Battery Pack System

Abstract

Aspects of the present disclosure include a battery pack including one or more stacks of battery cells, where the stack of battery cells is captured between plates or other members that are controlled to maintain a force on the cells to manage the pressure of the cells within the stack. Some battery cell technologies, such as certain forms of solid cells, operate optimally under the controlled stack pressure provided by the systems described herein.

Description

Technical Field

[0001] Cross - Reference to Related Applications This Patent Cooperation Treaty (PCT) application is related to and claims priority from U.S. Patent Application No. 63 / 343,433, entitled "Battery Pack System", filed on May 18, 2022, the entire content of which is incorporated herein by reference for all purposes.

[0002] Embodiments of the present invention generally relate to systems and methods for controlling the force applied to a battery cell to maintain proper operation of the battery cell through charge and discharge cycles.

Background Art

[0003] Solid - state battery cells are often deployed in a pouch configuration. The battery cell often has a layered structure that includes an anode and a cathode separated by a solid electrolyte. The layered structure, which may include multiple units of an anode layer, an electrolyte layer, and a cathode layer, is sometimes encapsulated in a flexible laminate structure called a pouch. The flexible pouch is used in some solid - state batteries because individual cells expand and contract during charging and discharging.

[0004] More specifically, referring to an example of a cathode material that is a lithium - containing compound, during charging, Li + ions are extracted from the cathode and move through the solid electrolyte to the anode, and electrons move from the cathode to the anode through whatever device is charging the battery. In contrast, during discharge, Li +Ions and electrons move and flow in opposite directions, accompanied by the reduction of the cathode and the oxidation of the anode. The electrons here flow through any device that is powered by the battery. Since the anode and cathode repeatedly expand and contract unevenly during charging and discharging, a pouch-type casing is advantageous. That is, the anode expands more unevenly than the contraction of the cathode, so that when ions move from the cathode to the anode during charging, the cell as a whole expands positively. Conversely, since the anode contracts more unevenly than the expansion of the cathode, the cell as a whole contracts negatively during discharging.

[0005] Among the situations where the cell undergoes different contractions and expansions, it is advantageous to maintain the contact and pressure between the particles and between the layers that make up the various layers. Furthermore, it may be important to manage the pressure so that it is evenly distributed and maintain the pressure at a specified value for any type of particle cell. Inappropriate pressure management can cause various problems such as an increase in resistance, non-uniformity inside the cell, a decrease in capacity, a decrease in cycle life, and the growth of dendrites.

[0006] Various aspects of the present disclosure have been devised, especially in view of such observations.

Summary of the Invention

Means for Solving the Problems

[0007] Aspects of the present disclosure include a battery force management system including a first cell stack that may be a solid cell, more particularly a solid pouch cell, disposed between a first member and a second member, wherein the first member is movably attached and arranged to apply a force to the first cell stack. The system includes a drive unit operably coupled to the first member to move the first member so as to controllably apply a force. The drive unit may be operably coupled to the first member to move the first member so as to controllably apply a force in response to a determination of the force on the first cell stack. The determination of the force on the first cell stack can be based on the change of the first cell stack during charging or discharging of the cell stack.

[0008] In certain embodiments, the system may further include a first threaded drive rod operably coupled to a drive unit to rotate a first threaded drive rod operably coupled to a threaded portion of a first member, wherein the operable coupling of the threaded portion of the first member and the threaded drive rod moves the first member to controllably apply force in response to a determination of force during a change in the cell stack. In another embodiment, the system may further include a second threaded drive rod operably coupled to a drive unit to rotate a second threaded drive rod movably attached to a second member and arranged to cooperate with the first member to apply force to the cell stack, wherein each of the first threaded drive rod and the second threaded drive rod includes a first threaded portion and a second threaded portion, the first threaded portion being coupled to the respective first threaded portion of the first member, and the second threaded portion being coupled to the respective second threaded portion of the second member to move the first member and the second member inwardly toward each other or outwardly away from each other to controllably apply force in response to a determination of force during a change in the cell stack.

[0009] In various possible embodiments, the drive unit comprises a planetary gear assembly having a planetary gear operably coupled to the drive rod and a sun gear driving the planetary gear. The drive unit may further comprise a motor supporting a worm gear for driving the sun gear. In another embodiment, the drive unit comprises a belt pulley system having a pulley coupled to the drive rod and a motor coupled to the pulley via a belt. In this example, the motor is coupled to a movable member.

[0010] In another example, the system can include a second cell stack, which can also be a solid cell, disposed between a third member and a fourth member, with the third member movably attached and arranged to apply a force to the second cell stack. In this example, the drive unit is disposed between the first cell stack and the second cell stack, and the drive unit is further operably coupled to the third member and configured to move the third member to controllably apply a force in response to a determination of the force during a change in the cell stack. The drive unit can be a motor configured to rotate a threaded shaft that cooperates with a first threaded portion of the first member and a third threaded portion of the third member to move the first member toward or away from the second member and to move the third member toward or away from the fourth member to controllably apply a force in response to a determination of the force during a change in the cell stack.

[0011] In various possible embodiments and arrangements, the system may include a load unit arranged to determine the force applied to the first cell stack and / or other cell stacks.

[0012] In various possible embodiments, the first, second, third, and / or fourth members can be plates, specifically box-shaped end plates.

[0013] Another aspect of the present disclosure is to access a value indicating the cell stack pressure and, in response to the value indicating the cell stack pressure, controllably change the position of at least one member operably engaged with the cell stack, wherein changing the position of the at least one member includes changing the cell stack pressure, including a method of controlling the battery cell stack pressure. The cell stack may comprise a plurality of solid pouch cells, each of the plurality of solid pouch cells changing volume in response to charging or discharging. In one configuration, the at least one member is a plate that operably contacts at least one cell of the cell stack, and changing the position of the plate adjusts the force applied to the cell stack. This value indicates the cell stack pressure and is a measured value of the force. This value may indicate the change in cell stack pressure during charging and discharging of the solid pouch cell. Further, this value indicates the cell stack pressure and may be a sensor measurement value indicating the force applied to the at least one member. Further, the at least one member may include a first plate and a second plate, the first plate and the second plate being controllably movable relative to the cell stack, and the cell stack being disposed between the first plate and the second plate such that relative movement of at least one of the first plate or the second plate adjusts the force applied to the cell stack.

[0014] These and other aspects of the present disclosure will be described in further detail below.

[0015] The various objects, features, and advantages of the present disclosure as defined herein will become apparent from the following description of embodiments of those inventive concepts, as illustrated in the accompanying drawings. It should be noted that the drawings are not necessarily to scale and may include only specific features representative of various features of the embodiments, with an emphasis on illustrating the principles of the inventive concept and other aspects. Also, in the drawings, like reference characters may refer to the same or similar parts throughout different figures. The embodiments and figures disclosed herein are intended to be considered illustrative rather than limiting.

