is between 1:0 and 0:1.

[0409] Ideally, the thermal conductivity of the or each thermal management duct is >≈0.8 W / m·K.

[0410] Ideally, the or each thermal management duct has a thermal conductivity of approximately 1 W / m·K.

[0411] Preferably, the thickness of the wall of the or each flexible duct is between 50 μm and 150 μm, advantageously a thickness which allows good heat transfer characteristics between the or each duct and the cells.

[0412] Preferably the or each thermal management duct is a single lumen duct.

[0413] Preferably the or each thermal management duct is a multi-lumen duct.

[0414] Optionally, the or each thermal management duct is a rigid duct, for example made from aluminium or copper.

[0415] Preferably, the or each thermal management duct is positioned adjacent to and / or between the cells in the battery module.

[0416] Preferably the or each thermal management duct is in a substantially expanded state.

[0417] Preferably the or each thermal management duct is expanding.

[0418] Preferably the or each thermal management duct expands into contact with a sidewall of one or more cells.

[0419] Preferably the or each thermal management duct is in an expanded state such that said thermal management duct has a shape that accommodates a surface shape of one or more cells.

[0420] Preferably the or each thermal management duct is in direct contact with one or more cells.

[0421] Preferably the or each thermal management duct is in indirect contact with one or more cells.

[0422] Optionally, the or each thermal management duct is in indirect contact with one or more cells via an interface area or material.

[0423] Optionally, the or each thermal management duct is in indirect contact with one or more cells via an interface area or material, such as a casing sheath that surrounds the cell.

[0424] Preferably, the or each thermal management duct is in indirect contact with one or more cells via a thermally conductive filler such as a conductive paste or additive.

[0425] Preferably the or each battery module is provided with potting means.

[0426] Preferably, the potting medium is poured into the battery module in a liquid state and allowed to set, harden or become rigid.

[0427] Preferably, the potting means, in a set, cured or hardened condition, is substantially rigid so as to secure the cells and thermal management ducts in place within the battery module.

[0428] Preferably the potting means is adhesively attached to the or each duct.

[0429] Preferably the potting means provides complete external support to the or each duct.

[0430] Preferably the potting means prevents over-expansion and / or rupture of the or each duct.

[0431] Preferably, the potting means maintains each duct in an open configuration so that coolant can flow easily through the or each duct.

[0432] Ideally the potting means is an expandable potting means.

[0433] Preferably, the potting means comprises a thermally insulating potting material such as expandable polyurethane foam. Advantageously, polyurethane foam is lighter than other potting means, thus providing a battery module with a lighter overall weight.

[0434] Preferably, the potting means, when in the expanded condition, substantially fills any gaps within the or each module.

[0435] Optionally, the potting material comprises a thermosetting plastic, a silicone rubber gel, or an epoxy resin.

[0436] According to another aspect of the invention there is provided a duct clamping means adapted to clamp the duct to another component, such as a nozzle. Advantageously the duct clamping means is adapted to prevent leakage from occurring at or around the other component.

[0437] According to another aspect of the invention there is provided a duct assembly comprising a duct, at least one nozzle and at least one duct fastening means, the nozzle being attached to the duct and the duct fastening means being adapted to fasten the duct to the nozzle. Advantageously the duct assembly can be provided in a battery module to enable thermal management of one or more cells.

[0438] Preferably, the or each battery module is provided with at least one duct assembly.

[0439] Preferably, the or each battery module comprises at least one nozzle.

[0440] Preferably the or each battery module is provided with at least one duct fastening means.

[0441] Preferably the or each duct forms part of such a duct assembly.

[0442] Preferably, the duct assembly comprises a duct having two open ends.

[0443] Preferably, the duct assembly includes an inlet nozzle.

[0444] Preferably the duct assembly comprises an inlet duct clamping assembly.

[0445] Preferably, the duct assembly includes an outlet nozzle.

[0446] Preferably, the duct assembly comprises an outlet duct clamping assembly.

[0447] Preferably, the or each duct clamping assembly is used to clamp the open end of the duct to a corresponding nozzle.

[0448] Preferably, the or each duct clamping assembly ensures that there is a fluid-tight connection between the duct and the corresponding nozzle.

[0449] Preferably, the or each duct clamping assembly prevents leakage from occurring at the corresponding nozzle-duct interface.

[0450] Preferably, the ends of the duct assembly are usable at both ends of the duct assembly.

[0451] Preferably, the inlet nozzle and the outlet nozzle are substantially identical.

[0452] Preferably, the inlet duct clamping assembly and the outlet duct clamping assembly are substantially identical.

[0453] Preferably, the nozzle comprises a nozzle body.

[0454] Preferably, the opening passes through the nozzle body.

[0455] Preferably, fluid can pass through the nozzle body through the opening.

[0456] Preferably, the nozzle body includes a flange portion.

[0457] Preferably, the nozzle body includes a mounting portion.

[0458] Preferably, the attachment portion is located within the open end of the duct.

[0459] Preferably the duct is heat welded to the attachment portion of the nozzle at the open end of the duct.

[0460] Preferably, the flange portion comprises a protrusion.

[0461] Preferably the flange portion, and particularly the projection, provides a surface to which another component, for example a fluid delivery array, can be attached.

[0462] Preferably the nozzle is attached to the fluid delivery arrangement, for example via plastic welding.

[0463] Preferably, the duct clamping assembly comprises a bearing member.

[0464] Preferably, the duct clamping assembly comprises at least one fastening member.

[0465] Preferably, the duct clamping assembly comprises a first fastening member and a second fastening member.

[0466] Preferably, the duct clamping assembly comprises a biasing member.

[0467] Preferably, the or each fixing member, and the bearing members are made from an insulating plastics material, or from a metal such as aluminium.

[0468] Preferably, the biasing member is made from a resilient material, preferably steel wire.

[0469] Preferably, during use, the duct clamping assembly compresses and holds the open ends of the duct and nozzle together.

[0470] Preferably the duct is joined to the attachment portion of the nozzle at the open end of the duct, for example via ultrasonic welding.

[0471] Preferably, the duct clamping assembly strengthens the joint between the open end of the duct and the mounting portion of the nozzle.

[0472] Preferably, the duct clamping assembly acts to prevent leakage from occurring at the interface between the duct and the nozzle.

[0473] Preferably, the bearing member comprises a first elongated portion.

[0474] Preferably, the bearing member includes a second elongated portion.

[0475] Preferably, the bearing member includes an interface portion.

[0476] Preferably, the interface portion joins the first elongated portion to the second elongated portion.

[0477] Preferably, a gap is located between the elongated portions. Advantageously, the gap allows the nozzle and the mounting portion to pass through the gap and move to a position between the elongated portions such that the nozzle and the mounting portion can be received by the bearing member.

[0478] Preferably, the gap is located between the ends of the elongate portion opposite the interface portion.

[0479] Preferably the bearing member is a U-shaped member.

[0480] Preferably, the bearing member is adapted to bear against the duct and the nozzle.

[0481] Preferably, the inner surface of the bearing member is adapted to bear against the duct at the position where the duct is attached to the nozzle.

[0482] Preferably, the inner surface of the bearing member is generally smooth.

[0483] Preferably, the bearing member further comprises a positioning element in the form of a protrusion extending from the first elongated portion and the second elongated portion.

[0484] Preferably, two positioning elements extend from the first elongated portion.

[0485] Preferably, two positioning elements extend from the second elongate portion.

[0486] Preferably, the positioning element is receivable within corresponding receiving portions of the first and second fixing members.

[0487] Preferably, the biasing member comprises a body.

[0488] Preferably, the biasing member includes a first arm portion and a second arm portion.

[0489] Preferably, the biasing member comprises a bridge portion.

[0490] Preferably, the first arm portion and the second arm portion are substantially straight and parallel.

[0491] Preferably, the first arm portion and the second arm portion are each connected at their corresponding ends to the bridge portion.

[0492] Preferably, each arm portion includes a corresponding maintainable portion.

[0493] Preferably the or each maintainable portion is a curved end portion.

[0494] Preferably, the biasing member is a spring.

[0495] Preferably, the biasing member is adapted to provide a force urging the first and second fixing members towards each other and towards the bearing member, the mounting portion of the nozzle and / or the open end of the duct.

[0496] Preferably, in use, the biasing member biases the first securing member and the second securing member.

[0497] Preferably, the force provided by the biasing member is transmitted to the joint between the duct and the nozzle by the first and second fixed members and the bearing member.

[0498] Preferably, the duct clamping assembly strengthens the joint between the duct and the nozzle.

[0499] Preferably, the duct clamping assembly ensures a leak-tight connection between the duct and the nozzle at the end of the duct.

[0500] Preferably, the fixation member comprises an elongated portion.

[0501] Preferably, the fixing member comprises two curved end portions.

[0502] Preferably, the fixing member comprises two curved end portions at either end of an elongate portion.

[0503] Preferably, the securing member comprises an inner surface.

[0504] Preferably, the inner surface is adapted to engage an outer surface of the bearing member.

[0505] Preferably, the inner surface of the fixation member comprises a receiving portion.

[0506] Preferably, the receiving portion is adapted to receive a positioning element of the bearing member.

[0507] Preferably, the receiving portion is adapted to receive and accommodate the positioning element when the fixing member is pressed against one side of the bearing member. Advantageously, the receiving portion enables the first fixing member to be accurately positioned against the side of the bearing member in the correct position. Further advantageously, engagement of the positioning element with the receiving portion prevents displacement of the first fixing member relative to the bearing member.

[0508] Preferably, the distance between the receiving portions is equal to the distance between the positioning elements.

[0509] Preferably, the securing member comprises an outer surface.

[0510] Preferably, the outer surface of the fixation member comprises a channel.

[0511] Preferably, the channel is an elongated slot.

[0512] Preferably, the channel is adapted to accommodate at least a portion of the biasing member.

[0513] Preferably, the channel is adapted to receive the arm of the biasing member.

[0514] Preferably, the channel is formed between the first wall and the second wall.

[0515] Preferably, the first wall and / or the second wall are continuous.

[0516] Optionally, the first wall and / or the second wall are discontinuous.

[0517] Optionally, the first wall and / or the second wall comprise one or more discontinuities.

[0518] Preferably, the first wall and / or the second wall extend along the fixing member.

[0519] Preferably, the first wall and / or the second wall extend along the entire length of the fixing member.

[0520] Preferably, the first wall and / or the second wall extend along the entire length of the elongated portion and the curved portion.

[0521] Preferably, the fixing member comprises a receiving means.

[0522] Preferably, the outer surface of the fixing member is provided with the receiving means.

[0523] Preferably, the receiving means is a recess.

[0524] Preferably, the receiving means is a recess in the body of the fixing member.

[0525] Preferably, the receiving means is adapted to receive a portion of the biasing member.

[0526] Preferably, the receiving means is adapted to receive one of the holding parts.

[0527] Preferably, the receiving means is adapted to engage a portion of the biasing member.

[0528] Preferably, the receiving means is adapted to engage one of the retainable portions of the biasing member. Advantageously, the receiving means allows the biasing member to be accurately positioned in the channel of the fixed member at the correct position. Further advantageously, engagement of the retainable portion of the biasing member with the receiving arrangement prevents displacement of the biasing member relative to the fixed member during use.

[0529] According to another aspect of the invention, there is provided a fluid distribution means for distributing a thermal management fluid to one or more thermal management ducts positionable within a battery module and / or battery pack, the fluid distribution means comprising a first connecting conduit adapted to provide a path for fluid to enter and / or exit the fluid distribution means, a second connecting conduit adapted to provide a path for fluid to enter and / or exit the fluid distribution means, and one or more distribution means adapted to provide a path for fluid to enter and / or exit the fluid distribution means, each distribution means being in fluid communication with the first connecting conduit and the second connecting conduit. Advantageously, the fluid distribution means provides a means by which fluid can be distributed to manage a number of cells within the battery pack.

[0530] According to another aspect of the invention, there is provided a fluid distribution means for delivering a thermal management fluid to one or more thermal management ducts positionable within a battery module and / or battery pack, the fluid distribution means comprising a plurality of paths by which fluid may pass into and / or out of the fluid distribution means. Advantageously, the fluid distribution means provides a distributable means for managing a large number of cells within a battery pack.

[0531] According to another aspect of the present invention, there is provided a battery module and / or battery pack comprising a fluid delivery means.

[0532] Preferably, the battery pack comprises at least one fluid delivery means.

[0533] Preferably, the battery pack comprises two fluid delivery means.

[0534] Preferably, the battery module comprises at least one fluid delivery means.

[0535] Preferably, the battery module comprises two fluid delivery means.

[0536] Preferably the thermal management means comprises at least one fluid delivery means.

[0537] Preferably the thermal management means comprises two fluid delivery means.

[0538] Preferably the or each duct is operatively connected to at least one fluid delivery means.

[0539] Ideally, the or each duct is operatively connected to two fluid delivery means.

[0540] Preferably the or each duct is sealably connected to at least one fluid delivery means.

[0541] Preferably the or each duct is welded to at least one nozzle or fluid delivery means.

[0542] Preferably, the or each fluid delivery means is adapted to deliver thermal management fluid to one or more thermal management ducts positionable within the battery module and / or battery pack.

[0543] Preferably the heat delivery means comprises a first connecting conduit.

[0544] Preferably the heat delivery means comprises at least one first connecting conduit.

[0545] Preferably, the fluid delivery means comprises at least one first connecting conduit adapted to provide a path for fluid to enter and / or exit the fluid delivery means.

[0546] Preferably the heat delivery means comprises a second connecting conduit.

[0547] Preferably, the heat delivery means comprises at least one second connecting conduit.

[0548] Preferably, the fluid delivery means comprises at least one second connecting conduit adapted to provide a pathway for fluid to enter and / or exit the fluid delivery means.

[0549] Preferably, the fluid delivery means comprises a body.

[0550] Preferably the fluid delivery means comprises a body formed from a front member and a rear member.

[0551] Preferably, the first connecting conduit and / or the second connecting conduit form part of the front member.

[0552] Preferably the or each fluid delivery means comprises a main chamber.

[0553] Preferably, the front member partially surrounds the main chamber.

[0554] Preferably, the rear member partially surrounds the main chamber.

[0555] Preferably, the rear member of the body comprises one or more distribution means.

[0556] Preferably, the main chamber is located inside the body.

[0557] Preferably, the main chamber is completely enclosed by the front and rear members.

[0558] Preferably, the front and rear members are sealably attached to one another.

[0559] Ideally, the or each fluid delivery means is a pressure regulated reservoir.

[0560] Preferably, the or each fluid delivery means is operatively connected to at least one duct and / or duct assembly.

[0561] Preferably, the or each fluid delivery means is operatively connected to at least one thermal management duct and / or duct assembly.

[0562] Preferably, the or each fluid delivery means is operatively connected to a plurality of ducts and / or duct assemblies.

[0563] Preferably, the or each fluid delivery means is operatively connected to a plurality of ducts and / or duct assemblies.

[0564] Preferably, the or each fluid delivery means is, in use, operatively connected to one or more other fluid delivery means.

[0565] Preferably, the first connecting conduit and / or the second connecting conduit provide a fluid path into and / or out of the fluid delivery means.

[0566] Preferably, the or each first connecting conduit and / or the or each second connecting conduit provides a fluid path into and / or a fluid path out of the main chamber.

[0567] Preferably, the first connecting conduit and / or the second connecting conduit are in fluid communication with the main chamber.

[0568] Preferably, the first connecting conduit and / or the second connecting conduit are in fluid communication with the main chamber via one or more fluid connection openings.

[0569] Preferably, the first connecting conduit and / or the second connecting conduit are in fluid communication with the main chamber via two fluid connection openings.

[0570] Preferably, the main chamber comprises a main chamber perimeter wall.

[0571] Preferably, the main chamber is located within a space defined by a main chamber peripheral wall.

[0572] Preferably, the main chamber peripheral wall is an annular wall.

[0573] Preferably, the main chamber peripheral wall surrounds the fluid connection opening.

[0574] Preferably, the or each first connecting conduit and / or the or each second connecting conduit is provided with a first fluid connection means.

[0575] Preferably, the or each first fluid connection means is a fluid inlet.

[0576] Preferably, the or each first connecting conduit and / or the or each second connecting conduit is provided with second fluid connection means.

[0577] Preferably, the or each second fluid connection means is a fluid outlet.

[0578] Preferably the first fluid connection means of the first connecting conduit and / or the second connecting conduit provides a fluid pathway into the fluid delivery means.

[0579] Preferably, the first fluid connection means of the first connecting conduit and / or the second connecting conduit is connectable to a source of thermal management fluid.

[0580] Preferably the second fluid connection means of the first connecting conduit and / or the second connecting conduit provides a fluid path out of the fluid delivery means.

[0581] Preferably, the first fluid connection means is provided at a first end of the first connecting conduit and / or the second connecting conduit.

[0582] Preferably, a second fluid connection means is provided at a second end of the first connecting conduit and / or the second connecting conduit.

[0583] Preferably, the first end of the first connecting conduit and / or the second connecting conduit is opposite the second end of the first connecting conduit and / or the second connecting conduit.

[0584] Ideally, the first connecting conduit and / or the second connecting conduit comprises a first connecting conduit wall and / or a second connecting conduit wall.

[0585] Preferably, the cross section of the first connecting conduit wall and / or the second connecting conduit wall is rectangular.

[0586] Preferably, the first connecting conduit wall and / or the second connecting conduit wall extends along the axis.

[0587] Preferably, the first connecting conduit wall and / or the second connecting conduit wall has a major or long axis.

[0588] Preferably, the major or long axis of the first connecting conduit and / or the second connecting conduit extends along the length of the first connecting conduit and / or the second connecting conduit.

[0589] Preferably, the major or long axis of the first connecting conduit and / or the second connecting conduit is substantially parallel to the direction of fluid flow through the first connecting conduit and / or the second connecting conduit from the first fluid connection means to the second fluid connection means of the first connecting conduit and / or the second connecting conduit.

[0590] Preferably, the major or major axis of the first and / or second connecting conduit is substantially parallel to the major or major axis of the first and / or second connecting conduit of an adjacent fluid delivery means.

[0591] Preferably, the first fluid connection means of the first connecting conduit and / or the second connecting conduit are connectable to the first fluid connection means and / or the second fluid connection means of another fluid delivery means.

[0592] Preferably, the second fluid connection means of the first connecting conduit and / or the second connecting conduit are connectable to the first fluid connection means and / or the second fluid connection means of another fluid delivery means.

[0593] Preferably, the first fluid connection means and / or the second fluid connection means comprise attachment means.

[0594] Preferably the or each mounting means comprises a flange.

[0595] Preferably the or each attachment means comprises a channel for receiving a seal.

[0596] Preferably, each flange includes two inclined surfaces.

[0597] Preferably the or each flange is provided with a channel.

[0598] Ideally, the inclined surfaces are substantially opposite the surfaces of each flange in which the channels are formed.

[0599] Preferably, the or each channel is adapted to receive and maintain a portion of the sealing means.

[0600] Preferably the or each channel has a predetermined depth.

[0601] Preferably, the or each channel has a depth suitable to receive at least a portion of the sealing means.

[0602] Preferably the fluid delivery means comprises a plurality of dispensing means.

[0603] Preferably, each dispensing means comprises a dispensing opening formed within the nozzle mounting portion.

[0604] Preferably, each nozzle mounting portion includes a recessed portion.

[0605] Preferably, each recessed portion is an annular recess extending around the periphery of the dispensing opening.

[0606] Preferably, each recessed portion is adapted to receive a portion of the nozzle, in particular a projection on the flange portion of the nozzle.

[0607] Preferably, the recessed portion allows accurate positioning of the nozzle relative to the dispensing opening and attachment to the dispensing means in the correct location.

