Battery Module and Battery Module Stack

Abstract

Battery modules and intermediate modules for use together within a module stack enable a flexible electrical configuration of the stack. The battery module has a plurality of conductive paths extending between its top and bottom surfaces, with one of the paths connected in series with the cells of the module and at least one of the other paths functioning as a pass-through that enables power or communication to pass through the module. The intermediate module further includes a pass-through electrical path that routes power or communication from one of the battery modules on one of the top and bottom surfaces of the intermediate module to the pass-through path of the battery module on the other of the top and bottom surfaces of the intermediate module. This enables the modules within the stack to be electrically connected within different series connection groups.

Description

Cross - reference to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 17 / 865,330, filed on July 14, 2022, the entire content of which is incorporated herein by reference.

Technical Field

[0002] The present disclosure relates to battery modules and battery module stacks comprising a plurality of battery modules.

Background Art

[0003] One type of rechargeable battery is a lithium - ion battery having a multi - layer structure comprising a positive electrode activated by various mixed oxides or olivines, a negative electrode activated by special carbon, and a separator, all of which are immersed in an organic electrolyte. The battery is typically housed in a housing to form a battery module. During normal operation, during charging, electrical energy is converted into chemical energy and stored as chemical energy, and during discharging, the stored chemical energy is converted into electrical energy. More specifically, during charging, lithium in the positive electrode is ionized and moves from layer to layer to the negative electrode, and during discharging, the ions move to the positive electrode and return to their original compounds. A plurality of lithium - ion battery modules can be attached to a rack assembly together with a control module for controlling the battery modules to form a battery pack.

[0004] For storing and transporting interconnected battery modules, various different types of racks can be used. In its simplest form, a rack can comprise a frame structure with several bays into which battery modules are inserted. Then, power lines and cooling lines can be connected to the battery modules. In another variant, the rack can include a backplane for housing power connections. The battery modules are inserted into the bays and plugged directly into the backplane with their power connectors at the back of the module.

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, generally, the use of a rack complicates the battery pack. For example, using a rack to accommodate battery modules increases the number of components forming the battery pack and increases the manufacturing cost of the pack. In addition, in a rack employing a backplane, alignment problems may easily occur between the power connectors of the battery modules and the power lines of the backplane.

[0006] Therefore, there is still a need in the art to provide a battery module that enables easier and more efficient storage and transportation of a plurality of interconnected battery modules.

Means for Solving the Problems

[0007] According to a first aspect, there is provided a battery module comprising a housing having opposing upper and lower surfaces, battery cells housed within the housing and electrically connected to each other, a first upper electrical contact and a second upper electrical contact located on the upper surface, a first lower electrical contact and a second lower electrical contact located on the lower surface, and a first conductive path and a second conductive path each terminating at the first upper electrical contact and the first lower electrical contact and the second upper electrical contact and the second lower electrical contact, wherein the first conductive path is electrically connected in series to the battery cells.

[0008] The battery module may further comprise a third upper electrical contact located on the upper surface, a third lower electrical contact located on the lower surface, and a third conductive path terminating at the third upper electrical contact and the third lower electrical contact.

[0009] The battery module may further comprise a fourth upper electrical contact located on the upper surface, a fourth lower electrical contact located on the lower surface, and a fourth conductive path terminating at the fourth upper electrical contact and the fourth lower electrical contact.

[0010] The housing can be conductive, and the battery module can further include a fifth upper electrical contact located on the upper surface, and each of the fifth upper electrical contact and the fifth lower electrical contact is electrically connected to the housing.

[0011] The battery module can further include a fifth conductive path that terminates at the fifth upper electrical contact and the fifth lower electrical contact.

[0012] The battery module can further include a male connector on one of the upper and lower surfaces of the module and a female connector on the other of the upper and lower surfaces of the module, and at least one of the upper electrical contacts terminates at a connector on the upper surface of the module, and at least one of the lower electrical contacts terminates at a connector on the lower surface of the module.

[0013] All of the upper electrical contacts may terminate at a connector on the upper surface of the module, and all of the lower electrical contacts may terminate at a connector on the lower surface of the module.