Brief Description of the Drawings

[0016]

Fig. 1A

[0017]

Fig. 1B

[0018]

Fig. 2

[0019]

Fig. 3A

[0020]

Fig. 3B

[0021]

Fig. 4

[0022]

Fig. 5A

[0023]

Fig. 5B

[0024]

Fig. 6

[0025]

Fig. 7

[0026]

Fig. 8

[0027]

Fig. 9A

[0028]

Fig. 9B

[0029]

Fig. 9C

[0030]

Fig. 9D

[0031]

Fig. 10

[0032] Detailed Description Aspects of the present disclosure monitor a battery pack of cells, which may be pouch-type cells, and maintain an optimal pressure on and within the cells for optimal operation as the pack of such cells cycles between a charged state and a discharged state, and also maintain an appropriate pressure when the pack of cells is in an equilibrium state and not charging or discharging, including various systems and methods for adjusting an external force on the cells. At a high level, for proper functioning, it is advantageous to maintain a uniform and appropriate pressure on each battery cell for optimal operation. Providing an appropriate pressure is advantageous for various cell types, including hybrid solid / liquid cells, some liquid cells using lithium metal and silicon anodes, and solid battery cells. In various examples described herein, solid battery cells may be referenced, but aspects of the present disclosure are understood to be useful for various forms of rechargeable battery cells in which appropriate pressure application is advantageous, as well as battery packs incorporating multiple batteries.

[0033] Generally, in various types of cells, it is advantageous to maintain appropriate and relatively uniform particle contact within the cell and between various layers of a particular cell configuration. If appropriate contact and / or pressure is not maintained, various potential problems may exist, including non-uniformity and increased resistance, which can have various potential adverse effects on the operation of the cell or the cell or pack of cells. Accordingly, the various embodiments discussed herein monitor the external force applied to the cells while accommodating the expansion of the cell during charging and the contraction of the cell during discharging, and optimally control the external force applied to the cells and the pressure within the cells. In addition to expansion and contraction due to charge and discharge, other factors such as temperature, state of charge, atmospheric pressure, etc. can be factors that change the force applied to the cell stack, either alone or in combination. Various aspects of the present disclosure may also improve the even distribution of the force on the cell such that the pressure within the cell and the associated particle contact are relatively evenly distributed, and may serve, among other advantages, to avoid discontinuities in any given layer or between layers.

[0034] The term "battery" in the relevant art and in this specification can be used in various ways and may refer to individual cells having an anode and a cathode separated by an electrolyte, which may be a solid electrolyte, as well as assemblies of such cells connected in various arrangements. A solid electrolyte battery cell can include a plurality of layers of anodes and cathodes separated by a solid electrolyte and can be encapsulated within a flexible "pouch" that accommodates the expansion and contraction of the anodes and cathodes associated with charging and discharging of the battery cell. Although many examples are described herein, the systems and methods described can be applied to many different types of batteries, battery chemistries, and can extend to batteries including different possible interconnections of cells, such as from individual cells, cells connected in parallel, in series, and in combinations of parallel and series. Also, the various implementations described herein can be applied to different structured battery arrangements, including pouch battery cells and other battery structures that can accommodate changes in the size of the electrodes.

[0035] Figures 1A and 1B are representative system diagrams of a battery pack 100 comprising an assembly of solid pouch cells 102 in a discharged state (Figure 1A) and a charged state (Figure 1B). Note that some of the details shown in Figure 1A do not exist in Figure 1B. As will be appreciated, the individual cells expand in the charged state relative to the discharged state. The battery pack may include some form of enclosure or housing 104 that houses the cells. Any number of possible housing configurations and arrangements are contemplated. As described above, the exemplary cells referred to in Figures 1A and 1B are solid battery cells, but the battery pack is not limited to use with solid battery cells and can be used with various types of cells where it may be advantageous to apply a controlled force to the cells. Note that the term "stack" does not mean a vertical arrangement or that the battery cells are stacked on top of each other, but rather means a plurality of battery cells (which may be pouch cells) arranged adjacent to each other within the battery pack.

[0036] Figure 2 is a representative isometric view of an example of the pouch cell 102. The pouch cell is generally rectangular, and the conductive tabs 200A and 200B extend from each end of the respective cell. In another arrangement, a pair of conductive tabs may extend from the same side of the cell. The conductive tab 200A from one end of the cell is connected to the anode (or in many cases multiple anodes) of the cell, often forms part of a layered structure, and is connected to a current collector having electrical contact with the anode. The conductive tab 200B at the other end of the cell is connected to the cathode (or in many cases multiple cathodes) of the cell, similarly forms part of a layered structure, and is connected to a current collector having electrical contact with the cathode. Pouch cells come in various configurations, shapes, and sizes. In the representative example shown, an outer flexible pouch material layer encapsulating the layered cell structure is adhered, and there is a boundary region 202 that seals the layered structure inside. The portion of the pouch in the inner layered structure 204 is relatively wider than the sealed region and is the portion of the pouch that undergoes expansion and contraction from the internal battery cell 206. The directions of expansion and contraction are represented by the arrows shown perpendicular to the outer surface of the region 204. Generally, the anode is the negative electrode of the cell, and the cathode is the positive electrode of the cell. As already mentioned, the battery pack system is useful with various different cell types including various different types of solid cells. Generally speaking, each cell has a certain open circuit voltage and capacity (often specified in units of Ah (ampere-hours)). In a battery pack, the cells are interconnected in various possible series and parallel arrangements to provide the overall pack voltage, capacity, charge and discharge current characteristics of the system to which the pack supplies power.

[0037] In FIGS. 1A and 1B, and in other figures, each cell 102 is shown in a top view having a separator 106 between each pouch cell. Note that the pouch cells shown in the figures including FIGS. 1A and 1B are represented as planar rectangles in various figures, but it should be noted that in order not to make FIG. 2 overly complex, a wider area such as area 204 in FIG. 2 is not shown. Tabs 200A, B of various cells (not shown in FIGS. 1A and 1B) are connected to their respective power rails. It should be noted that the tabs and power rails extending from the cells may not be shown in all figures in order not to make the figure too complex. Further, although the power rails are mentioned as being arranged along both sides of the pack adjacent to the tabs, the power rails may be arranged in other positions, and similarly the tabs may extend from other parts of any particular type of pouch-type cell.

[0038] Cell 102 is disposed between a first end plate 108 and a second end plate 110. The end plates may be planar. In an alternative example, particularly in configurations that may experience a wide pressure range and high pressures, such as 50 PSI (345 kPa) to 1500 PSI (10.34 MPa), the end plates may include a reinforcing structure to prevent or eliminate bending and other deformations. In other examples, the end plates may define a certain preset counter curve that deforms and flattens into a planar orientation under the battery stack pressure applied by the system. In one example, one or both of the end plates may be box-shaped end plates. The end plates, or more generally the retaining members, capture an assembly of pouch-type battery cells and controllably move inwardly towards each other as the cells are discharged and their volume decreases, or controllably move outwardly away from each other as the cells are charged and their volume increases, as will be described in more detail throughout, to maintain the force (pressure) on the assembly of cells. In short, during the charging and discharging cycles when the cells expand and contract, the end plates compress the assembly of cells between the end plates with a controlled force to maintain an appropriate force / pressure on the cells. The end plates maintain a consistent pressure across the opposing faces of the cells disposed adjacent and parallel to each plate, and that pressure is transmitted through the pouch-type cells disposed parallel between the end plates and is consistently maintained over the various changes that can occur in that pressure.