[0608] Preferably, the rear member of the fluid delivery means is provided with a plurality of distribution openings to allow fluid to flow between the main chamber and the distribution means.

[0609] Preferably, the rear member comprises eight distribution openings and eight distribution means.

[0610] Preferably, each distribution means is adapted to allow fluid to pass through said distribution means into and / or out of the corresponding duct / duct assembly.

[0611] Preferably, during use, coolant is allowed to flow from the main chamber through each distribution opening and into the duct / duct assembly / nozzle.

[0612] Preferably the dispensing openings of the fluid delivery means are aligned.

[0613] Preferably, the length of each distribution opening is equal.

[0614] Preferably, each distribution opening extends the full height of the aperture.

[0615] Preferably, each distribution opening is in fluid communication with both the first and second connecting conduits such that fluid passing into the fluid distribution means via either conduit can be distributed to any of the distribution openings.

[0616] Preferably, fluid passing through the main chamber is distributed evenly to each of the fluid distribution means.

[0617] Preferably, the fluid delivery means comprises a storage compartment.

[0618] Preferably, the storage compartment is a unitary storage compartment.

[0619] Preferably the storage compartment is integrally formed within the front member.

[0620] Preferably, the storage compartment is located between the first connecting conduit and the second connecting conduit.

[0621] Preferably, the storage compartment is a sealable chamber. Advantageously, the storage compartment can house, for example, a daughter board of a battery management computer. Further advantageously, the storage compartment is sealable, for example to prevent fluids from entering the storage compartment.

[0622] Preferably, the storage compartment comprises a peripheral wall.

[0623] Preferably, the storage compartment comprises one or more posts.

[0624] Preferably the, or each, post is adapted to receive a fixing means such as a screw.

[0625] Preferably the fluid delivery means comprises a cover member.

[0626] Preferably the cover member is attachable to the fluid delivery means.

[0627] Preferably, the cover means is adapted to seal the storage compartment.

[0628] Preferably the or each distribution means is mounted in a duct assembly.

[0629] Preferably the or each distributor means is mounted to a nozzle of the duct assembly.

[0630] Preferably the or each duct assembly is connected to two fluid delivery means.

[0631] Preferably the or each nozzle is attached in a fluid-tight manner to the dispensing means.

[0632] Preferably the, or each, nozzle is weldable to the rear member of the fluid distribution means.

[0633] Preferably, a projection on the flange portion of the nozzle is located within the recessed portion and the flange of the nozzle is welded to the nozzle mounting portion Advantageously, such mounting provides a fluid-tight connection between the nozzle and the rear member of the fluid distribution means.

[0634] Preferably, a clamping assembly is placed over the joint between the duct and the nozzle to strengthen the joint and prevent leakage.

[0635] Preferably, in use, the first and second connecting conduits are used to transport fluid to and / or from the chamber.

[0636] Preferably, the fluid connection means is open to allow fluid to pass into and out of the main chamber via the first and second connecting conduits.

[0637] Preferably, each distribution means has the same opening in fluid communication with the main chamber.

[0638] Optionally, the fluid delivery means comprises a septum.

[0639] Optionally, a septum is located inside the main chamber.

[0640] Optionally, a partition divides the main chamber into multiple sub-chambers.

[0641] Optionally, the septum follows a non-linear path.

[0642] Optionally, the bulkhead is crenellated.

[0643] Optionally, the septum comprises a plurality of crevices.

[0644] Optionally, the main chamber peripheral wall surrounds the bulkhead.

[0645] Optionally, the main chamber comprises a first sub-chamber and a second sub-chamber.

[0646] Optionally, a partition divides the main chamber into a first sub-chamber and a second sub-chamber.

[0647] Optionally, the first sub-chamber is located between the main chamber peripheral wall and the first side of the bulkhead.

[0648] Optionally, a second sub-chamber is located between the main chamber peripheral wall and the second side of the bulkhead.

[0649] Optionally, the second side of the partition is opposite the first side of the partition.

[0650] Optionally, the first and second connecting conduits and / or the distribution means of the fluid delivery means are in fluid communication with only a portion of the main chamber.

[0651] Optionally, the first connecting conduit is in fluid communication with the first sub-chamber via two fluid connection openings.

[0652] Optionally, the second connecting conduit is in fluid communication with the second sub-chamber via two fluid connection openings.

[0653] Optionally, the first connecting conduit is not in fluid communication with the second sub-chamber.

[0654] Optionally, the second connecting conduit is not in fluid communication with the first sub-chamber.

[0655] Optionally, the fluid delivery means comprises a plurality of first distribution means and a plurality of second distribution means.

[0656] Optionally, the dispensing openings of the plurality of first dispensing means are aligned.

[0657] Optionally, the dispensing openings of the plurality of second dispensing means are aligned.

[0658] Optionally, the distribution openings of the plurality of first distribution means are not aligned with the distribution openings of the plurality of second distribution means.

[0659] Optionally, the dispensing openings of the plurality of first dispensing means are offset relative to the dispensing openings of the plurality of second dispensing means.

[0660] Optionally, the distribution openings in each first distribution means and / or each second distribution means do not extend the entire length of the corresponding aperture portion.

[0661] Optionally, the or each distribution opening in each first distribution means and / or each second distribution means extends along part of the length of the corresponding aperture portion.

[0662] Optionally, the opening portion of each first distribution means and / or each second distribution means comprises a punched out portion adjacent the opening portion.

[0663] Optionally, the or each first distribution aperture is in fluid communication with a first connecting conduit via a first sub-chamber.

[0664] Optionally, fluid passing into the fluid distribution means via the first connecting conduit is evenly distributed to the first distribution openings.

[0665] Optionally, the or each second distribution aperture is in fluid communication with a second connecting conduit via a second sub-chamber.

[0666] Optionally, the punched portion of each first distribution means is on an opposite side of the rear member to the punched portion of each second distribution means.

[0667] Optionally, the dispensing opening of each first dispensing means is located on one side of the partition.

[0668] Optionally, the dispensing openings of each second dispensing means are located on opposite sides of the partition.

[0669] Optionally, the or each die cut portion coincides with the location of a septum and forms a seal with the septum.

[0670] Optionally, the distance between adjacent distribution means may correspond to the width of a cell.

[0671] Optionally, ducts may be provided on both sides of the cell, advantageously providing redundancy, i.e. if a duct on one side of the cell bursts or fails, the duct on the other side of the cell can be used to thermally manage the cell.

[0672] Optionally, fluid passing into the fluid distribution means via the first connecting conduit is evenly distributed to the first distribution openings.

[0673] Optionally, fluid passing into the fluid distribution means via the second connecting conduit is evenly distributed to the second distribution openings.

[0674] According to another aspect of the present invention, there is provided a multi-port fluid connector having a primary port and two branch ports, the multi-port fluid connector being a low-profile multi-port fluid connector that may advantageously fit within a constrained volume, such as a predefined volume within a battery pack.

[0675] According to another aspect of the invention, a multi-port fluid connector is provided for connecting a distribution array to a source of thermal management fluid.

[0676] In accordance with another aspect of the present invention, a multi-port fluid connector for a battery pack is provided.

[0677] Preferably, the multi-port fluid connector is a fluid connector.

[0678] Preferably, the multi-port fluid connector is adapted to fit within a predetermined volume.

[0679] Preferably, the multi-port fluid connector is a low profile fluid connector.

[0680] Preferably, the height of the multi-port fluid connector is limited.

[0681] Preferably, the multi-port fluid connector is adapted to split / combine the flow of fluids therethrough.

[0682] Preferably, the multi-port fluid connector is adapted to minimize the generation of vortex components and pressure drops over a limited distance.

[0683] Preferably, the multi-port fluid connector comprises a body.

[0684] Preferably, the multi-port fluid connector comprises a primary port.

[0685] Preferably, the multi-port fluid connector comprises at least one branch port.

[0686] Preferably, the multi-port fluid connector comprises two branch ports.

[0687] Preferably, the multi-port fluid connector further comprises an internal chamber.

[0688] Preferably, the primary port is in fluid communication with the or each branch port via an internal chamber.

[0689] Preferably the body is a two-part body.

[0690] Preferably, the body comprises a first body member and a second body member.

[0691] Preferably, the first body member and / or the second body member are preferably made from a plastic material and may be formed via injection molding techniques.

[0692] Preferably, the first and second body members may be joined using plastic welding or other suitable techniques.

[0693] Preferably, the first body member includes the primary port and a portion of the wall of the internal chamber.

[0694] Preferably, the primary port comprises a tubular member.

[0695] Preferably, the primary port is fluidly connected to the interior chamber.

[0696] Preferably, the primary port is fluidly connected to the inner chamber at or near the center of the inner chamber.

[0697] Preferably, the first body member includes a neck portion.

[0698] Preferably, the neck portion is located at an end of the primary port.

[0699] Preferably, the neck portion is located adjacent the interior chamber.

[0700] Preferably, the multi-port fluid connector comprises one or more protrusions. Advantageously, the shaping of the wall, and in particular of the protrusions, is adapted to direct the flow of fluid through the internal chamber.

[0701] Preferably, the first body member and / or the second body member comprise one or more protrusions. Advantageously, the or each protrusion is adapted to reduce the pressure drop and vortex components within the internal chamber.

[0702] Preferably, the first body member includes a main projection.

[0703] Preferably, the first body member includes two secondary projections.

[0704] Preferably the or each projection is a protrusion.

[0705] Preferably, the or each projection extends into the internal chamber.

[0706] Preferably, the main projection is proximate to the primary port.

[0707] Preferably, the main projection is located between the branch ports.

[0708] Preferably, the secondary projections are located on either side of the primary port.

[0709] Preferably, the primary projection is located on an opposite side of the interior chamber to the two secondary projections.

[0710] Preferably, the second body member includes two branch ports.

[0711] Preferably, the or each branch port comprises a tubular member fluidly connected to the internal chamber.

[0712] Preferably, the or each branch port comprises a tubular member fluidly connected to the internal chamber at or near the edge of the internal chamber.

[0713] Preferably, the second body member comprises a further protrusion. Advantageously, the further protrusion is adapted to reduce the pressure drop and vortex components within the internal chamber.

[0714] Preferably, the other projection is a protrusion that extends into the interior chamber.

[0715] Preferably, the other protrusion is located between the branch ports and opposite the tubular primary port.

[0716] Preferably, the or each branch port is provided with a flange.

[0717] Preferably the or each flange is in a retaining arrangement for a seal.

[0718] Preferably the or each flange is a seal receiving body provided with a channel.

[0719] Preferably, the or each channel is adapted to receive and maintain part of a sealing arrangement, namely part of an O-ring.

[0720] Preferably, the or each channel has a predetermined depth suitable to receive at least a retainable portion of an O-ring.

[0721] Preferably, the distance between the branch ports corresponds to the distance between a first connecting conduit and a second connecting conduit of the fluid delivery array.

[0722] Preferably, the branch ports are located symmetrically on either side of the primary port.

[0723] Preferably, the branch ports are equidistant from the primary port.

[0724] Preferably, the internal chamber comprises a main conduit portion.

[0725] Preferably, the internal chamber comprises two branched conduit portions.

[0726] Preferably, the internal chamber further comprises a flow separating portion and two corner connecting portions.

[0727] Preferably, the flow separation section provides a fluid communication path between the main conduit section and the or each corner connection section.

[0728] Preferably, the or each angled portion provides a fluid communication path between the flow separation portion and the branch conduit portion.

[0729] Preferably the main conduit portion comprises a narrowed portion.

[0730] Preferably, the location of the flow splitting portion corresponds to the location of the projection of the second body member and the main projection of the first body member.

[0731] Preferably, in use, the multi-port fluid connector is adapted to connect the fluid distribution array to a source of thermal management fluid.

[0732] Advantageously, fluid can flow in either direction through the multi-port fluid connector.

[0733] Optionally, during use, fluid may flow into the multi-port fluid connector via the primary port, into the main conduit portion, through the flow separation portion, each corner connection portion, and each branch conduit portion, and out of the multi-port fluid connector via the branch ports.

[0734] Optionally, during use, fluid may flow into the multi-port fluid connector via one or both branch ports, through each branch conduit portion, through each corner connection portion and the flow separation portion and the main conduit portion, and out of the multi-port fluid connector via the primary port.

[0735] According to another aspect of the invention there is provided a sealing means for providing a fluid-tight seal within a battery pack, the sealing means comprising a deformable annular body with a first elongated side portion and a second elongated side portion and positionable between two maintaining means within the battery pack. Advantageously the sealing means is capable of sealing a junction between adjacent first and / or second connecting conduits / pressure regulating reservoirs within the battery pack.

[0736] According to another aspect of the invention, there is provided a sealing means for providing a seal between fluid conduits in a battery pack or battery module, the sealing means comprising a deformable body, the deformable body comprising a central portion located between two maintaining portions, the maintainable portions being positionable within the maintaining channel in use, and in a deformed state the width of the central portion being increased. Advantageously, the sealing means may be accommodated within a positional tolerance between corresponding ends of the conduits of the first connecting conduit / pressure regulating reservoir and / or the second connecting conduit / pressure regulating reservoir inside the battery pack.

[0737] According to another aspect of the present invention, there is provided a battery pack having a sealing means.

[0738] Preferably, the sealing means is for providing a seal between fluid conduits within the battery pack.

[0739] Preferably, the sealing means is an O-ring.

[0740] Preferably the sealing means comprises a deformable body.

[0741] Preferably the sealing means comprises soft silicone or other suitable elastomeric material.

[0742] Preferably the sealing means comprises rubber.

[0743] Preferably the sealing means comprises a unitary body.

[0744] Preferably, the sealing means has a hardness of less than 50 Shore A.

[0745] Preferably, the sealing means has a hardness of greater than 15 Shore A.

[0746] Preferably, the sealing means has a Shore A hardness of between 30-40.

[0747] Preferably, the sealing means has a hardness of between 33-37 Shore A.

[0748] Preferably the sealing means has a Shore A hardness of 35.

[0749] Ideally the sealing means is annular.

[0750] Preferably, the body comprises a central portion.

[0751] Preferably, the cross-sectional shape of the body comprises a central portion located between the first maintainable portion and the second maintainable portion.

[0752] Preferably, the body comprises two maintainable portions.

[0753] Preferably, the cross-sectional shape of the body comprises a central portion located between the first maintainable portion and the second maintainable portion.

[0754] Preferably, the maintainable portion protrudes from the central portion.

[0755] Preferably, the maintainable portions protrude from opposite sides of the central portion.

[0756] Preferably, the body comprises two elongated maintainable portions.

[0757] Preferably, the cross-sectional shape of each maintainable portion comprises a first substantially straight edge portion and a second substantially straight edge portion.

[0758] Preferably, the first substantially straight edge portion and the second substantially straight edge portion are joined by a curved edge portion.

[0759] Preferably, the first substantially linear edge portion and the second substantially linear edge portion are joined by a semi-circular edge portion.

[0760] Preferably, the central portion is located between the two maintainable portions.

[0761] Preferably, the central portion is wider than the maintainable portion.

[0762] Preferably, the cross-sectional width of the central portion is greater than the cross-sectional width of each maintainable portion.

[0763] Preferably, the central portion includes a first curved edge portion and a second curved edge portion.

[0764] Preferably, the central portion includes a first semicircular edge portion and a second semicircular edge portion.

[0765] Preferably, the maximum distance between the first substantially straight edge portion and the second substantially straight edge portion of each maintainable portion is less than the maximum distance between the first curved edge portion and the second curved edge portion of the central portion.

[0766] Preferably, the maintainable portion is adapted to be located and maintained within the maintaining means.

[0767] Preferably, the maintainable portion is adapted to be located and maintained within a channel in a flange of the fluid delivery means.

[0768] Preferably the sealing means is substantially rectangular.

[0769] Preferably the sealing means comprises a deformable annular body.

[0770] Preferably, the sealing means comprises a first elongate side portion and a second elongate side portion.

[0771] Preferably, the first elongate side portion and the second elongate side portion are substantially straight.

[0772] Preferably, the first elongate side portion and the second elongate side portion are substantially parallel.

[0773] Preferably, the first elongate side portion and the second elongate side portion are equal in length.

[0774] Preferably, the body comprises a first shortened side portion and a second shortened side portion.

[0775] Preferably, the first shortened side portion and the second shortened side portion are substantially straight.

[0776] Preferably, the first shortened side portion and the second shortened side portion are substantially parallel.

[0777] Preferably, the first shortened side portion and the second shortened side portion are equal in length.

[0778] Preferably, the sealing means comprises one or more curved portions.

[0779] Preferably, the ends of adjacent side portions are joined by at least one curved portion.

[0780] Preferably, the first elongated side portion and the second elongated side portion are longer than the first shortened side portion and the second shortened side portion.

[0781] Preferably, the sealing means comprises four substantially rectilinear portions.

[0782] Preferably, each side portion is joined to an adjacent side portion by a corner portion.

[0783] Preferably the sealing means comprises two elongated side portions and two shortened side portions.

[0784] Preferably, the sealing means has an undeformed state.

[0785] Preferably, in an undeformed state, the cross-sectional width of the central portion is less than 10 mm.

[0786] Preferably, in the undeformed state, the cross-sectional width of the central portion is 2.8 mm.

[0787] Preferably, in an undeformed state, the cross-sectional width of each maintainable portion is less than 10 mm.

[0788] Preferably, in an undeformed state, the cross-sectional width of each maintainable portion is 1.8 mm.

[0789] Preferably, in an undeformed state, the sealing means has a cross-sectional height of 18mm.

[0790] Preferably, the sealing means has a deformed state.

[0791] Ideally, the sealing means enters into a deformed state when positioned within two channels of adjacent fluid delivery means and squeezed between the two channels.

[0792] Preferably, in the deformed state, the cross-sectional width of the central portion is greater than 2.8 mm.

[0793] Preferably, in the deformed state, the cross-sectional width of the central portion is 4.4 mm.

[0794] Preferably, in the deformed state, the cross-sectional width of each maintainable portion is 1.8 mm.

[0795] Preferably, in the deformed state the sealing means has a cross-sectional height of less than 18mm.

[0796] Preferably, in the deformed state the sealing means has a cross-sectional height of 14.4mm.

[0797] Preferably, in the deformed state the cross-sectional width of the central portion increases. Advantageously, the increased cross-sectional width of the central portion in the deformed state enables the sealing member to accommodate any slight differences in size / dimensions of corresponding channels / flanges of the fluid delivery means between which the seal is maintained.

[0798] Preferably, the width of the central portion in the deformed state is greater than the width of the central portion in the undeformed state.

[0799] Preferably, the width of the maintainable portion in the deformed state is substantially the same as the width of the maintainable portion in the undeformed state.

[0800] According to another aspect of the present invention, there is provided a method of manufacturing a battery pack, the method comprising the steps of forming one or more battery modules, forming a battery module subassembly, installing the battery module subassembly into a battery pack housing, and sealing the battery pack housing. Advantageously, the battery pack may be used to provide power in an industrial device.

[0801] According to another aspect of the invention there is provided a method of manufacturing a battery pack, the method comprising the step of disposing one or more battery modules within a battery pack housing, advantageously the housing providing additional protection and suitable containment means for the battery modules forming the battery pack.

[0802] Preferably, the method comprises forming one or more battery modules.

[0803] Preferably, the method comprises the step of choosing an appropriate number of cells.

[0804] Preferably, the method comprises the step of forming an array of cells.

[0805] Preferably the method comprises the step of providing thermal management means and / or electrical connection means.

[0806] Preferably, the method includes the step of forming a battery module subassembly.

[0807] Preferably, the step of forming a battery module subassembly comprises interconnecting two or more battery modules.