[0014] According to another aspect, there is provided an intermediate module that, when stacked between an upper battery module and a lower battery module, electrically connects the upper battery module as described in any one or more of the above aspects to the lower battery module as described in any one or more of the above aspects. The intermediate module includes a housing having opposing upper and lower surfaces, a first upper electrical contact and a second upper electrical contact located on the upper surface, a first lower electrical contact and a second lower electrical contact located on the lower surface, a first conductive path terminating at the first upper electrical contact and the first lower electrical contact, and a second conductive path terminating at the second upper electrical contact and the second lower electrical contact. The first upper electrical contact of the intermediate module is positioned to contact the first lower electrical contact of the upper battery module, the first lower electrical contact of the intermediate module is positioned to contact the third upper electrical contact of the lower battery module, the second upper electrical contact of the intermediate module is positioned to contact the second lower electrical contact of the upper battery module, and the second lower electrical contact is positioned to contact the fourth upper electrical contact of the lower battery module. The intermediate module may include battery cells electrically connected in series as part of the first conductive path.

[0015] The intermediate module may further include a third lower electrical contact and a fourth lower electrical contact located on the lower surface, and a third conductive path terminating at the third lower electrical contact and the fourth lower electrical contact. The third lower electrical contact of the intermediate module is positioned to contact the first upper electrical contact of the lower battery module, and the fourth lower electrical contact of the intermediate module is positioned to contact the second upper electrical contact of the lower battery module.

[0016] The intermediate module may further include a male connector on one of the upper and lower surfaces of the intermediate module and a female connector on the other of the upper and lower surfaces of the intermediate module. At least one of the upper electrical contacts of the intermediate module terminates at a connector on the upper surface of the intermediate module, and at least one of the lower electrical contacts of the intermediate module terminates at a connector on the lower surface of the intermediate module.

[0017] All of the upper electrical contacts of the intermediate module may terminate at connectors on the upper surface of the intermediate module, and all of the lower electrical contacts of the intermediate module may terminate at connectors on the lower surface of the intermediate module.

[0018] According to another aspect, an upper battery module as described in any one or more of the above aspects, a lower battery module as described in any one or more of the above aspects, and an intermediate module stacked between the upper battery module and the lower battery module, the intermediate module having a housing with opposing upper and lower surfaces, a first upper electrical contact and a second upper electrical contact located on the upper surface, a first lower electrical contact and a second lower electrical contact located on the lower surface, a first conductive path terminating at the first upper electrical contact and the first lower electrical contact, and a second conductive path terminating at the second upper electrical contact and the second lower electrical contact, wherein the first upper electrical contact of the intermediate module is positioned to contact the first lower electrical contact of the upper battery module, the first lower electrical contact of the intermediate module is positioned to contact the third upper electrical contact of the lower battery module, the second upper electrical contact of the intermediate module is positioned to contact the second lower electrical contact of the upper battery module, and the second lower electrical contact is positioned to contact the fourth upper electrical contact of the lower battery module. A battery module stack comprising the intermediate module is provided. The intermediate module may include battery cells electrically connected in series as part of the first conductive path.

[0019] The intermediate module may further include a third lower electrical contact and a fourth lower electrical contact located on the lower surface, and a third conductive path terminating at the third lower electrical contact and the fourth lower electrical contact, wherein the third lower electrical contact of the intermediate module is positioned to contact the first upper electrical contact of the lower battery module, and the fourth lower electrical contact of the intermediate module is positioned to contact the second upper electrical contact of the lower battery module.

[0020] The intermediate module may further include a male connector on one of the upper and lower surfaces of the intermediate module and a female connector on the other of the upper and lower surfaces of the intermediate module. At least one of the upper electrical contacts of the intermediate module terminates at a connector on the upper surface of the intermediate module, and at least one of the lower electrical contacts of the intermediate module terminates at a connector on the lower surface of the intermediate module.

[0021] All of the upper electrical contacts of the intermediate module may terminate at connectors on the upper surface of the intermediate module, and all of the lower electrical contacts of the intermediate module may terminate at connectors on the lower surface of the intermediate module.

[0022] According to another aspect, there is provided a battery module including a housing, battery cells housed in the housing and electrically connected to each other, first electrical contacts and second electrical contacts located on a first surface of the housing, first electrical contacts and second electrical contacts located on a second surface of the housing, and first conductive paths and second conductive paths terminated at the first electrical contacts and the second electrical contacts respectively, wherein the first conductive paths are electrically connected in series to the battery cells.