[0039] The end plates are movably supported within the battery pack 100. In the examples of FIGS. 1A and 1B, and in other examples described hereinafter, there are drive rods 112A, 112B disposed along the sides of the battery pack between the end plates. In one example, there are four rods disposed between respective corners and extending longitudinally between the rectangular end plates. The third and fourth (lower) drive rods are not visible in a top view. The drive rods, in one example, include threaded portions 114A, 114B and are supported by respective threaded portions (or threaded nuts attached coaxially with the openings, e.g., welded to the end plates) of openings 116 defined at the four corners of the rectangular end plates. By rotating the threaded drive rods, the end plates can be driven inwardly towards each other and outwardly away from each other.

[0040] In one example, each drive rod has a first threaded portion 114A and a second threaded portion 114B. The first threaded portion of the drive rod engages with the first plate 108, and the second threaded portion of the drive rod engages with the second plate 110. Both threaded portions are generally helical, and by rotating the threaded drive rod, the end plates engage with the corresponding threaded portions of their respective openings (or drive nuts) and move. The first threaded portion is threaded in the opposite direction to the second threaded portion. Since the threads are formed in opposite directions, rotating the drive rod in one direction can move the plates inward, and rotating the drive rod in the opposite direction can move the plates outward. In the views of FIGS. 1A and 1B, when the drive rod is rotated in one direction, the left box-shaped end plate 110 moves to the right (inward), and the right box-shaped end plate 108 moves to the left (inward) in the opposite direction. When the drive rod is rotated in the opposite direction, the left box-shaped end plate 110 moves to the left (outward), and the right box-shaped end plate 108 moves to the right (outward) in the opposite direction.

[0041] Generally, the end plates move between a maximum separation distance (outer) and a minimum separation distance (inner). The range of the separation distance is set to at least correspond to the range between the maximum width change and the minimum width change experienced between the state where the cell assembly is fully charged and the state where it is fully discharged. Depending on the degree of any charge or discharge cycle, the end plates may move within a range somewhat smaller than the maximum or minimum separation distance. Nevertheless, the first and second threaded portions of each tie rod should have a length sufficient to correspond to the maximum and minimum separation distances between the plates in any pack configuration of the cells. The drive rod may be evenly subdivided into a first half of the drive rod including the threaded portion 114A and another half including the threaded portion 114B, but the threaded portions may, in various embodiments, only extend sufficiently to correspond to the amount of movement of the plates, and / or may not be of equal size. In some of the various embodiments discussed herein, both end plates are moved inwardly or outwardly to maintain an appropriate pressure on the cells. However, in some configurations, it may be sufficient to fix one plate and move the other plate to accommodate the expanding and contracting cells. In such a configuration, the separation between the end plates to accommodate the expansion and contraction of the cells is achieved by moving only one plate. In such a configuration, one plate can include a threaded opening, a nut, a threaded insert, or other threaded configuration, and the other plate can include a bearing or other structure to support the rod.

[0042] To maintain the force (pressure) applied to the cells by the end plates relatively evenly, the end plates are arranged and maintained parallel to each other, and the pouches are also arranged such that the relatively planar portions of the cells facing each end plate are parallel to each other and generally parallel to the end plates. In one example, the plates are maintained in such an arrangement by tie rods at each corner. Since the thread pitch is the same between the four drive rods and their respective openings, the equal rotation of the drive rods moves each plate evenly. In this way, the respective planes of the plates facing the inside of the cells are parallel, and this parallel orientation is maintained when the plates are moved inward and outward, and the maintenance of the parallel planes maintains an even pressure distribution on the cells. Additionally, the end plates can include one or more guide members supported by guide rails 120 arranged below and above the pouch-type cells in the pack, on both sides of the pouch-type cells, or on the side walls of the pack, or other possible arrangements, as well as other possible guide structures. The guide members are planar and fit within the guide slots of the guide rails, or the guide members can define the slots and the guide rails can be planar members. In any arrangement, the cooperation of the guide members and the guide rails (in some cases multiple members and multiple rails) maintains the end plates in a fixed plane perpendicular to the inner and outer movement axes, reinforcing the consistent pressure on the stack of cells sandwiched between the plates.

[0043] In various examples, the drive rods are driven by a drive unit 118. Generally speaking, the drive unit rotates each drive rod in response to a determination of the force that needs to be applied to the cells. The drive unit communicates with a controller 122. The controller can receive various parameters, including sensors or other information indicating various parameters such as pressure, force, temperature, pack position, and / or other parameters, and can include a control process for moving and positioning the plates to apply pressure to the cells in the pack.

[0044] Figure 3A is a front view showing a possible example of the drive unit 300. Figure 3B is a side view of an alternative drive unit 350. Figure 3B further shows an internal portion of a battery pack including a plurality of laminated pouch cells 102 compressed by the configuration of the threaded tie rods 112 and end plates 108, 110 separated by the compliant pad 106 and driven by the drive unit 350. The drive unit can be disposed on one of the end plates on the side opposite to the stack of cells. The drive unit, in the embodiment of Figure 3A, comprises a planetary gear system 320 having planetary gears 322A - 322D coupled to respective drive rods 312A - 312D. In the examples of Figures 3A and 3B, there are four planetary gears for each of the four drive rods. The sun gear 324 is arranged to mesh with and drive the planetary gears. It should be noted that while some definitions of a conventional planetary gear system include planetary gears rotating around a sun gear, in the various embodiments discussed herein, the planetary gears do not rotate or revolve around the sun gear. In the illustrated embodiments of Figures 3A and 3B, the four planetary gears are driven by a single sun gear 324. The planetary gears are axially disposed on each drive rod 112 and can be coupled to each drive rod such that rotation of the planetary gears rotates each drive rod, and the rotation of the gears, and thus of the drive rods, is the same, thereby causing uniform planar movement of the end plates 108, 110 inwardly and outwardly consistent with the helical consistency between the threads on the rods. Further, since each planetary gear is of the same size, rotation of the sun gear rotates each planetary gear evenly, facilitating the maintenance of the planar parallel orientation of the end plates described above.

[0045] The arrangement of the planetary gear assembly in FIG. 3A shows an equal-distance relationship in both the vertical and horizontal directions between the planetary gears. Accordingly, the planetary gears are also arranged equidistantly around the outer diameter of the sun gear that meshes with each planetary gear. In such a symmetric arrangement, the force is evenly distributed to each drive rod by each planetary gear, so that driving the planetary gears with one motor can be enhanced. Since large forces up to 1500 pounds per square inch (PSI) (10.34 megapascals (MPa)) may be involved in some cells, this arrangement can be particularly advantageous when a single motor is involved and space for a plurality of relatively large and powerful motors is not available, not practical, or must be avoided for other reasons. FIG. 3B shows a similar arrangement, although with non-equidistant planetary gears. The sun gears are powered to rotate each planetary gear. In one arrangement, as shown in FIG. 3B, the sun gear can be directly driven by a motor 352 axially connected to the planetary gear shaft. Alternatively, as shown in FIG. 3A, a motor 354 is arranged adjacent to the planetary gear. The motor 354 includes a drive gear 356 that engages and rotates the planetary gear 324. This adjacent arrangement provides the possibility of arranging the motor assembly in a relatively small area compared to the case where the motor is directly coupled to the sun gear shaft. The motor and the drive gear can be arranged at any position between the respective planetary gears. When the motor and its drive axis are arranged in the transverse direction of the sun gear, the motor may include a worm drive gear that engages the sun gear.