[0808] Preferably, the method comprises the step of providing a mechanical, electrical and / or fluid connection between two or more battery modules.

[0809] Preferably, the method includes disposing the battery module subassembly within a battery pack housing.

[0810] Preferably, the method comprises the step of sealing the battery pack housing.

[0811] Preferably, the method includes the step of mounting a battery pack.

[0812] Preferably, the method comprises the step of mounting the battery pack to a chassis or other supporting structure.

[0813] Preferably, the method comprises the step of attaching the battery pack to a support structure via a mounting arrangement.

[0814] It will be appreciated that optional features applicable to one or more aspects of the invention may be used in any combination and in any number. Furthermore, optional features may also be used in any combination and in any number with any of the other aspects of the invention. This includes, but is not limited to, the use of a dependent claim from any claim as a dependent claim with respect to any other claim in the claims of this application.

[0815] The invention will now be described with reference to the drawings, which show, by way of example only, an embodiment of an apparatus according to the invention. [Brief description of the drawings]

[0816] [Figure 1] 1 is an exploded perspective view of a battery pack according to an aspect of the present invention; [Diagram 2] 1 is a perspective view of a battery pack according to an aspect of the present invention. [Diagram 3] 1 is a perspective view of a battery pack according to an aspect of the present invention. [Figure 4] FIG. 2 is a top view of a battery pack according to an aspect of the present invention. [Diagram 5] FIG. 2 is an end view of a battery pack according to an aspect of the present invention. [Figure 6] FIG. 2 is a perspective view of an end closure box. [Figure 7] FIG. 2 is a perspective view of an end closure box. [Figure 8] FIG. 2 is a side view of the end closure box. [Figure 9] FIG. 1 is a top view of the end closure box. [Figure 10] 1 is a schematic diagram of a battery pack, a load, and a thermal management system in accordance with an aspect of the present invention. [Figure 11]FIG. 2 is an exploded perspective view of a battery module subassembly in accordance with an aspect of the present invention. [Figure 12] FIG. 2 is a perspective view of a battery module subassembly in accordance with an aspect of the present invention. [Figure 13] 1A-1D show top, side and end views of a battery module subassembly in accordance with an aspect of the present invention. [Figure 14] FIG. 2 is an exploded end view of a battery module subassembly in accordance with an aspect of the present invention. [Figure 15] FIG. 2 is a perspective view of a battery module subassembly in accordance with an aspect of the present invention. [Figure 16] 1A-1D show top, side and end views of a battery module subassembly in accordance with an aspect of the present invention. [Figure 17] FIG. 1 is a perspective view of a mounting arrangement according to an aspect of the present invention. [Figure 18] 1 is a perspective view of a battery pack according to an aspect of the present invention. [Figure 19] FIG. 2 is an end view of a battery pack according to an aspect of the present invention. [Figure 20] FIG. 2 is a side view of a battery pack according to an aspect of the present invention. [Figure 21] 1 is a cross-sectional view of a battery pack according to an embodiment of the present invention. [Figure 22] FIG. 2 is a cross-sectional detailed view of a battery pack according to an embodiment of the present invention. [Figure 23] 1 is an exploded perspective view of a battery module according to an aspect of the present invention; [Figure 24] 1 is a perspective view of a battery pack according to an aspect of the present invention. [Diagram 25] FIG. 2 is a perspective view of a cell array member and a number of cells. [Figure 26] 1 is a perspective cutaway view of a battery module according to an embodiment of the present invention; [Figure 27] FIG. [Figure 28] FIG. [Figure 29] FIG. 2 is a perspective view of a cell array member and two bus bars according to an embodiment of the present invention. [Diagram 30]FIG. 2 is a perspective detail view of a cell array member and two bus bars according to an embodiment of the present invention. [Diagram 31] 1A-1D show top, side and end views of a cell array member and two bus bars in accordance with an embodiment of the present invention. [Diagram 32] FIG. 2 is a perspective view of a portion of a busbar in accordance with an aspect of the present invention. [Diagram 33] FIG. 2 is a side view of a portion of a busbar in accordance with an aspect of the present invention. [Diagram 34] FIG. 2 is an end view of a portion of a busbar in accordance with an aspect of the present invention. [Diagram 35] FIG. 2 is a side view of a battery module subassembly in accordance with an aspect of the present invention. [Diagram 36] FIG. 2 is a side detailed view of a battery module subassembly in accordance with an aspect of the present invention. [Figure 37] 1 is a perspective view of a thermal management arrangement according to an aspect of the present invention; [Figure 38] FIG. 2 is a top view of a thermal management arrangement according to an aspect of the present invention. [Figure 39] FIG. 2 is a perspective view of a duct and a number of cells. [Diagram 40] FIG. 2 is a top view of a duct and multiple cells. [Diagram 41] FIG. 1 is a top view of a duct, potting material, and multiple cells. [Diagram 42] FIG. 2 is a perspective view of a duct and a flexible carrier. [Diagram 43] 1 is a schematic diagram of a battery management system. [Diagram 44] 1 is a perspective view of a duct assembly according to an aspect of the present invention; [Diagram 45] 1A-1D show top, side and end views of a duct assembly in accordance with an aspect of the present invention; [Diagram 46] 1 is an exploded perspective view of a portion of a duct assembly in accordance with an aspect of the present invention; [Figure 47] 1 is a perspective view of a portion of a duct assembly in accordance with an aspect of the present invention; [Figure 48] FIG. [Figure 49] FIG. [Figure 50] FIG. [Figure 51] FIG. [Figure 52] 1 is an exploded perspective view of a fluid delivery arrangement according to an aspect of the present invention; [Diagram 53] 1 is a perspective view of a fluid delivery arrangement according to an aspect of the present invention. [Figure 54] 1 is a perspective view of a fluid delivery arrangement according to an aspect of the present invention. [Figure 55] 1A-1D show front, top and rear views of a fluid delivery array according to an embodiment of the present invention. [Figure 56] 1 is an exploded perspective view of a fluid delivery arrangement according to an aspect of the present invention; [Figure 57] 1 is a perspective view of a fluid delivery arrangement according to an aspect of the present invention. [Figure 58] 1 is a perspective view of a fluid delivery arrangement according to an aspect of the present invention; [Figure 59] 1A-1D show front, top and rear views of a fluid delivery array according to an embodiment of the present invention. [Figure 60] FIG. 2 is a rear view of a fluid delivery arrangement according to an aspect of the present invention. [Figure 61] 1A-1C are side and detailed cross-sectional side views of a battery module subassembly in accordance with an aspect of the present invention; [Figure 62] 1 is a perspective view of a seal according to an aspect of the present invention; [Figure 63] 1 is a perspective view of a seal according to an aspect of the present invention; [Figure 64] 1 shows a side view, a cross-sectional view, and a top view of a seal according to an embodiment of the present invention. [Figure 65] 1 shows a side view, a cross-sectional view, and a top view of a seal according to an embodiment of the present invention. [Figure 66] 1 is a side view of a multi-port fluid connector according to an aspect of the present invention; [Figure 67] 1 is a bottom view of a multi-port fluid connector according to an aspect of the present invention. [Figure 68] 1 is a cross-sectional view of a multi-port fluid connector according to an aspect of the present invention. [Figure 69]1 is a cross-sectional view of a multi-port fluid connector according to an aspect of the present invention. [Figure 70] 1 is a side view of an internal chamber of a multi-port fluid connector according to an aspect of the present invention. [Figure 71] 1 is a perspective view of an internal chamber of a multi-port fluid connector according to an aspect of the present invention. [Figure 72] 1 is an exploded perspective view of a multi-port fluid connector according to an embodiment of the present invention, a seal according to an embodiment of the present invention, and a retainer plate. [Figure 73] 1 is an exploded perspective view of a multi-port fluid connector according to an embodiment of the present invention, a seal according to an embodiment of the present invention, and a retainer plate. [Figure 74] 1 shows a perspective view of a multi-port fluid connector according to an embodiment of the present invention, a seal according to an embodiment of the present invention, and a retainer plate. [Figure 75] 1 is a top view of a multi-port fluid connector according to an embodiment of the present invention, a seal according to an embodiment of the present invention, and a retainer plate. [Figure 76] 1 is a side view of a multi-port fluid connector according to an embodiment of the present invention, a seal according to an embodiment of the present invention, and a retainer plate. [Figure 77] 1 is a bottom view of a multi-port fluid connector according to an embodiment of the present invention, a seal according to an embodiment of the present invention, and a retainer plate. [Figure 78] FIG. 2 is a rear view of a fluid delivery arrangement according to an aspect of the present invention. [Figure 79] FIG. 2 is a top view of a fluid delivery array according to an aspect of the present invention. [Figure 80] FIG. 2 is a front view of a fluid delivery arrangement according to an aspect of the present invention. [Figure 81] FIG. 81 is a front perspective view of the fluid delivery array of FIGS. 78-80, in accordance with an embodiment of the present invention. [Figure 82] FIG. 82 is a rear perspective view of the fluid delivery array of FIGS. 78-81, in accordance with an embodiment of the present invention. [Figure 83] FIG. 83 is a perspective exploded view of the fluid delivery array of FIGS. 78-82, in accordance with an embodiment of the present invention. [Figure 84] FIG. 84 is an enlarged perspective front view of the fluid delivery array of FIGS. 78-83 in accordance with an embodiment of the present invention. [Figure 85] 1 is a perspective view of a fluid delivery arrangement and ducts according to an aspect of the present invention; [Figure 86] 1 is a perspective view of a fluid delivery arrangement and ducts according to an aspect of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0817] 1 shows an exploded view of a battery pack 1 according to an embodiment of the present invention. The battery pack 1 includes a battery pack housing 2, a battery module subassembly 3, a plurality of mounting arrangements 4, a battery pack management system 5 for monitoring and / or controlling the operation of the battery pack 1, a battery pack fluid connection arrangement 6 for connecting the battery pack to a source of thermal management fluid, and an electrical connection arrangement 7 for electrically connecting the battery pack 1 to an external load.

[0818] The battery pack 1 can be placed within a volume within a device, such as a mobile device or industrial device. For example, the battery pack 1 can be placed within a volume within a road vehicle, such as a car, truck, lorry, road sweeper, or power shovel, or within an industrial device, such as a factory facility, crane, or other machine. When the battery pack 1 is used to convert an existing petroleum-based design to an electric design, the battery pack 1 can fit within a volume that was originally designed to be housed in, for example, a diesel engine.

[0819] The battery pack housing 2 includes a lower case member 21, a cover member 22, and an end closure box 23. The cover member 22 covers an opening 24 in the lower case member 21. The lower case member 21 defines a cavity 25 in which the battery module subassembly 3 can be placed. As shown in Figures 2 and 3, the battery pack housing 2 includes two side walls 26a, 26b, two end walls 27a, 27b, a bottom wall 28a, and a top wall 28b. The end closure box 23, which houses the battery pack management system 5, is attached to the end wall 27a of the battery pack 1. Figures 4 and 5 show top and end views of the battery pack 1, respectively.

[0820] The end enclosure 23 housing the battery pack management system 5 is shown in detail in Figs. 6-9. The end enclosure 23 comprises a housing member 23a and a lid member 23b. An indicator light 74 is visible through an opening in the lid member 23b. The indicator light 74 is adapted to display a coded signal, e.g., a flashing and / or colored light signal, indicative of the operating status of the battery 1. The end enclosure 23 further comprises an electrical adapter 73, a communication port 75, and internal electrical connectors 76, 77. The electrical adapter 73 provides electrical terminals for the battery 1. The communication port 75 allows for example an external computer to be connected to the battery 1, e.g., for monitoring and / or diagnostic purposes. The internal electrical connections 76, 77 are adapted to connect the end enclosure 23, and in particular the circuitry held within the end enclosure 23, to the terminals of the battery module subassembly 3 / battery module 10 via one or more bus bars passing through the battery pack housing 2.

[0821] The battery pack 1 includes a manual disconnect arrangement 8. The manual disconnect arrangement 8 is a manual service disconnect. The manual disconnect arrangement 8 includes a switch 81. The switch 81 is operatively connected to the battery modules within the battery pack 1. The manual disconnect arrangement 8 is configured to electrically disconnect two groups of battery modules within the battery pack 1, thereby disabling the terminals 71, 72 of the battery pack 1. When the switch 81 is open, the first and second groups of battery modules 10 are disconnected from each other such that no current flows between the first and second groups. As will be appreciated, the location within the battery module subassembly 3 at which the disconnect 8 operates can be varied such that an alternative number of battery modules 10 are included within each group.

[0822] 10, the battery pack 1 includes a battery pack electrical connection arrangement 7. The battery pack electrical connection arrangement 7 includes a positive battery pack terminal 71 and a negative battery pack terminal 72. In this embodiment, the positive battery pack terminal 71 and the negative battery pack terminal 72 are provided by an electrical adapter 73 that passes through a wall of the end enclosure 23. In use, the battery pack electrical connection arrangement 7 is adapted to allow the battery pack 1 to be electrically connected to an external load 1100, such as a motor or other electrical component of a vehicle or piece of industrial equipment.

[0823] The battery pack 1 comprises a battery pack fluid connection arrangement 6. The battery pack fluid connection arrangement 6 comprises a fluid inlet arrangement 61 and a fluid outlet arrangement 62. The fluid inlet arrangement 61 provides a fluid inlet, i.e. a path for fluid to enter the battery pack 1. Fluid can enter the battery pack 1 via an inlet adapter 63 (FIG. 1) which passes through an opening 29a in the end wall 27a of the battery pack housing 2 and is connectable to an inlet conduit 65 of the battery module subassembly 3. The fluid outlet arrangement 62 provides a fluid outlet, i.e. a path for fluid to exit the battery pack 1. The fluid outlet arrangement 62 comprises an outlet adapter 64 which passes through an opening 29a in the end wall 27a of the battery pack housing 2 and is connectable to an outlet conduit 66 of the battery module subassembly 3.

[0824] Fluid inlet array 61 and fluid outlet array 62 are in fluid communication with one another through battery module subassembly 3. As will be appreciated, fluid inlet array 61 and fluid outlet array 62 are interchangeable in that fluid may pass through these arrays, and through battery module subassembly 3 and / or battery module 10, in either direction as desired.

[0825] In use, the battery pack fluid connection arrangement 6 is adapted to allow the battery pack 1 to be operatively connected to a thermal management system 1000 that provides a source of thermal management fluid, preferably water and / or a water-glycol mixture. The thermal management system 1000 shown in FIG. 10 comprises a reservoir 1001 for receiving a coolant fluid, a heat exchanger 1002, and a pump 1003 connected to the battery pack 1 in a coolant loop 1004. The reservoir 1001 provides a hydrostatic pressure to the coolant fluid 1006 in the coolant loop 1004, and the pump 1003 is configured to pump the coolant 1006 obtained from the reservoir 1001 into the coolant loop 1004 to pressurize the coolant loop 1004. A pressure sensor 1005 is used to monitor the pressure of the coolant 1006 to maintain a target operating pressure in the coolant loop 1004.

[0826] 11 shows an exploded view of the battery module subassembly 3. The battery module subassembly 3 comprises a plurality of identical battery modules 10, an inlet side multi-port fluid connector 700a and an outlet side multi-port fluid connector 700b, and a support array 30.

[0827] In this example, the battery module subassembly 3 comprises six identical battery modules 10, although it will be appreciated that the number and mutual orientation of the battery modules 10 may be varied according to particular design requirements. The battery modules 10 are fluidly and electrically interconnected with each other to provide the desired electrical and thermal management characteristics required for a particular application. The battery modules 10 are also mechanically coupled to each other via the support arrangement 30.

[0828] Electrical connections are provided between the stacked battery modules 10 in the battery module subassembly 3 such that electrical current is operable to flow through the battery module subassembly 3. In this example, the battery modules 10 are connected in series and discharged in series during use. However, it will be appreciated that in alternative embodiments, one or more parallel electrical connections may be used as desired. Bus bars (not shown) are used to electrically interconnect the battery modules 10 and connect the battery module subassembly 3 to the battery pack terminals 71, 72.

[0829] Fluid connections are provided between the battery modules 10 in the battery module subassembly 3 such that thermal management fluid is operable to flow through the battery module subassembly 3 via the inlet side multiport fluid connector 700a, the battery modules 10, and the outlet side multiport fluid connector 700b. In this example, the fluid connections between the battery modules 10 are parallel fluid connections, i.e., fluid is operable to flow in parallel through each of the battery modules 10. However, it will be appreciated that in alternative embodiments, some or all of the fluid connections may be series fluid connections, i.e., fluid may flow in series through two or more battery modules 10.

[0830] The inlet side multiport fluid connector 700a is the primary fluid inlet for allowing thermal management fluid to enter the battery module subassembly 3. The outlet side multiport fluid connector 700b is the primary fluid outlet for allowing thermal management fluid to exit the battery module subassembly 3. The inlet side multiport fluid connector 700a is connected to and in fluid communication with the inlet side fluid delivery arrangement 200a of the battery module 10 located at the "top" of the stack of modules 10. The outlet side multiport fluid connector 700b is connected to and in fluid communication with the outlet side fluid delivery arrangement 200b of the battery module 10 located at the "top" of the stack of modules 10.

[0831] As shown in Figure 12, the battery modules 10 in a battery module subassembly 3 are stacked such that the thermal management arrays 140 of adjacent battery modules 10 are interconnected. Multi-port fluid connectors 700a, 700b are connected to the fluid distribution arrays 200a, 200b of the "top" battery module 10 at the "top" of the stack of battery modules 10. A sealed blanking plate is provided over the open end of the fluid distribution array (e.g., 200c in Figure 12) of the "bottom" battery module 10 on the opposite side of the stack. The blanking plate prevents thermal management fluid from leaking out of the fluid distribution array of the bottom battery module 10 in the stack during use.

[0832] The battery modules 10 in the battery module subassembly 3 and the inlet side multiport fluid connector 700a and the outlet side multiport fluid connector 700b are mechanically connected and held together by the support arrangement 30. The support arrangement 30 includes two end support members 31 located at the peripheral edges of the battery module subassembly 3. The battery module support arrangement 30 also includes four elongated corner support members 32. Each corner support member 32 is an L-shaped joint that can accommodate a corner of a plurality of battery modules 10 and a corner of each corresponding end support member 31. Each corner support member 32 is an elongated member that spans the distance between the end support members 31. Each elongated corner support member 32 is attached to the battery modules 10 and the end support members 31 via fasteners such as screws and / or bolts. The battery module support arrangement 30 also includes retention plates 33a, 33b for mounting and securing the inlet side multiport fluid connector 700a and the outlet side multiport fluid connector 700b to the battery module subassembly 3.

[0833] 15 and 16 show an alternative support arrangement 1030 for a battery module subassembly 3. The alternative support arrangement 1030 includes two end support members 1031 located at the peripheral edges of the battery module subassembly 3. The battery module support arrangement 1030 also includes two elongated end support members 1032. Each end support member 1032 is a C-shaped joint that can accommodate the ends of multiple battery modules 10. Each end support member 1032 includes a number of openings 1033 through which the seals 60 between the battery modules 10 can be seen / reachable. Each end support member 1032 is an elongated member that spans the distance between the end support members 1031. Each elongated end support member 1032 is attached to the battery modules 10 and the end support members 1031 via fasteners such as screws and / or bolts.

[0834] As shown in FIG. 16, the alternative support arrangement 1030 also includes retention plates 33a, 33b for mounting and securing the inlet side multi-port fluid connector 700a and the outlet side fluid connector 700b to the battery module subassembly 3. As shown in FIG.