[0046] As described above, the rotation of the planetary gear rotates the drive rod, and the drive rod acts to drive the plate inward or outward. However, the pressure from the cells between the plates will push the plates more or less depending on whether the cells are expanding or contracting. In embodiments where a worm gear is used to drive the sun gear, since the worm gear is not driven in the reverse direction, no holding force from the motor is required. That is, even if the pressure from the plates is returned to the sun gear through the planetary gear, the worm gear does not rotate. Thus, when the battery pack is not being charged or discharged and thus is not expanding or contracting, the plates can be positioned to maintain pressure on the stack of cells to set the pressure, but since the pressure from the cells on the plates does not drive the worm gear in the reverse direction, power can be removed from the system when setting the pressure (e.g., there is no need to supply power to the motor to maintain the pressure).

[0047] FIG. 4 shows an alternative planetary gear configuration 400 of the drive unit. That is, as shown in FIGS. 3A and 3B, there is a planetary gear for each drive rod. However, a first set of planetary gears 404A, 404B on one side of the box-shaped end plate 406 is driven by a first sun gear 408, and a second set of planetary gears 404C, 404D on the opposite side of the box-shaped end plate 406 is driven by a second sun gear 410. Each sun gear is driven. In one example, a first motor 424 may be arranged to directly drive the first sun gear 408, and a second motor 414 may be arranged to directly drive the second sun gear 410. Alternatively, the sun gears may be driven by respective drive gears. Each drive gear may be driven by a single motor that drives a third drive gear (not shown). Alternatively, the sun gears may each be driven by respective drive gears that are powered by respective motors. As yet another alternative, a worm gear may be disposed between the sun gears and engaged to rotate each of them.

[0048] Generally speaking, the embodiments of FIGS. 3A and 3B can be used with square or substantially square end plates configured to engage a similarly square or substantially square pouch cell. That being said, it is also possible to deploy a square end plate configuration on a rectangular or other shaped pouch cell. On the other hand, the embodiment of FIG. 4 can be used with a more rectangular and elongated pouch cell and a correspondingly more elongated rectangular end plate. Generally, the shape and dimensions of the end plate correspond to the shape and dimensions of the side of the pouch cell, applying a relatively even pressure to the cell across the entire surface area of the side of the cell, which is beneficial for an even pressure distribution and, among other advantages, particularly beneficial for optimizing the overall size of the pack. However, it should be noted that the plates can be sized and shaped based on the shape of the cells being pressurized in any arrangement and do not necessarily need to correspond to the shape in the described manner. Further, in some configurations, it may be beneficial for the plates to be larger than the cells in order to ensure that the pressure is relatively evenly distributed across the entire pouch surface associated with the surface of the internal cell and does not concentrate unevenly across the internal cell.

[0049] FIG. 5A is a top view of a battery pack 500 having an alternative drive unit assembly 502 in the form of a belt and pulley assembly shown in side view in FIG. 6. These are shown together with the pack depicted in FIG. 1A. However, it should be recognized that the alternative drive unit can be used in other pack configurations, like the other drive units discussed herein. In this arrangement, a pulley 504 is disposed at one end of each drive rod 112. The pulley may be integrally formed at the end of the drive rod or operatively coupled thereto. In any case, the rotation of each pulley rotates the respective drive rod, which in turn moves the end plates 110 and 108 inwardly or outwardly.

[0050] In one example, a motor 508 is disposed between respective pulleys and includes a drive pulley 510. The drive pulley and the drive rod pulley are shown with the same diameter, but the drive pulley may be larger or smaller than the drive rod pulley depending on the required torque, motor characteristics, and other factors. The motor includes a shaft 512 that rotates the drive pulley. A belt 514 is disposed around each pulley and the drive pulley such that rotation of the drive pulley drives each tie rod pulley via the belt. A belt tensioner may also be included but is not shown. In this example, the motor is fixed adjacent to one of the maximum outer ranges of the end plate 108. In one specific example, the motor is a pancake motor and is attached to a plate 516 that can be a side wall outside the battery pack housing, and the plate is located within or outside one of the maximum outer ranges of the end plate. The motor can also be attached to other frame assemblies. The drive rod is threaded as described above and engages corresponding threaded structures 116 of the respective end plates, and by rotating the rod, the end plate or multiple plates are translated inward or outward. The drive rod extends through a support plate 516 that fixes the motor, and supports each pulley 504 at the end of the rod with the drive pulley fixed to the shaft of the motor and the pulleys being planar-aligned. The shaft can be cantilevered from the motor or the end of the drive shaft can be supported by a bearing structure to reduce the side load on the shaft and the motor. In an alternative arrangement, instead of attaching the motor to the support plate, the bearing structure may be within the support plate, the motor can be attached to the pack surface, bracket, etc., the shaft extends outward in the direction of the support plate, and the drive pulley is located between the motor and the support plate. Nevertheless, the drive pulley is planar-aligned with the drive rod pulley.

[0051] In another arrangement, the drive shaft extending from the motor may be a splined shaft forming the drive pulley, or as shown, an individual drive pulley may be used depending on the torque requirements from the drive pulley relative to the drive shaft diameter. In either case, the belt 514 may be toothed, single-sided or double-sided depending on the routing around the drive rod pulley and the drive pulley. Similarly, the drive pulley can be toothed to engage the toothed belt. Such a toothed system can be used to maintain a consistent application of torque to the pulley by the belt and avoid slip therebetween.

[0052] Figure 5B is an alternative embodiment in which the drive unit assembly of FIGS. 5A and 6 is used to apply pressure to a pair of battery packs. In this example, each pack may be as depicted in FIG. 1A, although there are various details not shown in FIG. 5B. The pulley of the drive unit is coupled to a pair of drive rods, with one member of the pair being provided from one pack and the other member of the pair being provided from the other pack. In this way, one drive unit is arranged to control the plates of each pack and apply a controlled pressure to the battery cells of each pack.

[0053] In the alternative arrangement shown in FIG. 7, a further alternative drive unit assembly includes a motor 700, which can be a pancake motor, attached to the end plate 702. Thus, when the end plate moves inwards or outwards, the motor moves with the plate. In such an arrangement, the drive pulleys 704 are attached to their respective drive shafts 706 to rotate the drive shafts and can move inwards and outwards laterally along their respective drive shafts. Similarly, the drive pulley 708 can be attached to the splined motor shaft 710. The drive rod pulley as well as the motor (drive pulley) can be captured in the frame assembly 712 to maintain a planar alignment therebetween. The frame assembly may be supported translationally by a guide rail system or may be supported in a free floating state by respective drive rods and pulleys. In such an arrangement, when the motor is carried by the end plate and moves inwards and outwards, the pulley assembly moves similarly and the drive rod pulley moves inwards or outwards along its respective drive rod with the end plate.

[0054] In another alternative arrangement, the drive rod pulley is supported by a pulley assembly and fixed in a stationary position. In such an arrangement, the drive shaft along the lateral movement range of the pulley may include a splined shaft portion that corresponds to the lateral movement of the drive pulley and rotates the shaft while the pulley rotates. Here, when the motor translates inwards and outwards and thereby moves relative to the respective drive rod pulleys, the drive pulley can move along the drive shaft and maintain alignment with the drive rod pulley. If the lateral movement amount and spacing require a lateral movement so large that it cannot be accommodated by the spline shaft alone, the motor shaft can also be telescopic. Alternatively, the shaft can be telescopic, the pulley is fixed to the shaft, and the movement of the motor relative to the drive rod pulley is adjusted by the telescopic drive shaft. Using a telescopic shaft for the drive pulley allows for accommodation in a smaller space and enables a more compact overall design.

[0055] In another alternative embodiment, the drive pulley can further include a coaxial drive gear operably coupled to a worm gear powered by the motor. Such an arrangement can provide a similar ability that is not driven in the reverse direction and does not require power to maintain a static equilibrium position. Other pulley systems can include some form of mechanical brake that operates when the system powers down so that, for example, when the vehicle is parked and not connected to a charging station, power to the motor does not need to be maintained. The mechanical brake can take various forms and can be connected to various parts of the pulley system that controllably move a plate or directly engage the plate. Generally, the mechanical brake can include a function that causes engagement to limit movement of the plate when not powered and releases the brake when powered. For example, various spring-loaded brakes are used where the spring biases the brake member into an engaged state and is operably retracted to release the engagement upon power or other command. The retraction of the brake member can be done mechanically, electrically, magnetically, electromechanically, and other variations, either alone or in combination.

[0056] In various embodiments, the system can further include some form of load measurement system, such as a load cell or multiple load cells, a strain gauge or multiple strain gauges, or other mechanisms that can form part of a feedback loop where the force applied by the end plates on the captured cells is measured and various drive mechanisms are controlled to adjust the position of the plates. As used herein, the term force is used to describe various load measurement arrangements, but this term is intended to encompass other possible measurements including torque and pressure. Thus, other sensors such as pressure sensors can also be used. Further, force can also be measured or derived from other measurements. Force (pressure) may also be calculated through measurements such as position obtained from motor control measurements, plate position obtained from motor position, etc. It is also possible to fully characterize the battery system so that the state of charge, temperature, and other factors can be used to determine the position of the plate that provides the necessary pressure to the pouch for optimal operation. In various possibilities, the position of one or more plates relative to each other is based on the compressive force and pressure applied to the cell stack between the plates.

[0057] In one embodiment, a strain gauge is attached to one or more of the tie rods to correlate the axial compression or extension of the tie rod, more generally the displacement, with the force on the end plate. In another example, a strain gauge can be placed to measure the rotational torque on the tie rod and correlate such rotational torque with the force on the end plate and the similar pressure across the surface of the pouch cell. Various forms of load cells are also contemplated. For example, one or more load cells can be placed between one or both of the end plates and the first adjacent cell. Depending on the arrangement, an additional plate is placed inward from the end plate, the additional plate contacts the first cell or pad, and the load cell is placed between the plates. In such an arrangement, a flexible elastic pad is placed between the plates to maintain the additional inner plate in a planar arrangement with the outer end plate, ensuring an even force distribution across the plane of the plate while transmitting the force to the load cell therebetween.

[0058] Regardless of load measurement or load calculation, or calculation arrangement, and referring to FIG. 8, a method 800 for controlling the force on a stack of pouched battery cells includes the load measurement system obtaining the force from an end plate or a cell on the end plate (operation 802). If the force / pressure is calculated, the controller can not only calculate the pressure, but also control a motor or motors or other mechanisms that control the position of the plate. The system can include one or more forces to maintain the cells. In some examples, the force can be a function of other conditions such as state of charge, temperature, number of charge / discharge cycles, etc. Thus, the set force can vary during a charge / discharge cycle or over multiple cycles and can vary depending on the type of cell. Nevertheless, the system obtains the value or values of the force and controls the drive unit to maintain whatever the target force is (operation 804). Thus, for example, if the cells of a pack expand during a cycle, thereby pushing the end plate outward as a whole, an increasing force is detected. As that force increases, the plate or plates are moved outward to accommodate the expanding cells and the cells can be maintained at an appropriate force or within a range of forces for proper operation. Similarly, if the cells contract during the reverse cycle and the force from the current position of the plate decreases, the plate or plates are moved inward to maintain the pressure on the contracting cells. This method can include a feedback loop that moves the plate until the target force is achieved (e.g., repeatedly adjusting the plate position until a certain target force is achieved).

[0059] Each cell may be electrically coupled to other cells to form a series connection or a parallel connection, and / or may be coupled to a bus bar or other structure of the battery pack. Regardless of whether the cell is coupled to other cells, to a bus bar, or in some cases both, some adjustment is made to account for relative movement of the cells with respect to each other and with respect to the bus bar to which the cells may be electrically coupled. Thus, the cell tabs may have a length sufficient to accommodate movement, even if the tabs of adjacent cells are interconnected or the tabs are electrically connected to the bus bar by welding or other means. Alternatively, or additionally, wires or some form of conductor may be conductively coupled to the tabs of each cell and interconnected to adjacent tabs or bus bars as appropriate for the arrangement.

[0060] Figures 9A - 9D illustrate alternative arrangements of a battery pack. Referring first to Figure 9A, battery pack 900A includes two battery pressure modules 902, 904 of stacked cells 906 within each module. The battery cells here may be solid cells, as in other embodiments, or other cell types that gain an advantage by maintaining pressure on the cells. In the illustrated embodiment, each module includes fixed outer end plates 908, 910 and movably supported inner end plates 912, 914. The fixed end plates may be separate plates in various embodiments or the outer walls of the battery pack. Each of the inner movably attached plates faces each other with a drive unit 916 (or units) sandwiched therebetween. In contrast, the embodiments illustrated above other than the embodiment of Figure 5B can be considered to have a single battery pressure module with one or two movably controlled pressure (or force) plates that move relatively inward towards each other or outward away from each other to maintain an optimal pressure on the cells captured therebetween. In any case, in the embodiment of Figure 9A, the drive unit (or units) controllably drives each inner plate 912, 914 to maintain an appropriate force on the cells of each pressure module 902, 904.

[0061] In the illustrated example, it is possible to measure the force applied to the cells of one or both battery modules. If the number and type of cells are the same in each module, it can be assumed that the force required for each battery pressure module is the same. In any case, the system includes a force module or a plurality of force modules for obtaining the force on the cells. While the cells are expanding or contracting within their respective battery pressure modules, the motor can be controlled to maintain an appropriate force.