[0835] The battery pack 1 includes a number of mounting arrangements 4 that allow the battery pack 1 to be mounted to another structure, such as a vehicle chassis or other support structure. In this embodiment, the battery pack 1 includes eight mounting arrangements 4 that provide the battery pack housing 2 with eight positions at which the battery pack 1 can be securely mounted to, for example, a vehicle, chassis, or other structure. A fastening arrangement, such as a screw or bolt, can be used to attach, for example, the chassis to each mounting arrangement 4.

[0836] 2 and 3, the present invention provides a battery pack 1 in which a mounting arrangement 4 is mechanically connected to a battery module subassembly 3, specifically to an end support member 31 of the battery module subassembly 3, and accessible through the battery pack housing 2. The mounting arrangement 4 provides a mechanical connection point on the exterior of the battery pack 1. In use, when the battery pack 1 is mounted to a support structure, such as a chassis, via the mounting arrangement 4, the mounting arrangement 4 allows the weight of the battery module subassembly 3 to be transferred directly to the support structure, rather than being transferred to the support structure via, for example, the battery pack housing 2 and one or more external brackets. As a result, the battery pack housing 2 can be lighter since it does not need to support the subassembly 3.

[0837] In prior art systems, the battery module subassemblies are attached to the interior of the housing via welding. The battery pack housing includes one or more mounting brackets attached to the exterior of the battery pack housing. The mounting brackets can be used to mount the battery pack to a chassis or other support. As will be appreciated, the heaviest portion of the battery pack is the battery module subassembly. Thus, in such prior art systems, the battery pack housing needs to be sturdy enough to support the battery module subassemblies, and it needs to be sturdy enough to support the battery pack itself on the chassis or support structure. The strength required for the housing necessarily adds complexity to the structure and weight to the housing and pack. The present invention avoids these problems.

[0838] 2, the mounting means 4 is accessible through an opening 22a in the cover member 22 of the battery pack housing 2. The mounting arrangement 4 accessible through the cover member 22 is an upper mounting arrangement 41. The upper mounting arrangement 41 comprises a mounting member 45 that is directly accessible through the battery pack housing 2.

[0839] 3, another mounting arrangement 4 is located on the bottom wall 28a of the battery pack housing 2. The mounting arrangement 4 located on the bottom wall 28a of the battery pack housing 2 is a lower mounting arrangement 42. The lower mounting arrangement 42 includes a mounting member 45 covered by a leg covering member 44.

[0840] Returning to Figure 17, each mounting arrangement 4 comprises a mounting member 45. The mounting member 45 is a mounting block having a body 45a. The mounting member 45 comprises a first interface portion 46 that is adjacent the battery pack housing 2 in use. The mounting member 45 comprises a second interface portion 47 that is adjacent the battery module subassembly 3 in use. The second interface portion 47 is similar to the first interface portion 46.

[0841] The first interface portion 46 includes an annular recess 48 for receiving a seal, such as an O-ring. The seal can be used to seal the interface between the mounting member and an adjacent component, such as the cover 22 of the battery pack housing 2. The first interface portion 47 includes a receiving arrangement 49. The receiving arrangement 49 includes a tubular member having a threaded hole 49a. The receiving arrangement 49 is adapted to receive fastening means, such as screws and / or bolts, that can be used to attach the mounting member 45 to an external support or chassis, or the like.

[0842] The first interface portion 46 includes a further receiving arrangement 49b, in particular two further receiving arrangements 49b. The further receiving arrangements 49b include threaded holes. The further receiving arrangements 49b are adapted to receive fastening means, such as screws and / or bolts, that can be used to attach the mounting member 45 to the battery pack housing 2.

[0843] In use, each mounting member 45 is attached to the battery module subassembly 3, in particular to the end support member 31 of the battery module subassembly 3, and to the battery pack housing 2 via the other receiving arrangement 49b. In use, the mounting means 45 is a spacer that defines a gap between the battery module subassembly 3 and the battery pack housing 2. In use, the mounting member 45 is adapted to transfer the weight of the battery module subassembly 3 to the outside of the battery pack housing 2, for example to a support structure or a chassis. The mounting member 45 is directly accessible on the outside of the battery pack housing 2, for example via the opening 22a. The mounting member 45 can be covered with a covering member, such as the leg 44.

[0844] 18-23 disclose a battery pack 901 according to an embodiment of the present invention. Battery pack 901 is similar to battery pack 1, with like numbers indicating like features. Battery pack 901 comprises a battery pack housing 902, a battery module subassembly 903 comprising a plurality of battery modules, a plurality of mounting arrangements 904, a battery pack management system 905 for monitoring and / or controlling the operation of the battery pack 901, a battery pack fluid connection arrangement 906 for connecting the battery pack to a source of thermal management fluid, and an electrical connection arrangement 907 for electrically connecting the battery pack 901 to an external load. Key distinguishing features of battery pack 901 are the size of the battery module subassembly and housing 902, and the mounting arrangement 904.

[0845] The battery pack housing 902 includes a lower container member 921, a cover member 922, and an end closure box 923. The cover member 922 covers an opening in the lower container member 921. The lower container member 921 defines a cavity in which the battery module subassembly 903 can be placed. The battery pack housing 902 includes two side walls 926a, 926b, two end walls 927a, 927b, a bottom wall 928a, and a top wall 928b. The end closure box 923, which houses the battery pack management system 905, is attached to the end wall 927a of the battery pack 901. Figures 20 and 21 show side and end views of the battery pack 901, respectively.

[0846] 22 is a cross-sectional view through the battery pack 901 showing the mounting arrangements 904 and the connections between the battery module subassemblies 903 and the battery pack housing 902. The battery module subassemblies 903 are attached to the battery pack housing 902 inside the battery pack housing 902 via the mounting arrangements 904, in this example eight mounting arrangements 904. As shown, there is no direct contact between the battery module subassemblies 903 and the battery pack housing 902. The battery module subassemblies 3 are mounted within the battery pack housing 2 of the battery pack 1 in a similar manner.

[0847] 22, the mounting arrangement 904 passes through openings 922a, 928a in the cover member 922 and bottom wall 928 of the battery pack housing 902. The mounting arrangement 904 is at least partially accessible on the exterior of the battery pack housing 902. The mounting arrangement 904 includes a mounting member 945 similar to mounting member 45 described above.

[0848] Each mounting arrangement 904 comprises a mounting member 945 and a mounting cover 950. The mounting member 945 is a mounting block having a body 945a. The mounting member 945 comprises a first interface portion 946 that is adjacent the battery pack housing 902 during use. The mounting member 945 comprises a second interface portion 947 that is adjacent the battery module subassembly 903 during use. During use, the mounting member 945 is located inside the battery pack 901, while the mounting cover 950 is located on an outer surface of the battery pack 902. During use, the battery pack housing 902 is located between the mounting member 945 and the mounting cover 950.

[0849] The first interface portion 946 includes an annular recess 948 for receiving a seal, such as an O-ring. The seal can be used to seal the interface between the mounting member 945 and an adjacent component, such as the bottom wall 928 of the battery pack housing 902.

[0850] The first interface portion 946 comprises a receiving arrangement 949. The receiving arrangement 949 comprises a tubular member having a threaded hole 949a. The receiving arrangement 949 is adapted to receive fastening means, such as screws and / or bolts, that can be used to attach the mounting member 945 to an external support, chassis, or the like.

[0851] In use, each mounting member 945 is attached to a battery module subassembly 903, specifically to an end support member 931 of the battery module subassembly 903, and to the battery pack housing 902. As shown in FIG. 22 , in use, the receiving arrangement 949 of the mounting member 945 passes through an opening in the battery pack housing 902 and also passes through an opening in the mounting cover 950.

[0852] The mounting member 945 is a spacer that defines a gap G between the battery module subassembly 903 and the battery pack housing 902. The mounting member 945 is adapted to transfer the weight of the battery module subassembly 903 to an exterior of the battery pack housing 902, for example to a support structure or chassis bolted or screwed to the receiving arrangement 949. The mounting member 945 is directly accessible on the exterior of the battery pack housing 902. The mounting member 945 can be covered with a covering member, such as a leg.

[0853] FIG. 23 shows an exploded view of a battery module 10 for use in a battery module subassembly 3, 903 and a battery pack 1, 901. The battery module 10 comprises a battery module housing 100, one or more cells 120, and a thermal management arrangement 140 for thermally managing the one or more cells 120. The thermal management arrangement 140 comprises at least one thermal management duct 141, and two fluid delivery arrangements 200. Each battery module 10 further comprises a battery module housing 100, and the cells 120 are located inside the battery module housing 100. The battery module 10 further comprises a battery module electrical connection arrangement 160 for providing electrical connections between the battery module 10 and components such as other battery modules 10, bus bars, and / or an external load 1100. Each battery module 10 can be disposed inside the battery pack 1 and can also be connected to one or more other identical battery modules 10 located inside the battery pack 1.

[0854] The battery module housing 100 comprises an upper housing member 101 and a lower housing member 102. The lower housing member 102 comprises a substantially planar base 103 and two side walls 104a, 104b. Each side wall 104a, 104b extends in a direction substantially perpendicular to the respective base 103. The side walls 104 include a number of openings 106 that can provide electrical connection to the battery module terminals 171, 172. A fluid delivery arrangement 200 provides the end walls of the housing 100.

[0855] As shown in Figure 24, the battery module 10 comprises a top surface 110, a bottom surface 111, two side surfaces 112, and two end surfaces 113 comprising an end cover 114. The top surface 111 is formed by the base 103 of the upper housing member 101. The bottom surface 112 is formed by the base 103 of the lower housing member 102. The side surfaces 112 are formed by the side walls 104a, 104b of the lower housing member and the busbar 400 of the battery module 10. The end surfaces 113 are formed by the fluid delivery arrangement 200. At each corner of the battery module 10 is a structural support component 430 of the busbar 400.

[0856] A cell array member 180 is used within the battery module 10 to support and arrange the cells 120. FIG. 25 discloses an example of a cell array member 180 that includes a substantially planar body 181 and a number of receiving structures 182 formed within the body 181. Each receiving structure 182 is adapted to receive and arrange an end of a cell 120 within the battery module 10. The receiving structures 182 are arranged in a close-packed hexagonal or honeycomb pattern. The receiving structures 182 are adapted to hold the cells 120 within the battery module 10 in a close-packed hexagonal or honeycomb pattern. Each receiving structure 182 includes a through hole portion 183 that provides a path through which wire bonds can pass to electrically connect a bus bar on one side of the member 180 to a cell 120 on the other side of the member 180.

[0857] In use, each cell array member 180 is located between a corresponding end 122 of the plurality of cells 120 and at least a portion of the bus bar. Each cell array member 180 is electrically insulating. Each cell 120 is held within the battery module 10 between two cell array members 180. An example of a plurality of cells 120 associated with a cell array member 180 is shown in FIG. 25. Each battery module 10 includes an array of cylindrical cells 120, which may be 2170 cells and / or 18650 cells. Each battery module 10 includes a predetermined number of cells 120 arranged in a regular array. The cells 120 are provided in a close-packed hexagonal array. The minimum separation between cells is 2 mm. Each battery module 10 is a multiple of 6 cells long. Each battery module 10 is 24 cells long or 48 cells long.

[0858] Each battery module 10 includes a battery module electrical connection arrangement 160 for providing electrical connections between the battery module 10 and components such as other battery modules 10, bus bars, interconnects, and / or external loads. The battery module electrical connection arrangement includes a collection of battery module bus bars 170 that are used to electrically interconnect the cells 120, and battery module terminals 171, 172. Each battery module bus bar 170 includes a metal sheet, such as an aluminum or steel sheet, formed to a predetermined shape. The battery module bus bars 170 are themselves electrically connected via wire bonds and / or the cells 120.

[0859] FIG. 26 shows the battery module 10 with the housing members removed and one of the non-planar busbars removed. The battery module 10 includes a plurality of interconnect busbars 300 and two non-planar busbars 400. Each cell 120 in the battery module 10 is electrically connected to the electronics module busbar 170 via a wire bond, which is a fusible and / or frangible electrical connection. The wire bonds to the busbar 170 / cells are made using ultrasonic bonding, laser welding, ultrasonic welding, or resistance welding. In a preferred embodiment, each wire bond is an aluminum or steel wire bond and each battery module busbar 170 is made from aluminum or steel.

[0860] 27 and 28 show an interconnect busbar 300 for use in the battery module 10. Each interconnect busbar 300 is generally planar and cut or stamped from sheet metal. The interconnect busbar 300 comprises a body 301 having an edge portion 302. Each edge portion 302 comprises one or more recesses 303. When in situ within the battery module, the recesses 303 provide a gap through which the potting material 130 can be inserted into the battery module 10. The body 301 comprises a planar cell connection portion 310 adapted to be connectable to the terminals / casings of one or more cells 120 via wire bonds. The cell connection portion 310 comprises a plurality of cell connection openings 311. The cell connection openings 311 are generally rectangular, although any suitable shape may be used. The cell connection openings 311 are adapted to allow the wire bonds to pass completely therethrough. The arrangement of the cell connection openings 311 mirrors the arrangement of the cells 120 within the battery module 10. The interconnect busbar 300 also includes fastening openings 312 that allow the busbar 300 to be fixed in place within the battery pack 10 and / or to a non-planar busbar 300. The fastening openings 312 are located within the cell connection portions 310. A fastening arrangement, such as a screw, can pass through the fastening openings 312.

[0861] 29-31 provide diagrams of two bus bars 400 and a number of cell array members 180 in accordance with an embodiment of the present invention. The bus bars 400 may be used within the battery module 10 and / or battery pack 1 to provide electrical connection to the cells 120 maintained within the cell array members 180. The non-planar bus bars 400 are used to form the elongated positive terminal 171 and the elongated negative terminal 172 of the battery module 10. The bus bars 400, like other bus bars used in the battery pack 1, are at least partially formed from a conductive material such as aluminum or steel.

[0862] Each non-planar busbar 400 comprises an electrical connection portion 401 and two structural support components 430. The electrical connection portion 401 is adapted to electrically interconnect one or more cells with one or more other components, such as other busbars, terminals, interconnects, and / or an external load. The structural support components 430 are adapted to maintain the electrical connection portion 401 in place within the battery module 10 and to provide structural support to the battery module 10, allowing multiple battery modules 10 to be stacked in an aligned manner.

[0863] Each structural support component 430 can be positioned at a peripheral edge of the electrical connection portion 401. FIG. 30 shows the structural support component 430 in detail. The structural support component 430 comprises a body portion 431. The body portion 431 is preferably made from a non-conductive material such as plastic, but may alternatively be made from a conductive material such as aluminum or other metal. The structural support component 430 is rigidly attached to the electrical connection portion 401 and may be overmolded onto the electrical connection portion 401 via, for example, injection overmolding.

[0864] Structural support component 430 comprises end portion 432, top portion 433, bottom portion 434, and side portion 435. The outer surfaces of top portion 433 and bottom portion 434 are substantially parallel. The outer surfaces of end portion 432 and side portion 435 are substantially perpendicular to each other and to the outer surfaces of top portion 433 and bottom portion 434. By "outer surface" it is meant the surface that is outermost during use.

[0865] The structural support component 430 is attached to the electrical connection portion 401 via fastening members 428 that pass through openings at the peripheral ends of the external connection portion 420. The fastening members are screws and / or bolts that are maintained in threaded openings in the side portions 435. The side portions 435 of the structural support component 430 are attached to the external connection portion 420 of the bus bar 400. The peripheral ends of the external connection portion 420 of the bus bar 400 are received within the structural support component 430.

[0866] The structural support component 430 comprises a first receiving array 436 and a second receiving array 437 for receiving fastening means such as screws and / or bolts. The first receiving array 436 and the second receiving array 437 comprise threaded openings. The first receiving array 436 is located in the end portion 432 and the second receiving array 437 is located in the side portion 435. The receiving arrays 436, 437 are adapted to allow attachment of the busbar 400 to the elongated corner support members 32 of the support arrangement 3 via fastening means such as screws and / or bolts. An opening 429 is located in the external connection portion 420 corresponding to the location of the first receiving array 437.

[0867] 31-33 provide views of an electrical connection portion 401 of a non-planar busbar 400. The electrical connection portion 401 is generally non-planar and is cut from sheet metal, compression formed, and bent into a desired final shape. The electrical connection portion 401 comprises a cell connection portion 410 and an external connection portion 420. The cell connection portion 410 is adapted to connect to terminals of one or more cells and / or to one or more busbars 300. The external connection portion 420 is adapted to provide electrical connection to other components, such as other busbars, terminals, interconnects, and / or external loads, and to provide an electrical terminal for the battery module 10.

[0868] The generally planar cell connection portion 410 is adapted to be connectable to the terminals / casings of one or more cells 120 via wire bonds. The cell connection portion 410 includes a number of cell connection openings 411. The cell connection openings 411 are generally rectangular, although any suitable shape may be used. The cell connection openings 411 are adapted to allow a wire bond to pass completely therethrough. The cell connection portion 410 also includes fastening openings 412 that allow the bus bar 400 to be fixed in place within the battery pack 10 and / or to one or more interconnect bus bars 300. The fastening openings may be located within the cell connection portion 410. A fastening arrangement, such as a screw, may pass through the fastening openings.

[0869] The external connection portion 420 is a terminal portion adapted to connect to an external load. The external connection portion 420 includes a generally planar main plane portion 420a and a plurality of protrusions 421. The protrusions 421 are adapted to provide electrical connection to other components, such as other bus bars, terminals, interconnects, or external loads. The protrusions 421 are generally planar and protrude slightly above the main plane 420a of the external connection portion 420. Each protrusion 421 is formed to be reachable through the housing wall of the battery module 10, i.e., through an opening 106 in the wall of the battery module 10.

[0870] Each protrusion 421 is integrally formed in the external connection portion 420 and formed via compression molding. Each protrusion 421 comprises a planar portion 422 surrounded by a curved peripheral portion 423. Each protrusion 421 further comprises two retention arrangements 424 in the form of two screw holes. Each retention arrangement 424 is adapted to retain a fastening member, such as a bolt, allowing for example to securely attach another bus bar to the bus bar 400.

[0871] The cell connection portions 410 are disposed at an angle relative to the external connection portions 420. In this embodiment, the cell connection portions 410 are substantially perpendicular to the external connection portions 420. The angle between these portions allows the busbar 400 to receive the edges of the array of cells, and in particular the corners of the cell casings. In use, the busbar 400 sits at the edge of the array of cells of the battery module 10.

[0872] In use, the busbars 400 are located inside the battery module 10. An array of cells 120 inside the battery module 10 is located within the volume between the busbars 400. The internal corners of each busbar 400 between the cell connection portions and the primary electrical connection portions 420 are angled to accommodate the corners of a cell or array of cells. Each electrical connection portion 420 is reachable from outside the battery module 10 so that electrical connections, for example to an external load, can be made to the busbars 400 and the cells 120.

[0873] A battery module 10 using a busbar 400 includes a housing and at least an external connection portion 420 of the busbar, with an outer surface of a structural support component 430 accessible from outside the battery module 10. In particular, a protrusion 421 of the external connection portion 420 passes through an opening in a side wall of the battery module housing, and an outer surface of the structural support component 430 forms an exterior corner of the battery module 10. The non-planar shape of the busbar 400 provides additional structural integrity to the battery module 10. Each battery module 10 includes two non-planar busbars 400 located on opposite sides of the battery module housing 100.

[0874] FIG 35 shows multiple battery modules 10 in a stacked arrangement, together forming a battery module subassembly 3. As shown in detail in FIG 36, the structural support components 430 of adjacent battery modules 10 are located in close proximity to one another. Together, the structural support components 430 at each corner of the battery modules 10 within the battery module subassembly 3 provide additional structural integrity to the battery module subassembly 3.