[0062] In the example shown in FIG. 9A, threaded collars 918 are coupled to each of the movable inner end plates 912, 914, and the threaded collars are axially aligned. A motor 916 is disposed with threaded motor drive shafts 920 extending from each side of the motor. The motor shafts are axially aligned with and dimensioned to engage each of the threaded collars. This screw cooperation is such that rotation of the motor shaft moves each end plate away from the motor, thereby maintaining an appropriate force as the cells contract, or draws the end plate toward the motor, thereby maintaining an appropriate force as the cells expand.

[0063] The motor may be of the pancake type. It is also possible to drive each inner plate with a respective motor. Additionally, it is possible to add a compression spring to supplement the force provided by the motor or motors. For example, the compression spring can be arranged between the motor and each inner plate. The spring can be arranged coaxially with the collar and the shaft. It is also possible to include a plurality of springs that engage each inner plate. Further, a central wall that is parallel to each inner plate and has dimensions and a shape similar to the inner plate can be provided. The spring can be provided between the central wall and each respective inner plate and is arranged at each corner. In various possible arrangements using a spring or a plurality of springs that engage each inner plate, the spring supplements the force applied to the inner plate provided by the motor or motors and cooperates with the motor. By using a spring, a portion of the overall force is provided by the spring, allowing a relatively small motor to be used. This combination also allows for the use of relatively lightweight springs compared to a system that uses only springs, and compensates for the variable force profile experienced throughout the compression range of the spring via the motor that controls the force. In one possible example, a spring is selected that provides a spring force smaller than the minimum required pressure on the inner plate. In such an arrangement, the spring does not overly compress the cell, and the motor takes into account the difference between the spring force and the force that needs to be applied to each stack to maintain proper operation. In such an arrangement, by using a smaller motor, less energy is used compared to an embodiment that uses only a motor.

[0064] FIG. 9B shows an alternative arrangement of a battery pack 900B that includes two cell pressure modules 902, 904 of cells stacked within each module. The cells here may be solid cells, as in other embodiments, or other cell types that gain an advantage by maintaining pressure on the cells. In the illustrated embodiment, each module includes fixed outer end plates 908, 910 and movably supported inner end plates 912, 914. The fixed end plates may be separate plates, or the outer walls of the battery pack, in various embodiments. The plates movably attached to each inner side face each other with a piston assembly 940 sandwiched therebetween.

[0065] The piston assembly may be any of a variety of possible pneumatic, hydraulic, electrical, electromagnetic, and other devices that controllably drive the piston rod 942 or the piston rod, including, but not limited to, linear actuators, stepper motor-driven linear actuators, pneumatic cylinders, piston actuators, double-acting actuators, etc. In the embodiment shown in FIG. 9B, the piston assembly can include two piston rods that are separately controlled to engage the adjacent plates of each module. The housing of the piston assembly may be equidistantly mounted between the opposing plates 912, 914, and the piston rods extend from the housing and engage the adjacent plates of the opposing modules. Alternatively, there may be a first piston assembly having an associated piston rod that engages the end plate of one module and a second, separate, piston assembly having an associated piston rod that engages the end plate of the opposing module. In another alternative, there may be two separate piston assemblies disposed at the outer end of one plate (e.g., plate 912) and two separate piston assemblies disposed at the outer end of the end plate of the opposing battery module (e.g., plate 914). In such an arrangement, the four piston assemblies are disposed in the space between the two battery modules (e.g., between modules 902 and 904). Such an arrangement can be used to size the piston assembly to minimize the space required between the modules, while at the same time providing the range of forces required for a given module pressure range. In such a case, even if perfect precise motor control is not achieved, the two motors can provide force at each corner while maintaining the parallel position of the end plates by means of the end plates attached to the respective guide rails to maintain the parallel position of the module and the cell, thereby maintaining an even pressure distribution throughout the cell. Nevertheless, precise and common force control can be used to control each motor that engages the plate.

[0066] In the alternative battery pack 900C shown in FIG. 9C, the housing 950 of the piston assembly 952 that supports the motor or other drive mechanism is coupled to one plate 912 and can be positioned such that the piston rod 942 engages the opposing plate 914. In such an arrangement, the piston assembly housing moves with the plate to which it is attached, and the extension or contraction of the piston rod increases or decreases the force applied to the plates of the respective modules, thereby increasing or decreasing the pressure on the cells within the respective modules. In such an arrangement, there is one control point for applying pressure to the two modules. The piston assembly of FIG. 9C is generally mounted along the centerline between the plates. In the alternative battery pack 900D shown in FIG. 9D, the system can include two piston assemblies 950 mounted on opposite ends of the end plate 912 and between the opposite ends of the end plate 912 in a state where the respective piston rods 942 engage respective end regions of the opposing plates 914 of the opposing modules 904. Such an arrangement contemplates the use of relatively smaller piston assemblies to provide a greater collective force, or can be used when, for example, considering space, a smaller piston assembly is beneficial but insufficient on its own to provide sufficient force. In such an arrangement, each piston assembly is synchronously controlled such that the forces at the ends of the plates are equal.

[0067] Referring to FIG. 10, a detailed description of an exemplary computing system 1000 having one or more computing units capable of implementing the various systems and methods discussed herein is provided. Computing system 1000 may be part of a controller, may communicate operably with the various implementations discussed herein, may perform various operations related to the methods or plural methods discussed herein, and may be part of the overall system discussed herein. System 1000 may be part of a battery management system (BMS), for example, when used with a pack deployed in a vehicle. Computing system 1000 can receive a measured value of force, or calculate force, or obtain other sensor readings related thereto, and can control the various motors and pumps described to maintain the pressure applied to the cell stack through charge and discharge cycles. Specific implementations of these devices may be different specific computing architectures, from controllers to more complex systems, may be individual systems, may be part of a larger integrated system responsible for various tasks such as a battery management system, and although not all are specifically discussed herein, will be understood by those skilled in the art. As will be understood by those skilled in the art, in such various possible embodiments, more or fewer of the components described below can be included, and interconnections and other changes can be made.

[0068] The computer system 1000 can be a computing system capable of executing a computer program product to execute a computer process. Data and program files may be input into the computer system 1000, and the computer system 1000 reads the files and executes the programs therein. Some of the elements of the computer system 1000 are shown in FIG. 10 and include one or more hardware processors 1002, one or more data storage devices 1004, one or more memory devices 1006, and / or one or more ports 1008-1012. Additionally, other elements that would be recognized by those skilled in the art may be included in the computing system 1000 but are not explicitly depicted in FIG. 10 or further discussed herein. The various elements of the computer system 1000 can communicate with each other by one or more communication buses, point-to-point communication paths, or other communication means not explicitly depicted in FIG. 10. Similarly, in various implementations, the various elements disclosed in the system may or may not be included in any given implementation.

[0069] The processor 1002 can include, for example, a central processing unit (CPU), a microprocessor, a controller, a microcontroller, a digital signal processor (DSP), a field programmable gate array (FPGA), an application specific integrated circuit (ASIC), and / or combinations thereof, and can include one or more internal levels of cache. There may be one or more processors 1002 such that the processor 1002 comprises a single processing unit or multiple processing units capable of executing different instruction sets and / or performing operations in parallel with each other, generally referred to as a parallel processing environment.