[0875] In an optional embodiment, a structural support component may be provided in the center of the busbar 400, i.e., midway between the structural support components 430. In such an embodiment, adjacent battery modules 10 within a battery module subassembly can be mechanically connected to one another at or near the center of the assembly, i.e., at a location midway between the structural support components 430.

[0876] 37 and 38 show examples of thermal management arrangements 140 for battery modules 10 in a battery module subassembly 3. Each battery module 10 includes a thermal management arrangement 140 adapted to thermally manage (i.e., heat and / or cool) the cells 120 in the battery module 10. The thermal management arrangement 140 includes at least one thermal management duct 141 and at least one fluid delivery arrangement 200. In particular, the thermal management arrangement 140 includes eight duct assemblies 500 (each including a thermal management duct 141), an inlet side fluid delivery arrangement 200a, and an outlet side fluid delivery arrangement 200b. The inlet side fluid delivery arrangement 200a is in fluid communication with the outlet side fluid delivery arrangement 200b via the duct assembly 500. Each fluid delivery arrangement 200 comprises a first fluid connection conduit 210 and a second fluid connection conduit 220 for allowing thermal management fluid to enter and / or exit the thermal management array 140. Each fluid delivery arrangement 200 is connected to and in fluid communication with a duct 141 via a nozzle 501. Each thermal management duct 141 comprises two open ends 142 for allowing thermal management fluid to enter and / or exit the duct 141. When used in the battery module 10, the cells 120 are located in the spaces between adjacent ducts 141 and between the fluid delivery arrays 200a, 200b.

[0877] In this embodiment, the thermal management arrangement 140 comprises a plurality of substantially parallel ducts 141. In a preferred embodiment, each duct 141 is a flexible duct formed from an expandable plastic material, such as polyethylene (PE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), or high density polyethylene (HDPE). The use of an expandable plastic material is advantageous as the material is inherently electrically insulating, lightweight, and does not corrode or chemically interact with coolants, such as glycol water mixtures.

[0878] In a preferred embodiment, each duct 141 comprises one or more thermally conductive additives. Thermally conductive additives offer the advantage of being able to improve the thermal conductivity of the duct material. Ideally, each flexible duct 141 comprises a matrix (e.g. a flexible polymeric material such as LDPE) with thermally conductive additives (e.g. particles of carbon-based and / or ceramic-based materials such as graphite, multi-walled carbon nanotubes and / or boron nitride) dispersed throughout the matrix. The particles have a diameter between 1 nm and 10 nm, most preferably <5 μm. In a most preferred embodiment, the duct material comprises up to 30% additive. The filler is a mixture of graphite and boron nitride particles according to any suitable ratio, for example 1:1. When incorporated into the PE matrix, this provides a duct material with a thermal conductivity of >≈0.8 W / m·K, optionally around 1 W / m·K.

[0879] The wall thickness of each flexible duct 141 is between 50 μm and 150 μm. This thickness allows good heat transfer characteristics between the or each duct and the cells. In a preferred embodiment, each duct 141 is a single-lumen duct, but as will be appreciated, multi-lumen ducts may be used, for example in larger battery packs where single-lumen ducts may not promote even temperature distribution. In optional embodiments, the ducts 141 may be rigid, for example made from aluminum or copper. In the example provided, each duct 141 is a substantially straight manifold duct configured to carry a coolant fluid, such as a water-glycol mixture, but may follow different paths within the array of cells 120, for example serpentine. The or each battery module 10 may include any number of ducts 141, for example one duct 141.

[0880] Each duct 141 in the battery module 10 may directly contact a side of an adjacent cell 120 through an interface area or interface material, such as a casing sheath surrounding the cell 120, or may indirectly contact one or more sides of one or more cells 120. Alternatively or additionally, each duct 141 may indirectly contact one or more cells 120 through a thermally conductive filler, such as a conductive paste or additive.

[0881] As illustrated in FIGS. 39-41, each flexible duct 141 in the battery module 10 is positioned adjacent to and between the cells 120 in the battery module 10. FIG. 39 shows details of two rows of cells 120 with ducts 141 between them. During manufacture of the battery module 10, each duct 141 is located within the array of cells in a substantially unexpanded state (FIG. 40). Once properly aligned, each duct 141 is expanded using a fluid that expands the duct into contact with the sidewalls of the cells 120 (FIG. 41). When in an expanded state, each duct 141 is in intimate physical contact with one or more cells 120. Expanding each flexible duct 141 so that its shape conforms to the shape of the cell 120 improves duct-cell thermal contact so that the fluid may more efficiently transfer thermal energy between the fluid and the cell 120.

[0882] Once the ducts 141 in the battery module 10 are in their expanded state and under sufficient pressure, the potting material 130 is injected into the battery module 10. The potting material 130 is poured into the battery module 10 in a liquid state and is allowed to set, harden, or become rigid. In the set, hardened, or hardened state, the potting material 130 becomes substantially rigid to secure the cells 120 and the ducts 141 in place inside the battery module 10. This is advantageous because the potting material 130 reduces the effects of vibration on the components inside the battery module 10. Once set, hardened, and / or hardened, the potting material 130 adhesively adheres to each duct 141, providing complete external support and preventing excessive expansion and / or rupture of each duct 141. Moreover, the potting material 130 keeps each duct 141 in an open configuration so that thermal management fluid can easily flow through each duct 141.

[0883] In a preferred embodiment, the potting means 130 is an insulating potting means such as an expandable / polyurethane foam. Polyurethane foam is lighter than other potting means, thus providing the battery module 10 with a lighter overall weight. The presence of the insulating potting material 130 within the battery module 10 reduces the effect of external temperature fluctuations on the battery module 10 and helps ensure that the duct 141 is the primary controller of thermal energy within the battery module 10 and prevents high energy thermal events from propagating through the battery module 10. When the potting material 130 is in an expanded state, it substantially fills gaps within the battery module 10. In an optional embodiment, the potting material 130 comprises a thermosetting plastic, a silicone rubber gel, or an epoxy resin.

[0884] In a preferred embodiment, each battery module 10 includes one or more sensors 126. These sensors can be used to measure the temperature of one or more of the cells 120 in each battery module 10. The sensor 126, such as a temperature sensor, can be located on a flexible carrier 125, which is a flexible PCB, and the flexible carrier can be attached to a duct 141 as shown in FIG. 42. In use, the sensor 126 on the carrier 125 is located between the duct 141 and the cell 120 so that the sensor can measure, for example, the temperature of the cell. In an expanded state, the duct presses the temperature sensor against the cell to ensure good thermal contact between the duct and the cell. The carrier 125 includes conductive traces that allow the sensor 126 to be operably connected, for example, to a daughter board 51 of the battery module 10, so that the temperature of the one or more cells 120 can be communicated, for example, to the battery management computer 50 for analysis by the battery management computer 50. The communication connections between the sensor 126, the daughter board 51, and the battery management computer 50 are shown in FIG. 43.

[0885] FIG. 44 shows an example of a duct assembly 500. Each duct 141 in the battery module 10 forms a part of the duct assembly 500. The duct assembly 500 includes a duct 141 having two open ends 142, an inlet nozzle 501a, an inlet duct clamping assembly 510a, an outlet nozzle 501b, and an outlet duct clamping assembly 510b. Each duct clamping assembly 510a, 510b is used to clamp the open end 142 of the duct 141 to the corresponding nozzle 501a, 501b. Each duct clamping assembly 510a, 510b ensures that there is a fluid-tight connection between the duct 141 and the corresponding nozzle 501a, 501b. Each duct clamping assembly 510a, 510b is adapted to clamp the duct to another component, such as a nozzle. Each duct clamping assembly 510a, 510b prevents leakage from occurring at the corresponding nozzle-duct interface. Figure 45 shows top, side, and end views of a duct assembly 500 in accordance with an embodiment of the present invention.

[0886] Figure 46 is an exploded view of one end of a duct assembly 500, including one end of a duct 141, a nozzle 501, and a duct clamping assembly 510. The end of the duct assembly 500 shown in Figure 46 can be used with both ends of the duct assembly 500 shown in Figure 44. In a preferred embodiment, the inlet nozzle 501a / duct clamping assembly 510a and the outlet nozzle 501b / duct clamping assembly 510b are substantially identical.

[0887] The nozzle 501 comprises a nozzle body 502 and an opening 503 through the body 502. Fluid can pass through the nozzle body 502 via the opening 503. The body 502 comprises a flange portion 504 and a mounting portion (not shown). The mounting portion is located within the open end 142 of the duct 141. The duct 141 is heat welded to the mounting portion of the nozzle 501 at the open end 142 of the duct 141. The flange portion 504 comprises a protrusion 506. The flange portion 504, and more particularly the protrusion 506, provides a surface that can be attached to another component, for example the fluid delivery array 200. The nozzle 501 can be attached to the fluid delivery array, for example via plastic welding.

[0888] Duct clamping assembly 510 includes bearing member 520, first and second fixing members 530a, 530b, and biasing member 550. First and second fixing members 530a, 530b, and bearing member 520 are preferably made from an insulating plastic material, although it is envisioned that a metal such as aluminum may be used. Biasing member 550 is preferably formed from a resilient material such as steel wire.

[0889] In use, as shown in Figure 47, the duct clamping assembly 510 presses and compresses the open end 142 of the duct 141 and the nozzle 501. As previously noted, the duct 141 is joined to the attachment portion of the nozzle 501 at the open end 142 of the duct 141 via, for example, ultrasonic welding. The duct clamping assembly 510 strengthens the bond between the open end 142 of the duct 141 and the attachment portion of the nozzle 501. The duct clamping assembly 510 acts to prevent leakage from occurring at the interface between the duct 141 and the nozzle 501.

[0890] FIG. 48 is a perspective view of an example of a bearing member 520. The bearing member 520 comprises a first elongated portion 522 and a second elongated portion 523. A joining portion 521 joins the first elongated portion 522 to the second elongated portion 523. At the ends of the elongated portions 522, 523 opposite the joining portion, a gap 524 exists. The gap 524 allows the nozzle 141 and the mounting portion 505 to pass through the gap 524 and move to a position between the elongated portions 522, 523 such that the nozzle 141 and the mounting portion 505 can be received by the bearing member 520. The bearing member 520 is a U-shaped member adapted to bear against the duct 141 and the nozzle 501. In particular, the inner surface 524 of the bearing member 520 is adapted to bear against the duct 141 at the position where the duct is attached to the nozzle 501. The inner surface 524 of the bearing member 520 is generally smooth.

[0891] The bearing member 520 further comprises positioning elements 525 in the form of protrusions extending from the first elongated portion 522 and the second elongated portion 523. Two positioning elements 525a, 525b extend from the first elongated portion 522. Two positioning elements 525c, 525d extend from the second elongated portion 523. As will be described in more detail below, the positioning elements 525 are receivable within corresponding receiving portions 535 of the first and second fixing members 530a, 530b.

[0892] 49 shows a perspective view of a biasing member 550. The biasing member 550 comprises a body 551. The biasing member 550 comprises a first arm portion 552a and a second arm portion 552b, and a bridge portion 553. Preferably, the first arm portion 552a and the second arm portion 552b are substantially straight and parallel. The first arm portion 552a and the second arm portion 552b are respectively connected to the bridge portion 552 at corresponding ends. At the other corresponding end of each arm portion 552a, 552b is a corresponding retainable portion 554a, 554b. Each retainable portion 554a, 554b is a curved end portion.

[0893] The biasing member 550 is adapted to provide a force urging the first fixing member 530a and the second fixing member 530b towards each other and towards the bearing member 520, the mounting portion of the nozzle 501 and / or the open end of the duct 142.

[0894] In use, the biasing member 550 compresses the first and second fixing members 530a, 530b. The force provided by the biasing member is transferred to the joint between the duct 141 and the nozzle 501 by the first and second fixing members 530a, 530b and the bearing member 320. The duct clamping assembly 510 strengthens the joint between the duct 141 and the nozzle 501 and ensures that there is a leak-tight connection between the duct 141 and the nozzle 501 at the end 142 of the duct 141.

[0895] Figures 50 and 51 disclose front and rear perspective views of an example of a fixing member 530. Each of the first fixing member 530a and the second fixing member 530b shown in Figures 46 and 47 is identical to the example of the fixing member 530. The fixing member 530 comprises an elongated portion 531. The fixing member 530 comprises two curved end portions 532, 533 at either end of the elongated portion 531.

[0896] The fixing member 530 includes an inner surface 534. The inner surface 534 is adapted to engage with an outer surface of the bearing member 520. The inner surface 534 of the fixing member 530 includes a receiving portion 535. The receiving portion 535 is adapted to receive the positioning element 525 of the bearing member 520. The receiving portion 535 is adapted to receive and accommodate the positioning element 525 when the fixing portion 530 is pressed against one side of the bearing member 520. This allows the first fixing member 530 to be accurately positioned in a precise position relative to one side of the bearing member 520. The engagement of the positioning element 525 and the receiving portion 535 also prevents the first fixing member 530 from being displaced relative to the bearing member 520. As will be appreciated, the distance between the receiving portions 535a, 535b is equal to the distance between the positioning elements 525a, 525b and 525c, 525d.

[0897] The fixing member 530 further comprises an outer surface 536. The outer surface 536 of the fixing member 530 comprises a channel 537 adapted to accommodate at least a portion of the bearing member 550. In particular, the channel 537 is adapted to receive the arm 551 of the biasing member 550. The channel 537 is formed between a first wall 538a and a second wall 538b. The first wall 538a is continuous and extends along the fixing member 530 along the entire length of the elongated portion 531 and the curved portions 532a, 532b. The second wall 538b is discontinuous and comprises two discontinuities 539a, 539b. Either or both of the first wall 538a and the second wall 538b may be continuous or discontinuous.

[0898] The outer surface 536 of the fixing member 530 comprises a receiving arrangement 545. The receiving arrangement 545 is a recess. The receiving arrangement 545 is adapted to receive a portion of the biasing member 550, in particular one of the retainable portions 554a, 554b. The receiving arrangement 545 is a recess in the body of the fixing member 530. The receiving arrangement 545 is adapted to engage a portion of the biasing member 550, in particular one of the retainable portions 554a, 554b. This allows the biasing portion 550 to be accurately positioned in the channel of the fixing member 530 at a precise location. The engagement of the retainable portion 554 of the biasing member 550 with the receiving arrangement 545 (see FIG. 47) also prevents the biasing member 550 from being displaced relative to the fixing member 530 during use.

[0899] 52 discloses an exploded perspective view of a fluid delivery arrangement 200 according to an embodiment of the present invention. Each battery module 10 and its thermal management arrangement 140 comprises two fluid delivery arrangements 200. Each duct 141 / duct assembly 500 in the battery module 10 is in fluid communication with each fluid delivery arrangement 200 in the battery module 10. The fluid delivery arrangements 200 are adapted to deliver a thermal management fluid 1006 to the thermal management ducts 141 / duct assemblies 500 which may be located inside the battery module 10 and the battery pack 1.

[0900] The fluid delivery array 200 comprises a first connecting conduit 210 adapted to provide a path for fluid to enter and / or exit the fluid delivery array 200, a second connecting conduit 220 adapted to provide a path for fluid to enter and / or exit the fluid delivery array 200, and a plurality of distribution arrays 230 adapted to provide a path for fluid to enter and / or exit the fluid delivery array 200 and a path for fluid to enter and / or exit the thermal management duct 141 and / or duct assembly 500. Each distribution array 230 is in fluid communication with the first connecting conduit 210 and the second connecting conduit 220.

[0901] The fluid delivery arrangement 200 comprises a two-part body 201 formed from a front member 202 and a rear member 203. A first connecting conduit 210 and a second connecting conduit 220 form part of the front member 202. Each distribution array 230 is formed in the rear member 203. In use, the front member 202 and the rear member 203 are sealably attached to one another, for example via welding / plastic welding.

[0902] The main chamber 240 is located within the body 201 of the fluid delivery arrangement 200. The main chamber 240 is surrounded by a front member 202 and a rear member 203. The front member 202 partially surrounds the main chamber 240. The rear member 203 also partially surrounds the main chamber 240. The first connecting conduit 210 is in fluid communication with the main chamber 240 via two fluid connection openings 241a, 241b. Similarly, the second connecting conduit 220 is in fluid communication with the main chamber 240 via two fluid connection openings 242a, 242b. The main chamber 240 of the fluid delivery arrangement 200 is adapted to contain and confine the thermal management fluid as it flows through the fluid delivery arrangement 200. The main chamber 240 is in fluid communication with the first connecting conduit 210, the second connecting conduit 220, and each distribution array 230.

[0903] The main chamber 240 of the fluid delivery arrangement 200 is located within a space defined by a main chamber peripheral wall 243. The main chamber peripheral wall 243 is an annular wall that surrounds the fluid connection openings 241a, 241b, 242a, 242b.

[0904] Each connecting conduit 210, 220 of the fluid delivery arrangement 200 provides multiple fluid paths into and / or out of the thermal management arrangement 140. In particular, a first connecting conduit 210 provides two paths for fluid to enter and / or exit the fluid delivery arrangement 200. A second connecting conduit 220 provides two other paths for fluid to enter and / or exit the fluid delivery arrangement 200.

[0905] As shown in FIG. 53 , the first connecting conduit 210 comprises a first fluid connection arrangement (fluid inlet) 211 and a second fluid connection arrangement (fluid outlet) 212. The first fluid connection arrangement 211 of the first connecting conduit 210 provides a path for fluid to enter the fluid delivery arrangement 200. The first fluid connection arrangement 211 of the first connecting conduit 210 is connectable to a source of thermal management fluid 1006, for example a reservoir 1001 in a coolant loop 1005. The second fluid connection arrangement 212 of the first connecting conduit 210 provides a path for fluid to exit the fluid delivery arrangement 200. The first fluid connection arrangement 211 and the second fluid connection arrangement 212 are substantially identical. In use, fluid may enter and / or exit the fluid delivery arrangement 200 via either or both of the first fluid connection arrangement 211 and the second fluid connection arrangement 212 of the first connecting conduit 210.

[0906] A first fluid connection arrangement 211 is provided at a first end 213 of the first connecting conduit 210. A second fluid connection arrangement 212 is provided at a first end 214 of the first connecting conduit opposite the first end 213. As will be appreciated, the connection arrangements at both ends of the first connecting conduit 210 can be used as fluid inlets / fluid outlets.

[0907] The first connecting conduit 210 comprises a conduit wall 215. The conduit wall 215 has a regular cross-section such that the cross-section of the first connecting conduit 210 is substantially constant along a major or long axis A of the first connecting conduit 210. The major axis A of the first connecting conduit 210 extends along the length of the first connecting conduit 210 and is substantially parallel to the direction of fluid flow through the first connecting conduit 210 from the first fluid connection array 211 to the second fluid connection array 212.

[0908] Both the first connecting arrangement 211 and the second connecting arrangement 212 of the first connecting conduit 210 include flanges 216. Each flange 216 is a retention arrangement for a seal 60. Each flange 216 is a seal receiving body including a channel 217. Each channel 217 is adapted to receive and retain a portion of the sealing arrangement 60, i.e., a portion of an O-ring 60. Each channel 217 has a predetermined depth suitable for receiving at least the retainable portion 603 of the O-ring 60.

[0909] The second connecting conduit 220 comprises a first fluid connection arrangement (fluid inlet) 221 and a second fluid connection arrangement (fluid outlet) 222. The first fluid connection arrangement 221 of the second connecting conduit 220 provides a path for fluid to enter the fluid delivery arrangement 200. The first fluid connection arrangement 221 of the second connecting conduit 220 is connectable to a source of thermal management fluid 1006, for example a reservoir 1001 in the coolant loop 1005. The second fluid connection arrangement 222 of the second connecting conduit 220 provides a path for fluid to exit the fluid delivery arrangement 200. The first fluid connection arrangement 221 and the second fluid connection arrangement 222 are substantially identical. In use, fluid may enter and / or exit the fluid delivery arrangement 200 via either or both of the first fluid connection arrangement 221 and the second fluid connection arrangement 222 of the second connecting conduit 220.

[0910] A first fluid connection arrangement 221 is provided at a first end 223 of the second connecting conduit 220. A second fluid connection arrangement 222 is provided at a second end 224 of the first connecting conduit opposite the first end 223. As will be appreciated, the connection arrangements at both ends of the second connecting conduit 220 can be used as fluid inlets and / or fluid outlets.

[0911] The second connecting conduit 220 comprises a conduit wall 225. The conduit wall 225 has a regular cross-section, i.e. the cross-section of the second connecting conduit 220 is substantially constant along a major or long axis A' of the second connecting conduit 220. The major axis A' of the second connecting conduit 220 extends along the length of the second connecting conduit 220 and is substantially parallel to the direction of fluid flow from the first fluid connection array 221 to the second fluid connection array 222 through the second connecting conduit 220. The major axis A' of the second connecting conduit 220 is substantially parallel to the major axis A of the first connecting conduit 210.

[0912] The first connecting arrangement 221 and the second connecting arrangement 222 of the second connecting conduit 220 both comprise a flange 226. Each flange 226 is a retaining arrangement for a seal 60. Each flange 226 is a seal receiving body comprising a channel 227. Each channel 227 is adapted to receive and retain a portion of the sealing arrangement 60, i.e. a portion of the O-ring 60. Each channel 227 has a predetermined depth suitable for receiving at least the retainable portion 603 of the O-ring 60. The flanges 216, 226 and the channels 217, 227 are identical.

[0913] As shown in FIG. 54, the fluid delivery arrangement 200 includes a storage compartment 250. The storage compartment 250 is an integrated storage compartment integrally formed within the front member 202. The storage compartment 250 is located between the first connecting conduit 210 and the second connecting conduit 220. The storage compartment 250 is a sealable chamber that can store, for example, a daughter board 51 of the battery management computer 50. The storage compartment 250 includes a peripheral wall 251. The storage compartment 250 includes a number of posts 252 adapted to receive fastening means such as screws. A cover member 114 may be attached to the fluid delivery arrangement 200 to seal the storage compartment. The storage compartment 250 is sealable, for example to prevent fluid from entering the storage compartment 250.

[0914] The fluid delivery array 200 includes a plurality of distribution arrays 230. As shown in FIG. 53, each distribution array 230 includes a distribution opening 234 formed within a nozzle mounting portion 235. Each nozzle mounting portion 235 includes a recessed portion 236. Each recessed portion 236 is an annular recess extending around the distribution opening 234. Each recessed portion 236 is adapted to receive a portion of a nozzle 501, specifically a protrusion 506 on a flange portion 504 of the nozzle 501. The recessed portion 236 allows the nozzle 501 to be accurately positioned relative to the distribution opening 234 for attachment to the distribution array 200 in the correct location.

[0915] 55, the lower panel or rear member 203 of the fluid delivery means 200 comprises a plurality of distribution openings 234 through which fluid can flow between the main chamber 240 and the distribution arrays 230. The rear member 203 comprises eight distribution openings 234 and eight distribution arrays 230. Each distribution array 230 is adapted to allow fluid to pass through said distribution array 230 into and / or out of a corresponding duct 141 / duct assembly 500. In use, coolant can flow from the main chamber 240 through each distribution opening 234 into the duct 141 / duct assembly 500 / nozzle 501.

[0916] The distribution openings 234 of the fluid delivery array 200 are aligned. Each distribution opening 234 is equal in length. Each distribution opening 234 extends the full height of the aperture 235. Each distribution opening is in fluid communication with both the first connecting conduit 210 and the second connecting conduit 220 such that fluid traveling into the fluid distribution array 200 via either conduit 210, 220 can be distributed to any distribution opening 234. Fluid passing through the main chamber 240 is distributed evenly to each distribution array 230.

[0917] When the fluid delivery array 200 is used in the thermal management arrangement 140 of the battery module 10, each distribution array 230 is attached directly to a nozzle 501 of the duct assembly 500. Each duct assembly 500 is connected to two fluid delivery arrays 200 via a nozzle 501, and each nozzle 501 is attached to the distribution array 230 in a fluid-tight manner. Each nozzle 501 can be welded to the rear member 203 of the fluid distribution array 200. In particular, the protrusion 506 of the flange portion 504 of the nozzle 501 is located within the recessed portion 236, and the flange 504 of the nozzle is welded to the nozzle attachment portion 235. This attachment provides a fluid-tight connection between the nozzle 501 and the rear member 203 of the fluid distribution array 200. Ideally, a clamping assembly is placed above the joint between the duct 141 and the nozzle 501 to strengthen the joint and prevent leakage.

[0918] In use, the first connecting conduit 210 and the second connecting conduit 220 are used to transport fluid to and / or from the chamber 240. Each fluid connection arrangement 211, 221, 212, 222 is open to allow fluid to pass into and out of the main chamber 240 via the first connecting conduit 210 and the second connecting conduit 220. Each distribution array 230 has an identical opening in fluid communication with the main chamber 240. Fluid is distributed equally to all distribution arrays 230 and to each duct 141 / duct assembly 500 attached to the fluid delivery arrangement 200. Fluid passing through the fluid delivery array is distributed equally to each duct 141 / duct assembly 500.

[0919] 56-60 disclose an alternative fluid delivery arrangement 1200 in accordance with an embodiment of the present invention. The alternative fluid delivery arrangement 1200 is generally similar to the fluid delivery arrangement 200, with like numbers (e.g., 210 / 1210 and 220 / 1220) indicating like features. An important distinguishing feature of the alternative fluid delivery arrangement is the division of the main chamber into sub-chambers and the distribution array 1230.

[0920] FIG. 56 discloses an exploded perspective view of the fluid delivery arrangement 1200. As will be appreciated, other fluid delivery arrangements 1200 are interchangeable with the fluid delivery arrangement 200. A battery module 10 within a battery pack 1 may use two fluid delivery arrangements 200 or two alternative fluid delivery arrangements 1200. In embodiments where redundancy is required, each battery module 10 and its thermal management arrangement 140 includes two fluid delivery arrangements 1200. In such embodiments, the fluid delivery arrangements 1200 are adapted to deliver a thermal management fluid 1006 to a thermal management duct 141 / duct assembly 500 that may be located within the battery module 10 and battery pack 1.

[0921] The fluid delivery array 1200 comprises a first connecting conduit 1210 adapted to provide a path for fluid to enter and / or exit the fluid delivery array 1200, a second connecting conduit 1220 adapted to provide a path for fluid to enter and / or exit the fluid delivery array 1200, and a plurality of distribution arrays 1230a, 1230b adapted to provide a path for fluid to enter and / or exit the fluid delivery array 1200, and / or a path for fluid to enter and / or exit the thermal management duct 141 and / or duct assembly 500.

[0922] The fluid delivery arrangement 1200 comprises a two-part body 1201 formed from a front member 1202 and a rear member 1203. A first connecting conduit 1210 and a second connecting conduit 1220 form part of the front member 1202. Each distribution array 1230a, 1230b is formed in the rear member 1203. In use, the front member 1202 and the rear member 1203 are sealably attached to one another, for example via welding / plastic welding.

[0923] The main chamber 1240 is located within the body 1201 of the fluid delivery arrangement 1200. The main chamber 1240 is surrounded by a front member 1202 and a rear member 1203. The front member 1202 partially surrounds the main chamber 1240. The rear member 1203 also partially surrounds the main chamber 1240. The first connecting conduit 1210 is in fluid communication with the main chamber 1240 via two fluid connection openings 1241a, 1241b. The second connecting conduit 1220 is in fluid communication with the main chamber 1240 via two fluid connection openings 1242a, 1242b. The main chamber 1240 of the fluid delivery arrangement 1200 is adapted to contain and confine a thermal management fluid as it flows through the fluid delivery arrangement 1200.

[0924] The main chamber 1240 is in fluid communication with the first connecting conduit 1210, the second connecting conduit 1220, and each distribution array 1230. However, unlike in the fluid delivery array 1200, the first connecting conduit 1210 and the second connecting conduit 1220, and each distribution array 1230 of the fluid delivery array 1200 are in fluid communication with only a portion of the main chamber 1240.

[0925] The main chamber 1240 is located within a space defined by a main chamber peripheral wall 1243. The main chamber peripheral wall 1243 is an annular wall surrounding the fluid connection openings 1241a, 1241b, 1242a, 1242b. A partition 1244 is located within the main chamber 1240. The partition 1244 divides the main chamber into a number of sub-chambers 1245a, 1245b. The partition 1244 follows a non-linear path. In particular, the partition 1244 is crenellated. The partition 1244 comprises a number of crenellations 1246. The main chamber peripheral wall 1243 surrounds the partition 1244.

[0926] The main chamber 1240 comprises a first sub-chamber 1245a and a second sub-chamber 1245b. A partition 1244 divides the main chamber 1240 into the first sub-chamber 1245a and the second sub-chamber 1245b. The first sub-chamber 1245a is located between the main chamber peripheral wall 1243 and a first side 1244a of the partition 1244. The second sub-chamber 1245b is located between the main chamber peripheral wall 1243 and a second side 1244b of the partition 1244. The second side 1244b of the partition 1244 is opposite the first side 1244a of the partition 1244.

[0927] The first connecting conduit 1210 is in fluid communication with the first sub-chamber 1245a via two fluid connection openings 1241a, 1241b. The second connecting conduit 1220 is in fluid communication with the second sub-chamber 1245b via two fluid connection openings 1242a, 1242b. The first connecting conduit 1210 is not in fluid communication with the second sub-chamber 1245b, and similarly the second connecting conduit 1220 is not in fluid communication with the first sub-chamber 1245a.

[0928] Each connecting conduit 1210, 1220 of the fluid delivery arrangement 1200 provides multiple fluid paths into and / or out of the thermal management arrangement 140. In particular, the first connecting conduit 1210 provides two paths for fluid to enter and / or exit the fluid delivery arrangement 1200. The second connecting conduit 1220 provides two other paths for fluid to enter and / or exit the fluid delivery arrangement 1200.

[0929] 57, the first connecting conduit 1210 comprises a first fluid connection arrangement (fluid inlet) 1211 and a second fluid connection arrangement (fluid outlet) 1212. The first fluid connection arrangement 1211 of the first connecting conduit 1210 provides a path for fluid to enter the fluid delivery arrangement 1200. The first fluid connection arrangement 1211 of the first connecting conduit 1210 is connectable to a source of thermal management fluid 1006, for example a reservoir 1001 in the coolant loop 1005. The second fluid connection arrangement 1212 of the first connecting conduit 1210 provides a path for fluid to exit the fluid delivery arrangement 1200. The first fluid connection arrangement 1211 and the second fluid connection arrangement 1212 are substantially identical. During use, fluid may enter and / or exit the fluid delivery arrangement 1200 via either or both of the first fluid connection arrangement 1211 and the second fluid connection arrangement 1212 of the first connecting conduit 210.

[0930] A first fluid connection arrangement 1211 is provided at a first end 1213 of the first connecting conduit 1210. A second fluid connection arrangement 1212 is provided at a second end 1214 of the first connecting conduit opposite the first end 1213. As will be appreciated, the connection arrangements at both ends of the first connecting conduit 1210 can be used as fluid inlets / fluid outlets.

[0931] The first connecting conduit 1210 comprises a conduit wall 1215. The conduit wall 1215 has a regular cross-section such that the cross-section of the first connecting conduit 1210 is substantially constant along a major or long axis A of the first connecting conduit 1210. The major axis A of the first connecting conduit 1210 extends along the length of the first connecting conduit 1210 and is substantially parallel to the direction of fluid flow through the first connecting conduit 1210 from the first fluid connection array 1211 to the second fluid connection array 1212.

[0932] Both the first connecting arrangement 1211 and the second connecting arrangement 1212 of the first connecting conduit 1210 include a flange 1216. Each flange 1216 is a retention arrangement for a seal 60. Each flange 1216 is a seal receiving body that includes a channel 217. Each channel 217 is adapted to receive and retain a portion of the sealing arrangement 60, i.e., a portion of the O-ring 60. Each channel 217 has a predetermined depth suitable for receiving at least the retainable portion 603 of the O-ring 60.

[0933] 57, the second connecting conduit 1220 comprises a first fluid connection arrangement (fluid inlet) 1221 and a second fluid connection arrangement (fluid outlet) 1222. The first fluid connection arrangement 1221 of the second connecting conduit 1220 provides a path for fluid to enter the fluid delivery arrangement 1200. The first fluid connection arrangement 1221 of the second connecting conduit 1220 is connectable to a source of thermal management fluid 1006, for example a reservoir 1001 in the coolant loop 1005. The second fluid connection arrangement 1222 of the second connecting conduit 1220 provides a path for fluid to exit the fluid delivery arrangement 1200. The first fluid connection arrangement 1221 and the second fluid connection arrangement 1222 are substantially identical. During use, fluid may enter and / or exit the fluid delivery arrangement 1200 via either or both of the first fluid connection arrangement 1221 and the second fluid connection arrangement 1222 of the second connecting conduit 1220.

[0934] A first fluid connection arrangement 1221 is provided at a first end 1223 of the second connecting conduit 1220. A second fluid connection arrangement 1222 is provided at a second end 1224 of the second connecting conduit opposite the first end 1223. As will be appreciated, the connection arrangements at both ends of the second connecting conduit 1220 can be used as fluid inlets and / or fluid outlets.

[0935] The second connecting conduit 1220 comprises a conduit wall 1225. The conduit wall 1225 has a regular cross-section, i.e. the cross-section of the second connecting conduit 1220 is substantially constant along a major or long axis A' of the second connecting conduit 1220. The major axis A' of the second connecting conduit 1220 extends along the length of the second connecting conduit 1220 and is substantially parallel to the direction of fluid flow through the second connecting conduit 1220 from the first fluid connection arrangement 1221 to the second fluid connection arrangement 1222. The major axis A' of the second connecting conduit 1220 is substantially parallel to the major axis A of the first connecting conduit 1210.

[0936] Both the first connecting arrangement 1221 and the second connecting arrangement 1222 of the second connecting conduit 1220 include a flange 1226. Each flange 1226 is a retaining arrangement for a seal 60. Each flange 1226 is a seal receiving body including a channel 1227. Each channel 1227 is adapted to receive and retain a portion of the sealing arrangement 60, i.e., a portion of the O-ring 60. Each channel 1227 has a predetermined depth suitable for receiving the retainable portion 603 of the O-ring 60. As will be appreciated, the flanges 1216, 1226 and the channels 1217, 1227 may be identical.

[0937] As shown in FIG. 58, the fluid delivery arrangement 1200 comprises a storage compartment 1250. The storage compartment 1250 is an integrated storage compartment integrally formed within the front member 1202. The storage compartment 1250 is located between the first connecting conduit 1210 and the second connecting conduit 1220. The storage compartment 1250 is a sealable chamber that can house, for example, a daughter board 51 of the battery management computer 50. The storage compartment 1250 comprises a peripheral wall 1251. The storage compartment 1250 comprises a number of posts 1252 adapted to receive fastening means such as screws. A cover member 114 may be attached to the fluid delivery arrangement 1200 to seal the storage compartment. The storage compartment 1250 is sealable, for example to prevent fluid from entering the storage compartment 1250.

[0938] The fluid delivery array 1200 includes a plurality of distribution arrays 1230a, 1230b. Each distribution array 1230a, 1230b includes a distribution opening 1234a, 1234b formed within a nozzle mounting portion 1235a, 1235b. Each nozzle mounting portion 1235a, 1235b includes a recessed portion 1236a, 1236b. Each recessed portion 1236a, 1236b is an annular recess extending around the distribution opening 1234a, 1234b. Each recessed portion 1236a, 1236b is adapted to receive a portion of the nozzle 501, specifically a protrusion 506 on a flange portion 504 of the nozzle 501. The recessed portion 1236a, 1236b allows the nozzle 501 to be accurately positioned relative to the distribution opening 1234a, 1234b for attachment to the distribution array 1200 in the correct location.

[0939] As shown in Fig. 59, the lower panel or rear member 1203 of the fluid delivery means 1200 comprises a plurality of distribution openings 1234a, 1234b through which fluid can flow between the main chamber 1240 and the distribution arrays 1230a, 1230b. The rear member 1203 comprises eight distribution openings 1234a, 1234b and eight distribution arrays 1230a, 1230b. Each distribution array 1230a, 1230b is adapted to allow fluid to pass through said distribution array 1230a, 1230b into and / or out of the corresponding duct 141 / duct assembly 500. In use, coolant can flow from the main chamber 1240 through each distribution opening 1234a, 1234b into the duct 141 / duct assembly 500 / nozzle 501.

[0940] The fluid delivery array 1200 comprises a plurality of first distribution arrays 1230a and a plurality of second distribution arrays 1230b. As shown in FIG. 60, the distribution openings 1234a of the lower panel, i.e., the plurality of first distribution arrays 1230a, are aligned, and the distribution openings 1234b of the plurality of second distribution arrays 1230b are also aligned. The distribution openings 1234a of the plurality of first distribution arrays 1230a are not aligned with the distribution openings 1234b of the plurality of second distribution arrays 1230b. The distribution openings 1234a of the plurality of first distribution arrays 1230a are offset relative to the distribution openings 1234b of the plurality of second distribution arrays 1230b.

[0941] Each distribution aperture 1234a, 1234b has an equal length. Each distribution aperture 1234a, 1234b extends a portion of the height of the aperture portion 1235a, 1235b. Each distribution aperture is in fluid communication with the first connecting conduit 1210 or the second connecting conduit 1220 such that fluid traveling through the conduits 1210, 1220 into the fluid delivery arrangement 200 can be resolved into a subset of the distribution apertures 1234a, 1234b.

[0942] Each first distribution array 1230a includes a distribution opening 1234a formed within the nozzle attachment portion 1235a and the recessed portion 1236a. The distribution opening 1234a in each first distribution array 1230a does not extend the entire height of the corresponding opening 1235a. Each distribution opening 1234a in each first distribution array 1230a extends along a portion of the height of the corresponding opening 1235a. The opening 1235a of each first distribution array 1230a includes a punched portion 1237a adjacent the opening 1235a. If the opening 1234a allows fluid to pass through the first distribution array 1230a, the punched portion 1237a is a rigid portion that prevents fluid from passing through a portion of the first distribution array 1230a, specifically through a portion of the opening 1235a.

[0943] Each second distribution array 1230b includes a nozzle attachment portion 1235b and a distribution opening 1234b formed within the recessed portion. The distribution opening 1234b in each second distribution array 1230b does not extend the entire height of the corresponding opening 1235b. Each distribution opening 1234b in each second distribution array 1230b extends along a portion of the height of the corresponding opening 1235b. The opening 1235b of each second distribution array 1230b includes a punched portion 1237b adjacent the opening 1235b. If the opening 1234b allows fluid to pass through the second distribution array 1230b, the punched portion 1237b is a rigid portion that prevents fluid from passing through a portion of the second distribution array 1230b, specifically through a portion of the opening 1235b.

[0944] The distribution openings 1234a of the fluid delivery array 1200 are aligned. Each first distribution opening 1234a is in fluid communication with the first connecting conduit 1210 via a first sub-chamber 1245a. Fluid traveling into the fluid distribution array 1200 via the first connecting conduit 1210 is evenly distributed to the first distribution openings 1234a. Similarly, the second distribution openings 1234b of the fluid delivery array 1200 are aligned. Each second distribution opening 1234b is in fluid communication with the second connecting conduit 1220 via a second sub-chamber 1245b.