[0070] In various possible combinations, and particularly in relation to the control method, the techniques currently being described are at least partially implemented in software stored in the data storage device 1004, software stored in the memory device 1006, and / or software communicated via one or more of the ports 1008 - 1012, whereby the computer system 1000 of FIG. 10 is transformed into a special-purpose machine for performing the operations described herein.

[0071] One or more data storage devices 1004 can include any non-volatile data storage device capable of storing data generated or employed within computing system 1000, such as computer-executable instructions for executing computer processes, where the computer-executable instructions can include instructions for both application programs and an operating system (OS) that manages various components of computing system 1000. The data storage device 1004 can include, but is not limited to, magnetic disk drives, optical disk drives, solid state drives (SSDs), flash drives, etc. The data storage device 1004 can include removable data storage media, non-removable data storage media, and / or external storage devices made available via a wired or wireless network architecture, which can include such computer program products that include one or more database management products, web server products, application server products, and / or other additional software components. Examples of removable data storage media include compact disc read-only memory (CD-ROM), digital versatile disc read-only memory (DVD-ROM), magneto-optical discs, flash drives, etc. Examples of non-removable data storage media include built-in magnetic hard disks, SSDs, etc. One or more memory devices 1006 can include volatile memory (e.g., dynamic random access memory (DRAM), static random access memory (SRAM), etc.) and / or non-volatile memory (e.g., read-only memory (ROM), flash memory, etc.).

[0072] A computer program product including a mechanism for implementing a system and method in accordance with the techniques described herein can reside on a data storage device 1004 and / or a memory device 1006, which may be referred to as machine-readable media. A machine-readable media can include any tangible non-transitory media that can store or encode instructions for performing any one or more of the operations of the present disclosure for machine execution, or can be utilized by or associated with such instructions, or can store or encode data structures and / or modules associated with such instructions. It will be appreciated that a machine-readable media can include a single media or multiple media (e.g., a centralized or distributed database, and / or associated caches and servers) that store one or more executable instructions or data structures.

[0073] In some implementations, computer system 1000 includes one or more ports such as input / output (I / O) port 1008, communication port 1010, and subsystem port 1012 for communicating with other computing devices, network devices, or vehicle devices. It will be appreciated that ports 1008 - 1012 may be combined or separated, and that more or fewer ports may be included in computer system 1000. I / O port 1008 can be connected to an I / O device, or other device, through which information can be input to or output from computing system 1000. Such I / O devices can include, but are not limited to, one or more input devices, output devices, and / or environmental transducer devices.

[0074] In one implementation, the input device converts signals generated by a human, such as a human voice, physical movement, physical contact, or pressure, into electrical signals as input data to the computing system 1000 via the I / O port 1008. In some examples, such input may be different from the various systems and methods discussed with respect to the preceding figures. Similarly, the output device may convert the electrical signals received from the computing system 1000 via the I / O port 1008 into signals that can be sensed or used by the various methods and systems discussed herein. The input device may be an alphanumeric input device that includes alphanumeric and other keys for communicating information and / or command selections to the processor 1002 via the I / O port 1008.

[0075] The environmental transducer device converts one form of energy or signal into another for input to or output from the computing system 1000 via the I / O port 1008. For example, an electrical signal generated within the computing system 1000 can be converted into another type of signal and / or vice versa. In one implementation, the environmental transducer can include various possible sensors that measure force, load, pressure, or sense characteristics or aspects of the environment from local or remote of the computing device 1000, such as battery voltage, open circuit battery voltage, charging current, load current, battery temperature.

[0076] In one embodiment, communication port 1010 can be connected to a network, through which computer system 1000 can receive network data useful for executing the methods and systems described herein and can transmit the determined information and network configuration changes. For example, updates to the charging protocol, battery measurements or calculation data shared with an external system, etc. can be mentioned. Communication port 1010 connects computer system 1000 to one or more communication interface devices configured to transmit and / or receive information between computer system 1000 and other devices via one or more wired or wireless communication networks or connections. Examples of such networks or connections include, but are not limited to, Universal Serial Bus (USB), Ethernet, Wi-Fi®, Bluetooth®, Near Field Communication (NFC), Long-Term Evolution (LTE), etc. Such one or more communication interface devices can be utilized to communicate with one or more other machines via direct communication through a point-to-point communication path, communication via a wide area network (WAN) (e.g., the Internet), communication via a local area network (e.g., third generation (3G), fourth generation (4G), or fifth generation (5G)) network, or communication via another communication means through communication port 1010.

[0077] Computer system 1000 can include a subsystem port 1012 for communicating with one or more systems related to a device being charged according to the methods and systems described herein to control its operation and / or to exchange information between computer system 1000 and one or more subsystems of the device. Examples of such subsystems of a vehicle include, but are not limited to, motor controllers and systems, battery management systems, etc.

[0078] The system shown in FIG. 10 is one possible example of a computer system that may be employed or configured in accordance with aspects of the present disclosure. It will be understood that other non-transitory tangible computer-readable storage media storing computer-executable instructions for implementing the techniques of the present disclosure on a computing system may be utilized.

[0079] Embodiments of the present disclosure include various operations, which may also be referred to as steps as described herein. The operations may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the operations. Alternatively, the operations may be performed by a combination of hardware, software, and / or firmware.

[0080] Although various representative embodiments of the present invention have been described in some detail above, those skilled in the art can make numerous changes to the disclosed embodiments without departing from the spirit or scope of the subject matter of the present invention described herein. References to all directions (e.g., upper, lower, above, below, left, right, leftward, rightward, top, bottom, up, down, vertical, horizontal, clockwise, and counterclockwise) are used for identification purposes only to assist the reader's understanding of embodiments of the present invention and do not impose limitations, particularly on the position, orientation, or use of the present invention, unless specifically recited in the claims. References to coupling (e.g., attached, coupled, connected, etc.) should be construed broadly and may include intermediate members between the connection of elements and relative movement between elements. Thus, references to coupling do not necessarily infer that two elements are directly connected and in a fixed relationship to each other.

[0081] In some examples, components are described with reference to "ends" that have certain characteristics and / or are connected to other components. However, one of ordinary skill in the art will recognize that the present invention is not limited to components that terminate immediately beyond the connection point to other components. Thus, the term "end" should be broadly construed to include the region adjacent to, behind, in front of, or otherwise in the vicinity of the terminus of a particular element, link, component, member, etc. In the methods described directly or indirectly herein, the various steps and operations are described in one possible order of operation, but one of ordinary skill in the art will recognize that the steps and operations can be reconfigured, replaced, or deleted without necessarily departing from the spirit and scope of the present invention.

[0082] Without departing from the scope of the present invention, various modifications and additions can be made to the illustrated exemplary embodiments described. For example, the above-described embodiments, also referred to as implementation forms or examples, refer to specific features, but the scope of the present invention includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations together, and all equivalents thereof in all possible combinations of the various different features of the different embodiments combined to form further alternative embodiments.

[0083] Specific embodiments are described, but it should be understood that this is for illustrative purposes only. One of ordinary skill in the relevant art will recognize that other components and configurations can be used without departing from the spirit and scope of the present disclosure. Accordingly, the above description and drawings are illustrative and should not be construed as limiting. Numerous specific details are set forth to provide a complete understanding of the present disclosure. However, in some instances, well-known or conventional details are not described to avoid obscuring the description.