[0945] The punched portion 1237a of each first distribution array 1230a is on the opposite side of the rear member 1203 from the punched portion 1237b of each second distribution array 1230b. In the view of FIG. 59, where the punched portion 1237a of each first distribution array 1230a is on the "upper" side of the rear member 1203, the punched portion 1237b of each second distribution array 1230b is on the "lower" side of the rear member 1203.

[0946] 60, the dispensing openings 1234a of each first dispensing array 1230a are located on one side of the septum 1244 and the dispensing openings 1234b of each second dispensing array 1230b are located on the opposite side of the septum 1244. Each die cut portion 1237a, 1237b aligns with the septum and forms a seal with the septum 1244.

[0947] The distance between adjacent distribution arrays 1230a, 1230b may correspond to the width of one or more cells, see FIG. 80. In such example embodiments, a duct 141 may be provided on one side of each cell 120 in the battery module 10. These embodiments are illustrated in FIG. 85 and FIG. 86. FIG. 78-FIG. 84 illustrate fluid delivery arrangements designed to allow this level of redundancy. FIG. 80 illustrates that there are eight first distribution arrays 1230a and seven second distribution arrays 1230b located on opposite sides of the partition wall 1244, see FIG. 84.

[0948] The distance between adjacent distribution arrays 1230a, 1230b may correspond to the width of the cell. In such an example embodiment, ducts 141 may be provided on both sides of the cell. This can provide redundancy, i.e., if the duct 141 on one side of the cell bursts or fails, the duct on the other side of the cell can be used to thermally manage the cell, as shown in Figures 85 and 86.

[0949] When the fluid delivery arrangement 1200 is used in the thermal management arrangement 140 of the battery module 10, each fluid delivery arrangement 1230a, 1230b is directly attached to a nozzle 501 of the duct assembly 500. Each duct assembly 500 is connected to the two fluid delivery arrangements 1200 via a nozzle 501, and each nozzle 501 is attached in a fluid-tight manner to the distribution array 1230a, 1230b. Each nozzle 501 can be welded to the rear member 1203 of the fluid delivery arrangement 1200. In particular, the protrusion 506 on the flange portion 504 of the nozzle 501 is located within the recessed portion 236a, 1236b, and the flange 504 of the nozzle is welded to the nozzle attachment portion 1235a, 1235b. This attachment provides a fluid-tight connection between the nozzle 501 and the rear member 1203 of the fluid distribution array 1200. A clamping assembly is placed over the joint between the duct 141 and the nozzle 501 to strengthen the joint and prevent leakage.

[0950] In use, the first connecting conduit 1210 and the second connecting conduit 1220 are used to transport fluid to and / or from the main chamber 1240. Each fluid connection arrangement 1211, 1221, 1212, 1222 is open to allow fluid to pass into and out of the main chamber 1240 via the first connecting conduit 1210 and the second connecting conduit 1220. Each distribution array 1230a, 1230b has an opening in fluid communication with the main chamber 1240. Fluid passing into the fluid distribution array 1200 via the first connecting conduit 1210 is evenly distributed to the first distribution openings 1234a. Fluid passing into the fluid distribution array 1200 via the second connecting conduit 1220 is evenly distributed to the second distribution openings 1234b.

[0951] When used within the battery pack 1, each fluid delivery arrangement 200, 1200 provides a means by which thermal management fluid 1006 can be distributed within the battery pack 1, and in particular to each battery module 10, for thermally managing the cells 120. Each fluid delivery arrangement 200, 1200 is a pressure regulated reservoir that is operably connected to a number of ducts 141 within the battery module 10 during use, and also operably connected to one or more other fluid delivery arrangements 200 of the other battery modules 10 within the battery pack 1.

[0952] Each fluid delivery array 200, 1200 can be fluidly connected to one or more other fluid delivery arrays 200, 1200. Figure 61 details a cross-section of a connection between two fluid delivery arrays 200. The two fluid delivery arrays 1200 can be fluidly connected in a similar manner.

[0953] 61 shows a battery module subassembly 3 comprising a battery module 10 and another battery module 10'. The battery module 10 is fluidly connected to the other battery module 10'. Each first connecting conduit 210 and each second connecting conduit 220 of the battery module 10 is connected to a corresponding first connecting conduit and second connecting conduit of the other battery module 10'.

[0954] Detail of FIG. 61 shows the fluid connection between the fluid delivery arrangement 200 of the first battery module 10 and the fluid delivery arrangement 200' of the second battery module 10'. The first connecting conduits 210, 210' are connected via a seal member 60, and similarly, the second connecting conduit (not shown) is also connected via a seal member 60. When connected in this manner, the main chambers of the fluid delivery arrangements 200, 200' are in fluid communication with each other. The seal member 60 is used to seal the interface between the fluid delivery arrangements of adjacent connecting conduits 210, 210'. Together, the joined connecting conduits 210, 210' and the seal 60 provide a sealed structure for transporting thermal management fluid inside the battery pack 1.

[0955] The detail of Figure 61 also shows the fluid connection between the fluid delivery arrangement 200 of the first battery module 10 and the multi-port fluid connector 700. A first connecting conduit 210 of the fluid delivery arrangement 200 is connected to a branch port 705 of the multi-port fluid connector 700 via a sealing member 60. Similarly, a second connecting conduit 210 of the fluid delivery arrangement 200 is connected to another branch port 706 of the multi-port fluid connector 700 via a sealing member 60.

[0956] 62 and 63 show in detail a sealing member 60 for providing a seal between fluid conduits in a battery pack 1 and / or between battery modules 10. The sealing member 60 comprises a deformable annular body 601. The body 601 comprises a first elongated side portion 604a and a second elongated side portion 604b, and a first shortened side portion 605a and a second shortened side portion 605b. The cross-sectional shape of the body 601 comprises a central portion 602 located between the first maintainable portion 603a and the second maintainable portion 603b. By cross-sectional shape is meant the shape of the cross section of the body 601 when viewed in cross section, in particular when the body is cut open in the XZ plane (see the central portion of FIG. 64 and FIG. 65). The cross-sectional shape of the body 601 is constant throughout the body, in particular along the entire length of each side portion 604a, 604b, 605a, 605b. The cross-sectional width of the central portion 602 (corresponding to the cross-sectional width of the elongated side portions 604a, 604b along the X-axis direction) is greater than the cross-sectional width of each of the retainable portions 603a, 603b.

[0957] The sealing member 60 is an O-ring. The unitary body 601 is made of soft silicone or other suitable elastomer material such as rubber. The purpose of the sealing member 60 is to seal the interface between the interconnected fluid-carrying conduits inside the battery pack 1 and prevent fluid leakage. This application requires the sealing member 60 to have an appropriate hardness. A softer sealing material with a lower Shore A hardness rating will more easily flow into gaps, grooves, and imperfections between mating parts (flanges 216) and may be extruded or blown through such gaps, resulting in seal failure. A harder material with a higher Shore A hardness rating offers more resistance to extrusion, but also requires more compressive force to seal. It has been found that the deformable body 601 should ideally have a Shore A hardness less than 50 and greater than 15. In some preferred embodiments, the deformable body 601 has a Shore A hardness between 30 and 40. In a most preferred embodiment, the deformable body has a Shore A hardness between 33 and 37, in particular 35.

[0958] As shown in the side views (top portion) of Figures 64 and 65, the body 601 comprises a central portion 602 located between two maintainable portions 603a, 603b. The maintainable portions 603a, 603b are adapted to be located and maintained within a retaining member, for example within a channel 217 formed in a flange 216 of the fluid delivery arrangement 200. The central portion 602 is adapted to expand or widen under a compressive force, for example to seal a gap or space between the two retaining members.

[0959] 64 and 65, the cross-sectional shape of each maintainable portion 603a, 603b comprises two substantially straight edge portions 613 joined by a curved and / or semicircular edge portion 623. The central portion 602 comprises two curved and / or semicircular edge portions 623. When squeezed or otherwise deformed under a compressive force (acting along the Z axis), the edge portions 612, 622 become bent and move away from each other such that the width of the central portion 602 increases.

[0960] As shown in the top view (lower portion) of FIG. 64 and FIG. 65, the sealing member body 601 is substantially rectangular and includes four substantially straight side portions 604a, 604b, 605a, 605b joined by corner portions 606a-606d. Opposite side portions, e.g., elongated side portions 604a, 604b, are substantially parallel and of equal length. Each side portion 604a, 604b, 605a, 605b is joined to an adjacent side portion by a smooth corner portion 606a-606d. The substantially rectangular body 601 includes two elongated side portions 604a, 604b (extending along the Y-axis direction), two short side portions 605a, 605b (extending along the X-axis direction), and four corner portions 606a-606d. The substantially rectangular shape of the body 601 corresponds to the shape of the retention channel 217 in the flange 216.

[0961] Figure 64 illustrates the sealing member 60 in an undeformed state 60a. The undeformed state illustrated in Figure 64 is the default state of the sealing member 60 and represents the shape that the sealing member 60 adopts when no forces, such as compressive forces, are applied to the sealing member 60.

[0962] Figure 65 shows the sealing member 60 in a deformed state 60b during use. The deformed state shown in Figure 65 represents the shape that the sealing member 60 adopts when a longitudinal compressive force is applied to the sealing member 60. The longitudinal compressive force is applied along a direction parallel to the direction between the maintainable portions 603a, 603b, i.e., parallel to the axis Z shown in Figures 64 and 65 (middle portion).

[0963] In use, the sealing member 60 is used as a seal and a compressive force is applied to the sealing member 60. The maintainable portions 603a, 603b are located and maintained within the maintainer, for example within the channel 217 in the flange 216 of the fluid delivery array 200. A compressive force is applied to the sealing member 60. This force acts to press the maintainable portions 603a, 603b together along a direction parallel to the axis Z shown in Figures 64 and 65 (central portion). The sealing member 60 is located within the first and second maintainer arrays, for example within the channel 217 of adjacent fluid delivery arrays 200, and enters a deformed state when squeezed between the first and second maintainer arrays, for example between the channel 217 of adjacent fluid delivery arrays 200. In the deformed state shown in Figures 63 and 65, the cross-sectional width of the central portion 602 increases. The cross-sectional width of the central portion 602 in the deformed state 60b is wider than the cross-sectional width of the central portion 602 in the undeformed state 60a. The cross-sectional width of the maintainable portions 603a, 603b in the deformed state is substantially the same as the cross-sectional width of the maintainable portions 603a, 603b in the undeformed state due to the fact that these portions are held within the channel 217 and cannot expand or become wider in a similar manner. The increased cross-sectional width of the central portion 602 in the deformed state allows the sealing member 60 to accommodate any slight differences in the size / dimensions of the corresponding channels / flanges of the fluid delivery means 200 between which the sealing member 60 is maintained.

[0964] In a most preferred embodiment, in the undeformed state, the cross-sectional width of the central portion is 2.8 mm and the cross-sectional width of each maintainable portion is 1.8 mm. In the undeformed state, the cross-sectional height of the sealing means is 18 mm. In the deformed state, the cross-sectional width of the central portion is greater than 2.8 mm, most preferably 4.4 mm, and the cross-sectional width of each maintainable portion is 1.8 mm. In the deformed state, the cross-sectional height of the sealing means is less than 18 mm, most preferably 14.4 mm.

[0965] 66-69 show a multi-port fluid connector 700 for connecting a fluid distribution array 200, 1200 to a source of, for example, thermal management fluid. The multi-port fluid connector 700 is a fluid connector adapted to fit within a predetermined volume. The multi-port fluid connector 700 is a low profile fluid connector having a limited height H. The multi-port fluid connector 700 is adapted to split / combine the flow of fluid therethrough while minimizing the creation of vortex components and pressure drops over a limited distance.

[0966] The multi-port fluid connector 700 comprises a body 701, a primary port 704, and two branch ports 705, 706. The multi-port fluid connector 700 further comprises an internal chamber 710. The primary port 704 is in fluid communication with the branch ports 705, 706 via the internal chamber 710.

[0967] Body 701 is a two-part body comprising a first body member 702 and a second body member 703. First body member 702 and / or second body member 703 are preferably made from a plastic material and may be formed via injection molding techniques. First body member 702 and second body member 703 may be joined using plastic welding or other suitable techniques.

[0968] The first body member 702 comprises a primary port 704 and a portion of a wall 711 of an internal chamber 710. The primary port 704 comprises a tubular member fluidly connected to the internal chamber 710 at or near the center of the internal chamber 710. The first body member 702 comprises a neck portion 707. As shown in the cross-sectional view of FIG. 69, the neck portion 707 is located at the end of the tubular primary port 704 proximate the internal chamber 710.

[0969] As shown in FIG. 68, the first body member 702 includes a primary protrusion 709 and two secondary protrusions 718, 719. Each protrusion 709, 718, 719 is a protrusion that extends into the internal chamber 710. The primary protrusion 709 is adjacent to the primary port 704. The primary protrusion 709 is located between the branch ports 705, 706. The two secondary protrusions 718, 719 are located on either side of the primary port 704. The primary protrusion 709 is located on the opposite side of the internal chamber 710 to the two secondary protrusions 718, 719. The shaping of the wall, specifically the protrusions 709, 718, 719, is adapted to guide the flow of fluid through the internal chamber 710. The protrusions 709, 718, 719 are adapted to reduce the pressure drop and vortex components within the internal chamber 710.

[0970] The second body member 703 includes two branch ports 705, 706 and a portion of a wall 711 of an internal chamber 710. Each branch port 705, 706 includes a tubular member fluidly connected to the internal chamber 710 at or near the edge of the internal chamber 710.

[0971] As shown in FIG. 69, the second body member 703 includes a further protrusion 708. The further protrusion 708 is a protrusion that extends into the internal chamber 710. The further protrusion 708 is located between the branch ports 705, 706 and opposite the tubular primary port 704. The wall formed, in particular the protrusion 708 opposite the T-junction, induces a flow split to reduce the pressure drop in this region of the internal chamber 710. The further protrusion 708 is adapted to reduce the pressure drop and vortex components within the internal chamber 710.

[0972] Each branch port 705, 706 includes a flange 716. Each flange 716 is a retention arrangement for a seal 60. Each flange 716 is a seal receiving body including a channel 717. Each channel 717 is adapted to receive and retain a portion of the sealing arrangement 60, i.e., a portion of an O-ring 60. Each channel 717 has a predetermined depth suitable for receiving at least the retainable portion 603 of the O-ring 60. The flanges 716 and channels 717 are similar to the flanges 216 and channels 217 of the fluid delivery arrangements 200, 1200 described above.

[0973] The distance between the branch ports 705, 706 corresponds to the distance between the first connecting conduit 210, 1210 and the second connecting conduit 220, 1220 of the fluid delivery arrangement 200, 1200. The branch ports 705, 706 are located symmetrically on either side of the primary port 704, i.e. the branch ports 705, 706 are equidistant from the primary port 704.

[0974] The shape of the internal chamber 710 is shown in Figures 70 and 71. The internal chamber 710 comprises a main conduit portion 720 and two branch conduit portions 721, 722. The internal chamber 710 further comprises a flow separation portion 723 and two corner connection portions 723, 724. The flow separation portion 723 provides a fluid communication path between the main conduit portion 720 and each of the corner connection portions 723, 724. Each of the angled portions 723, 724 provides a fluid communication path between the flow separation portion 723 and the branch conduit portions 721, 722. In the flow separation portion 723, a fluid flow can proceed between the main conduit portion 720 and the two corner connection portions 723, 724 during use.

[0975] The main conduit portion 720 includes a narrowed portion 725. The location of the narrowed portion 725 corresponds to the location of the neck portion 707 of the first body portion 702.

[0976] The flow separation section 723 connects the main conduit section 720 / narrowed section 725 and the angled sections 723, 724 / branched conduit sections 721, 722. The flow separation section 723 allows for the fluid flows to separate and / or recombine while minimizing pressure drop and vortex components in this region. The location of the flow separation section 723 corresponds to the location of the protrusion 708 of the second body member 703 and the main protrusion 709 of the first body member 702. The geometrically induced secondary rotational flow helps reduce recirculation at the bend, ideally at the 90° bend, thereby resulting in a more even flow distribution. Also, the shaped walls on the opposite sides of the T-junction generally induce flow separation to reduce pressure drop in this region.

[0977] In use, the multi-port fluid connector 700 is adapted to connect the fluid distribution array 200, 1200 to, for example, a source of thermal management fluid. Fluid can flow in either direction through the multi-port fluid connector 700. For example, fluid may flow into the multi-port fluid connector 700 via the primary port 704, into the main conduit portion 720, through the flow separation portion 723, each corner connection portion 723, 724, and each branch conduit portion 721, 722, and out of the multi-port fluid connector 700 via the branch ports 705, 706. Alternatively, fluid may flow into the multi-port fluid connector 700 via one or both branch ports 705, 706, through each branch conduit portion 721, 722, through each corner connection portion 723, 724, and the flow separation portion 723 and the main trunk portion 720, and out of the multi-port fluid connector 700 via the primary port 704.

[0978] 72 and 73 disclose exploded views of the multi-port fluid connector 700 and the retaining plate 33. The retaining plate 33 can be used to hold and retain the multi-port fluid connector 700 within the battery module subassembly 3 such that the branch ports 705, 706 are in fluid communication with the first fluid connection conduits 210, 1210 and second fluid connection conduits 220, 1220 of the peripheral fluid delivery array 200, 1200 (see FIGS. 13 and 14).

[0979] The retainer plate 33 comprises a main planar portion 331 and three attachment portions 332, 333. The main planar portion 331 is adapted to engage and bear against the multi-port fluid connector 700, specifically the first body member 702, during use. The first body member 702 can be attached to the retainer plate 33 via a fastening arrangement such as a screw 741. The screw 741 is fastened into a threaded hole 335 in the main planar portion 331 of the retainer plate 33 to attach the body member 702 to the retainer plate 33. The screw 741 passes through a retaining portion 740 that protrudes from the first body portion 702. The primary port 704 passes through a port opening 334 in the main planar portion 331. Each attachment portion 332, 333 extends from the main planar portion 331. Each mounting portion 332 , 333 includes a plurality of openings 336 for receiving a fastening arrangement, such as screws or bolts, for fastening the retainer plate to another component, such as the fluid delivery arrangement 200 , 1200 .

[0980] Manufacturing the battery pack 1 includes the steps of forming a battery module 10, forming a battery module subassembly 3, installing the battery module subassembly 3 in a battery pack housing 2, and sealing the battery pack housing 2.

[0981] When forming the battery module 10, an appropriate number of cells 120 are selected and placed within receiving structures 182 in the cell array member 180. The cells 120 form an array. A thermal management system 140 is provided that includes two fluid delivery arrays 200, 1200 and one or more ducts 141 / duct assemblies 500 attached thereto. The thermal management array 140 is positioned such that the ducts 141 are located between adjacent rows of cells 120 in the array. A non-planar bus bar 400 is located on either side of the array of cells. One or more planar bus bars are located above the array of cells. The bus bars are electrically connected to the cells via wires. A housing member is provided to cover the internal components of the battery pack, such as the bus bars and cells. The or each duct 141 is inflated with a fluid and a potting material is poured into the pack. The potting material is allowed to set, harden or harden.

[0982] When forming the battery module subassembly 3, an appropriate number of battery modules 10 are provided. The battery modules are interconnected, for example, by stacking and mechanically interlocking with one another using the battery module support array 30. Corresponding fluid delivery arrays 200 and multi-port fluid connectors 700a, 700b are aligned and interconnected. A retaining plate 33 is placed over the multi-port fluid connectors 700a, 700b to hold them in place. Electrical bus bars (not shown) are connected between each battery module.