[0084] A reference to "one embodiment" or "an embodiment" means that the particular features, structures, or characteristics described in connection with the embodiment are included in at least one embodiment of the present disclosure. Although the phrases "in one embodiment," "in an example," or "in an illustration" may appear in various places throughout this specification, they are not necessarily all referring to the same embodiment, and separate or alternative embodiments are not mutually exclusive of other embodiments. Further, various features may be described that may be shown in one embodiment and not in others.

[0085] The terms used herein generally have their ordinary meaning within the context of the present disclosure and in the particular context in which each term is used. Alternative languages and synonyms may be used for any one or more of the terms described herein, and no special significance should be placed on whether a term is elaborated or described herein. In some cases, synonyms for particular terms are provided. The listing of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any of the terms discussed herein, is for illustrative purposes only and is not intended to further limit the scope or meaning of the present disclosure or of any example term. Similarly, the present disclosure is not limited to the various embodiments given herein.

[0086] Although not intended to limit the scope of the present disclosure, examples of apparatuses, devices, methods, and the results related thereto according to embodiments of the present disclosure are shown below. Note that, for the convenience of the reader, titles or subtitles may be used in various embodiments, but this should in no way limit the scope of the present disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning generally understood by one of ordinary skill in the art to which the present disclosure pertains. In case of conflict, the present specification, including definitions, will control.

[0087] The various features and advantages of the present disclosure are set forth in the foregoing description, some of which will be apparent from the description, or can be learned by practice of the principles disclosed herein. The features and advantages of the present disclosure can be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

Claims

1. A battery power management system, A first battery cell stack disposed between a first member and a second member, wherein the first member is movably mounted and positioned to apply force to the first battery cell stack; A battery power management system comprising a drive unit operably coupled to the first member, which moves the first member and applies a controllable force, wherein the drive unit is operably coupled to the first member via a threaded drive rod operably coupled to a corresponding threaded portion of the first member, moves the first member and applies a controllable force in response to a determination of the pressure applied to the first battery cell stack.

2. The battery power management system according to claim 1, wherein the determination of the pressure applied to the first battery cell stack is made based on a change in the size of the first battery cell stack during charging or discharging of the battery cells of the first battery cell stack.

3. The battery power management system according to claim 1, wherein the drive unit is configured to rotate a first threaded drive rod, move the first member, and apply a controllable force in response to the determination of the pressure during a change in the first battery cell stack.

4. A battery power management system according to claim 3, further comprising a second threaded drive rod, the second threaded drive rod being operably coupled to the drive unit for rotating the second threaded drive rod, wherein the second member is movably mounted and arranged to cooperate with the first member to apply force to the first battery cell stack, and each of the first threaded drive rod and the second threaded drive rod includes a first threaded portion and a second threaded portion, the first threaded portion being coupled to each first threaded portion of the first member, and the second threaded portion being coupled to each second threaded portion of the second member, causing the first member and the second member to move inward toward each other or outward toward each other, thereby applying force in a controllable manner in response to the determination of the pressure during a change in the size of the cell stack.

5. The battery power management system according to claim 3, wherein the drive unit comprises a planetary gear assembly having a planetary gear operably coupled to a drive rod and a sun gear that drives the planetary gear.

6. The battery power management system according to claim 5, wherein the drive unit further comprises a motor supporting a worm gear for driving the sun gear.

7. The battery power management system according to claim 3, wherein the drive unit comprises a belt-pulley system having a pulley coupled to the drive rod and a motor coupled to the pulley via a belt.

8. The battery power management system according to claim 7, wherein the motor is coupled to a movable member.

9. The battery power management system according to claim 1, wherein the first member is a first plate.

10. The battery power management system according to claim 9, wherein the first plate is a first box-shaped end plate.

11. The system further includes a second battery cell stack positioned between a third member and a fourth member, the third member being movably mounted and positioned to apply force to the second battery cell stack. The battery power management system according to claim 1, wherein the drive unit is positioned between the first battery cell stack and the second battery cell stack, and the drive unit is further operably coupled to the third member, which moves the third member and applies a controllable force to the second battery cell stack.

12. The battery power management system according to claim 11, wherein the drive unit is a motor configured to rotate a threaded shaft which cooperates with a first threaded portion of the first member and a third threaded portion of the third member, thereby moving the first member toward or toward the second member, and moving the third member toward or toward the fourth member, thereby applying a controllable force to the first battery cell stack and applying a controllable force to the second battery cell stack.

13. The battery power management system according to claim 1, further comprising a load unit arranged to determine the pressure applied to the first battery cell stack.

14. The battery power management system according to claim 1, wherein the first battery cell stack comprises solid pouch cells.

15. The battery power management system according to claim 1, wherein the drive unit comprises a motor that drives a threaded shaft operably coupled to a threaded opening of the first member, and the rotation of the threaded shaft moves the first member and applies force to the first battery cell stack.

16. The battery power management system according to claim 1, wherein the drive unit comprises a piston rod and an actuator, the piston rod being coupled to the first member, and moving the first member to apply force to the first battery cell stack.

17. The system further comprises a second battery cell stack positioned between a third member and a fourth member, the third member being movably mounted and positioned to apply force to the second battery cell stack. The battery power management system according to claim 16, wherein the actuator is coupled to the third member of the second battery cell stack, and the operation of the piston rod moves both the first member and the third member to control the force applied to the first battery cell stack and the force applied to the second battery cell stack.

18. A method for controlling the battery cell stack pressure, Accessing values ​​that indicate the pressure of multiple battery cells; A method comprising controlling a drive unit to change the position of at least one member operably engaged with the plurality of battery cells in response to a pressure-indicating value, wherein the change in the position of the at least one member changes the pressure, and the drive unit is operably coupled to the first member via a threaded drive rod which is operably coupled to a corresponding threaded portion of the first member.

19. The method according to claim 18, wherein the plurality of battery cells comprises a plurality of solid pouch cells, and each of the plurality of solid pouch cells changes its volume in response to charging or discharging.

20. The method according to claim 19, wherein the change in position of the at least one member operably engaged with the plurality of solid pouch cells maintains a predetermined pressure on the plurality of solid pouch cells while the volume changes in response to charging or discharging.

21. The method according to claim 19, wherein the at least one member is a plate that operably contacts at least one solid pouch cell among the plurality of battery cells, and changing the position of the plate adjusts the force applied to the plurality of battery cells.

22. The method according to claim 18, wherein the pressure value is a force measurement value.

23. The method according to claim 19, wherein the value of the pressure changes during charging and discharging of the solid pouch cell.

24. The method according to claim 18, wherein the pressure value is a sensor measurement value indicating the force applied to the at least one member.

25. The method according to claim 18, wherein the at least one member comprises a first plate and a second plate, the first plate and the second plate being controllably movable with respect to the plurality of battery cells, and the plurality of battery cells being arranged between the first plate and the second plate such that the relative movement of at least one of the first plate or the second plate adjusts the force on the plurality of battery cells.

Images