[0983] When the battery module subassembly 3 is ready to be inserted into the housing 2, it is moved into the housing 2 through the opening 24 toward the bottom wall 28a until the inlet conduit 65 and outlet conduit 66 are aligned with the openings 29a, 29b in the end wall 27a. Once the conduits 65, 66 and opening 29 are properly aligned, the inlet opening 63 and outlet opening 64 are secured to the conduits 65, 66 and end wall 27a. The adapters 63, 64 may be threaded and are tightened until the joints between the components are fluid tight. The appropriate electrical connections are made between the battery module subassembly and the battery pack management system 5 / end enclosure 23. A cover member is placed over the opening 24 and sealed.

[0984] The battery pack 1 may be mounted, for example, to a chassis or other support structure. A fastening arrangement, such as screws, nuts, and / or bolts, is used to attach the battery pack to the support structure via a mounting arrangement 4.

[0985] As one skilled in the art will appreciate, the example embodiments presented above can be modified in a number of ways without departing from the scope of the present invention. For example, the battery module 10 may have any suitable length, width, height, and / or number of cells 120, and the battery module subassembly 3 may include any suitable number of specially designed battery modules 10 for the particular application required. The or each bus bar may be made from any suitable material, such as aluminum or steel.

[0986] When adjusting the size of the battery module 10, only a subset of the components need to be specially designed to allow for packs with different lengths and numbers of cells. Battery modules 10 of any length can be constructed by adjusting the sizes of the housing members, bus bars, and ducts while maintaining a fixed width and height.

[0987] The battery pack housing 2 may include potting material 130, for example, to hold the battery module subassemblies 3 in place and / or to support and position components within the battery housing 2. The battery modules 10 can be connected in a number of configurations to meet a particular set of design requirements. For example, some or all of the battery modules 10 can be electrically connected in series or parallel and / or the fluid connections can be made in series or parallel.

[0988] Each battery module may include any suitable number of sensors, such as any combination of temperature sensors, strain sensors, pressure sensors, volatile organic compound (VOC) sensors, carbon monoxide (CO) sensors, carbon dioxide (CO2) sensors, smoke sensors, leak detectors, acceleration sensors, microelectromechanical system (MEMS) sensors, voltage detection sensors, heat detection sensors, and moisture detection sensors.

[0989] In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values ​​relative to the upper or lower limits of an acceptable range of a parameter, coupled with an indication that one of said values ​​is significantly more preferred than the other, should be construed as an implicit statement that each intermediate value of said parameter between the more preferred and less preferred alternatives among said alternatives is itself preferable to the less preferred value, and is preferable to each value between the less preferred value and said intermediate value.

[0990] The features disclosed in the foregoing description or in the following drawings, expressed in specific forms or in terms of means for achieving a disclosed function, or in terms of methods or processes for achieving a disclosed result, may be utilized, as appropriate, separately or in any combination of such features, to realize the invention in its various forms as defined in the appended claims.

Claims

1. A battery pack comprising a battery module subassembly comprising one or more battery modules, wherein two or more of the battery modules within the battery module subassembly are electrically interconnected, and two or more of the battery modules within the battery module subassembly are fluidly interconnected so that a fluid can flow through the battery module subassembly; a thermal management means comprising one or more thermal management ducts for thermally managing one or more cells inside the battery pack, the battery module subassembly, or the battery modules; a battery pack management means for monitoring and / or controlling the operation of the battery pack; and a battery pack fluid connection means for connecting the one or more thermal management ducts to a source of thermal management fluid, wherein the thermal management ducts or each of the thermal management ducts comprises a flexible and / or expandable battery pack fluid connection means and a battery pack electrical connection means for electrically connecting the battery pack to an external load, and the battery pack is modular.

2. The battery pack according to claim 1, wherein the battery pack comprises a battery pack housing, the battery pack housing comprises a lower container member and a cover member, the lower container member comprises one or more openings and a cavity for receiving one or more battery modules and / or for receiving a battery module subassembly.

3. The battery pack according to claim 1, wherein the battery pack comprises a battery pack fluid connection means having a battery pack fluid inlet and a battery pack fluid outlet, and the battery modules within the battery pack or the thermal management means of each battery module are connected to the battery pack fluid connection means by fluid.

4. The battery pack according to claim 1, characterized in that the fluid delivery means on the inlet side of each battery module is fluidly connected to the fluid delivery means on the inlet side of at least one other battery module, and the fluid delivery means on the outlet side of each battery module is fluidly connected to the fluid delivery means on the outlet side of at least one other battery module.

5. The battery pack fluid connection means is adapted to enable the battery pack to be operably connected to a thermal management system, the thermal management system comprising the source of the thermal management fluid, a reservoir for holding the thermal management fluid, a heat exchanger, a pump, and further comprising a coolant loop and a pressure sensor, the pressure sensor being adapted to monitor the pressure in the thermal management system, more specifically in the coolant loop, the battery pack according to claim 1.

6. The battery pack fluid connection means comprises a battery pack fluid inlet comprising an inlet adapter and an inlet conduit so that fluid can enter the battery pack via an inlet adapter and an inlet conduit, and further comprises a battery adapter fluid outlet comprising an outlet adapter and an outlet conduit so that fluid can exit the battery pack via an outlet adapter and an outlet conduit, wherein the battery pack fluid inlet and the battery pack fluid outlet are fluidly connected to each other via the battery module or each of the battery modules, as described in claim 1.

7. The battery pack according to claim 6, wherein the inlet conduit and the outlet conduit each have a first end and a second end, the first end of the inlet conduit and / or the first end of the outlet conduit being connectable to one or more battery modules, the second end of the inlet conduit and / or the second end of the outlet conduit each having a substantially flat and generally square arranging member, the arranging member being arrangable within a retaining means, the retaining means being located inside the battery pack housing to allow the arranging means to be reliably and accurately positioned during the manufacture of the battery pack, the inlet conduit being operably connected to a main fluid inlet of one or more battery modules, and the outlet conduit being operably connected to a main fluid outlet of one or more battery modules.

8. The battery pack according to claim 1, wherein the battery pack comprises electrical connection means for electrically connecting the battery pack to an external load such as a motor or other electrical components of a vehicle, machine, or industrial equipment, and the electrical connection means comprises a positive battery pack terminal and a negative battery pack terminal provided by an electrical adapter.

9. The battery pack according to claim 8, wherein the battery pack comprises an end sealed box, the end sealed box comprises a status indicator means, further comprises one or more communication ports, and further comprises one or more internal electrical connectors, the internal electrical connectors are adapted to pass through the battery pack housing to the end sealed box, and more specifically, to connect a circuit held inside the end sealed box to the terminals of the battery module sub-assembly / the battery module.

10. The battery pack according to claim 1, wherein the battery module subassembly comprises the main fluid inlet and the main fluid outlet, and is provided with a multi-port fluid connector on the inlet side and a multi-port fluid connector on the outlet side so that the fluid can flow through the battery module subassembly via the main fluid inlet, the battery module, and the main fluid outlet, and at least some or all of the fluid connections between the battery modules are parallel or series fluid connections.

11. The battery pack according to claim 1, characterized in that two or more of the battery modules in the battery module subassembly are electrically interconnected in parallel or in series, the battery module subassembly comprises one or more intermodule busbars, the two or more battery modules are connected via the intermodule busbars, the positive side of at least one of the battery modules is connectable to the negative side of an adjacent battery module via one or more intermodule busbars, and the intermodule busbars or each of the intermodule busbars are planar conductive members.

12. The battery pack according to claim 1, wherein the battery module subassembly comprises two peripheral battery modules, each of which is located on the outer peripheral edge of the battery module subassembly, the battery module subassembly comprises a positive terminal busbar and a negative terminal busbar, the peripheral battery modules are connectable to a positive battery pack terminal and a negative battery pack terminal, the positive battery pack terminal is electrically connected to a first peripheral battery module via the positive terminal busbar, and the negative battery pack terminal is electrically connected to a peripheral battery module via the negative terminal busbar.

13. The battery pack according to claim 1, wherein the battery pack comprises a manual disconnection means that can be operated as a manual service disconnection with a switch, the manual disconnection means being configured to electrically disconnect two groups of the battery modules inside the battery pack and / or to disable the terminals of the battery pack.

14. The battery pack according to any one of claims 1 to 13, wherein the battery pack comprises a support means, the battery module subassembly comprises a support means, the battery modules within the battery module subassembly are mechanically connected to one another via the support means, the support means comprises two end face support members located at the peripheral end of the battery module subassembly, and four elongated corner support members adapted to receive the corners of a plurality of the battery modules, and each of the end face support members is connected to the corresponding corner support member.

15. The battery pack according to claim 14, dependent on claim 10, wherein the support means comprises one or more retaining means for attaching and fixing the multiport fluid connector to the battery module subassembly, the retaining means comprises a main plane portion, the main plane portion is fitted to engage with the multiport fluid connector and press the multiport fluid connector against it, and during use, the main plane portion comprises port openings, and the primary ports of the multiport fluid connector pass through the port openings in the main plane portion.

16. The battery pack according to claim 2, comprising a housing and a battery module subassembly, wherein the battery module subassembly is at least partially located inside the housing and is mechanically connected to at least one mounting means such that the mounting means can transmit the weight of the battery module subassembly to other components such as an external chassis or support structure.

17. The battery pack according to claim 16, characterized in that the mounting means or each of the mounting means is accessible through the battery pack housing and provides a mechanical connection point to the outside of the battery pack, and the mounting means is accessible from the outside of the battery pack housing and is adapted to directly transmit the weight of the battery module subassembly to components on the outside of the housing.

18. The battery pack according to claim 1, wherein the battery module is connectable to one or more other identical battery modules, comprises a battery module housing, and electrical and / or fluid connections are made to the battery module through recesses or openings in the housing, and the battery module comprises at least one cell or a plurality of cells arranged in the form of a regular array, each of which is electrically connected to a busbar.

19. The battery pack according to claim 1, wherein each of the battery modules comprises at least one cell arrangement means for supporting and arranging the plurality of cells, the cell arrangement means being a plate and comprising a plurality of receiving structures, the receiving structures being adapted to receive and arrange the ends of the cells and being arranged in a close-packed hexagonal or honeycomb pattern such that the minimum separation between the cells is predetermined.

20. The battery pack according to claim 1, comprising one or more sensing means used to measure the parameters of the cells, wherein the sensing means is located on a flexible carrier which is a flexible PCB that can be attached to a duct and is located between the thermal management duct and one or more of the cells, and the one or more cells are mounted in an array on the flexible carrier so as to enable mapping of the performance and physical characteristics of the battery pack, and also comprising one or more sensors which include a pressure sensor, a temperature sensor, a voltage sensor, and / or a fluid / moisture sensor that determines the difference in the total volume of the pack so as to estimate / predict the fluid flow rate and the rate of temperature change.

21. The battery pack according to claim 1, wherein the battery module comprises battery module electrical connection means for providing electrical connections between the battery module and other battery modules, busbars, interconnects, and / or components such as external loads, and the battery module electrical connection means comprises one or more busbars and comprises positive and negative terminals located on opposing side walls of the battery pack housing.

22. The battery pack according to claim 1, wherein the busbar for the battery module and / or the battery pack comprises an electrical connection portion and at least one structural support means, and the busbar not only provides means for making electrical connections inside the battery module and / or the battery pack, but also provides additional structural support and mechanical strength to the battery module and / or the battery pack, thus serving two functions.

23. The battery pack according to claim 22, wherein the busbar for the battery module and / or the battery pack comprises a cell connection portion and an external connection portion, the cell connection portion being positioned at an angle to the external connection portion, and the construction of the busbar enables electrical contact between one or more cells inside the battery pack or the battery module and external components, and the busbar further comprises an electrical connection portion adapted to electrically interconnect one or more cells with one or more other components such as other busbars, terminals, interconnects, and / or external loads.

24. The battery pack according to claim 22 or 23, wherein the busbar comprises at least structural support means, the structural support means or each of the structural support means is adapted to maintain the electrical connection portion in a predetermined position within the battery module and / or to provide structural support to the battery module, the structural support means is adapted to allow a number of battery modules to be stacked in a straight line, and the structural support means or each of the structural support means is positioned at the peripheral end of the electrical connection portion having a body portion made of a non-conductive material such as plastic, and is overmolded over the electrical connection portion.

25. The battery pack according to claim 1, wherein the battery module or each of the battery modules comprises the thermal management means for thermally managing one or more of the cells, the thermal management means is configured to enable fluid connections to the battery module at multiple locations and / or orientations, comprises the inlet-side fluid delivery means and the outlet-side fluid delivery means, and comprises one or more substantially parallel, flexible, and / or expandable thermal management ducts.

26. The battery pack according to claim 25, wherein the heat management duct and each of the heat management ducts are provided with one or more thermally conductive additives for improving the thermal conductivity of the duct material, and the thermally conductive additives are provided with particles of a thermally conductive filler.

27. The battery pack according to claim 25 or 26, wherein the thermal management duct or each of the thermal management ducts comprises a matrix material and a thermally conductive filler, the matrix material comprising an expandable plastic material such as polyethylene (PE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), or high-density polyethylene (HDPE), and the thermally conductive filler comprising any one or any combination thereof of carbon-based fillers such as carbon, carbon black, graphite, graphene, multi-walled carbon nanotubes, or single-walled carbon nanotubes, or comprising an inorganic filler or a ceramic filler, or comprising aluminum oxide, silicon carbide, boron nitride, silicon nitride, alumina, aluminum nitride, or zinc oxide.

28. The battery pack according to claim 1, wherein the battery module or each of the battery modules comprises a sealing means, which is substantially rigid to fix the cells and the thermal management ducts in place within the battery module, is adhesively attached to the ducts or each of the ducts, provides complete external support to the ducts or each of the ducts, prevents excessive expansion and rupture of the ducts or each of the ducts, keeps each of the ducts open so that fluid can easily flow through the ducts or each of the ducts, and is made of an insulating sealing material such as expandable polyurethane foam.

29. A battery pack according to claim 1, comprising a duct, at least one nozzle, and at least one duct clamping means, wherein the nozzle is attached to the duct, the duct clamping means is adapted to clamp the duct to the nozzle, the duct assembly is provided within the battery module to enable thermal management of one or more of the cells, and the duct clamping assembly or each duct clamping assembly ensures that a fluid-seal connection exists between the duct and the corresponding nozzle, thereby preventing leakage from occurring at the corresponding nozzle-duct interface.

30. The battery pack according to claim 29, characterized in that the nozzle comprises a nozzle body, an opening passing through the nozzle body so that fluid can pass through the opening to the nozzle body, the nozzle body comprises a flange portion and a mounting portion, the mounting portion is located inside the open end of the duct, and the duct is heat-welded at the open end of the duct to the mounting portion of the nozzle.

31. The battery pack according to claim 29 or 30, wherein the duct clamping assembly comprises a bearing member, and a first fixing member and a second fixing member, and further comprises a biasing member, wherein the fixing member and the bearing member are made of an insulating plastic material or a metal such as aluminum, and the biasing member is formed of an elastic material such as steel wire, thereby, during use, the duct clamping assembly compresses and presses against the duct and the open end of the nozzle, the duct is also joined to the mounting portion of the nozzle at the open end of the duct via welding, and the duct clamping assembly works to reinforce the joint between the open end of the duct and the mounting portion of the nozzle, thereby preventing leakage from occurring at the interface between the duct and the nozzle.

32. The battery pack according to claim 1, characterized in that it provides a fluid delivery means for delivering the thermal management fluid to one or more thermal management ducts, wherein the fluid delivery means comprises a plurality of paths through which the fluid travels in and / or out of the fluid delivery means, and provides means for distributing the fluid within the battery pack to thermally manage a large number of cells.

33. The battery pack according to claim 32, wherein the fluid delivery means comprises a first connecting conduit and a second connecting conduit adapted to provide a path for fluid to enter the fluid delivery means and / or a path for fluid to exit the fluid delivery means, and comprises a body formed from a front member and a rear member, the first connecting conduit and the second connecting conduit forming part of the front member, the fluid delivery means comprises a main chamber surrounded by the front member and the rear member, the rear member of the body comprises one or more distribution means, the front member and the rear member are attached so as to be sealed to each other, and the fluid delivery means is a pressure regulating tank.

34. The battery pack according to claim 32 or 33, characterized in that the fluid delivery means or each of the fluid delivery means is operably connected to a plurality of ducts and / or duct assemblies, and is operably connected to one or more other fluid delivery means during use, and the first connecting conduit and / or the second connecting conduit provides a fluid path into and / or out of the main chamber, and is fluidly connected to the main chamber via one or more fluid connection openings.

35. The battery pack according to claim 33, wherein the first fluid connecting means and the second fluid connecting means of the first connecting conduit and the second connecting conduit are connectable to the first fluid connecting means and the second fluid connecting means of the other fluid delivery means, the first fluid connecting means and the second fluid connecting means are provided with mounting means, each of the mounting means is provided with a channel for receiving a seal to prevent leakage between adjacent fluid delivery means.

36. The battery pack according to claim 33, wherein the fluid delivery means comprises a plurality of distribution means, each of the distribution means comprises a distribution opening formed inside a nozzle mounting portion, each of the nozzle mounting portions comprises a recess, each of the recesses is an annular recess extending around the distribution opening, and a portion of the nozzle is fitted to receive, in particular, a projection on the flange portion of the nozzle, the recesses enable the nozzle to be precisely positioned relative to the distribution opening and attached to the distribution means in the correct location, and the rear member of the fluid delivery means comprises a plurality of distribution openings through which fluid can flow between the main chamber and the distribution means, such that during use, fluid can flow from the main chamber through each of the distribution openings to the duct / duct assembly / nozzle.

37. The battery pack according to claim 33, wherein the fluid delivery means comprises a storage compartment which is an integrated storage compartment having a sealable chamber for preventing fluid from entering the chamber, and the storage compartment is adapted to house a sub-board of a battery management computer.

38. The battery pack according to claim 33, characterized in that the main chamber is divided into at least two sub-chambers, the distribution means is divided into at least two sets of distribution means, each set of distribution means is associated with each sub-chamber to provide built-in redundancy to the battery pack, and if a duct on one side of the cell bursts or fails, the cell can be thermally managed using the duct on the other side of the cell.

39. The battery pack according to claim 38, characterized in that the main chamber has a partition wall for dividing the main chamber into at least two sub-chambers, the first connecting conduit and the second connecting conduit and each of the one set of distribution means of the fluid delivery means are fluidly connected to only a portion of the main chamber, the first connecting conduit is fluidly connected to the first sub-chamber via at least one fluid connection opening, and the second connecting conduit is fluidly connected to the second sub-chamber via at least one connection opening.

40. The battery pack according to claim 38, characterized in that the distance between adjacent distribution means corresponds to the width of the cell so that the ducts are provided on both sides of the cell, and if the duct on one side of the cell bursts or fails, the duct on the other side of the cell can be used to thermally manage the cell.

41. The battery pack according to claim 1, comprising a multiport fluid connector having a primary port and two branch ports, wherein the multiport fluid connector is a low-profile multiport fluid connector for connecting the fluid distribution array to the supply source of the thermal management fluid.

42. The battery pack according to claim 41, wherein the multi-port fluid connector is adapted to divide / combine the flow of fluid passing through it and to minimize the generation of vortex components and pressure drops over a limited distance.

43. The battery pack according to claim 35, wherein the battery pack has sealing means for providing a seal between fluid conduits in the battery pack or the battery module, the sealing means comprising a deformable body, the deformable body comprising a central portion located between two retainable portions, the retainable portions being able to be positioned in retaining channels during use, the width of the central portion increasing when deformed, and the sealing means being able to accommodate positional tolerances between corresponding ends of conduits of the first and / or second connecting conduits / pressure regulating tanks within the battery pack.

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