[0023] The first surface of the housing may be an upper surface, the first electrical contacts and the second electrical contacts located on the first surface of the housing may be a first upper electrical contact and a second upper electrical contact, the second surface of the housing may be a lower surface, and the first electrical contacts and the second electrical contacts located on the lower surface of the housing may be a first lower electrical contact and a second lower electrical contact.

[0024] This summary is not necessarily intended to describe the entire scope of all aspects. Other aspects, features, and advantages will become apparent to those skilled in the art upon consideration of the following description of specific embodiments. Embodiments of the present disclosure will be described below in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0025]

Figure 1

Figure 2

Figure 3

Figures 4A-D

Figure 5

Figure 6A

Figure 6B

Figure 6C

Figure 7

Figure 8

Figures 9A-C

Figure 10A

Figures 10B-D

DETAILED DESCRIPTION OF THE INVENTION

[0026] The present disclosure aims to provide an improved battery module and battery pack. Although various embodiments of the present disclosure will be described below, the present disclosure is not limited to these embodiments, and variations of these embodiments can be fully included within the scope of the present disclosure that should be limited only by the appended claims.

[0027] The term "a" or "an" can mean "one" when used in conjunction with the terms "comprising" or "including" in the claims and / or the specification, but also, unless the context clearly dictates otherwise, is consistent with the meaning of "one or more", "at least one", and "one or two or more". Similarly, the term "another" can mean at least a second or more, unless the context clearly dictates otherwise.

[0028] As used herein, the terms "coupled", "coupling", or "connected" can have several different meanings depending on the context in which these terms are used. For example, the terms "coupled", "coupling", or "connected" can have a mechanical or electrical connotation. For example, as used herein, the terms "coupled", "coupling", or "connected" can indicate that two elements or devices are directly connected to each other, or are connected to each other through one or more intermediate elements or devices via electrical elements, electrical signals, or mechanical elements, depending on the particular context. As used herein, the term "and / or" when used in connection with a list of items means any one or more of the items in that list.

[0029] As used herein, "about" or "approximately" a number, or when a number is "substantially" equal to a certain number, means within + / - 10% of that number.

[0030] In the following, a battery module generally refers to a housing that houses a plurality of interconnected battery cells. The battery cells form one or more battery cell stacks (which may also be referred to as battery cell strings). A plurality of stacked battery modules generally form a battery module stack (or simply a module stack). When one or more battery modules are connected to a pack controller, the combination of the battery module(s) and the module controller generally forms a battery pack. The pack controller can be stacked together with the battery module stack or can be located outside the module stack.

[0031] Returning to FIG. 1, a battery module stack 100 according to an embodiment of the present disclosure is shown. The module stack 100 is formed in a stacked arrangement of different components. In particular, the module stack 100 includes a module stack base 10 at its lower part, a stack of interconnected battery modules 50 stacked on top of the module stack base 10, and a module stack cover 80 positioned at the top of the module stack 100 directly adjacent to the topmost battery module 50. The module stack 100 is stacked on the interface base 95 such that the module stack base 10 engages with the upper surface of the interface base 95. It will be understood by those skilled in the art that the present disclosure extends to battery packs having any number of stacked battery modules and any number of columns of stacked battery modules. Further, in some embodiments, the module stack may be formed without using the module stack cover 80 and / or without using the module stack base 10. Thus, in some embodiments, the module stack may be composed of only one or more columns of stacked battery modules.

[0032] The installation area of the module stack 100 is approximately the same as the installation area of a standard-sized pallet. In particular, the installation area of the module stack 100 is approximately the same as that of a standard EUR2 European-sized pallet (e.g., 1,200 × 1,000 × 144 millimeters) as defined by the European Pallet Association, but as will be appreciated by those skilled in the art, the present disclosure extends to module stacks having any other suitable installation area size.

[0033] Referring to FIGS. 2 and 3, top and bottom views of the battery module 50 are shown. The battery module 50 includes a pair of cell housings 52a, 52b that respectively house battery cell stacks (not shown). Cooling fins 53 are provided on the left, right, and bottom surfaces of the cell housings 52a, 52b that extend in a direction away from the battery module 50 to promote heat transfer from the inside of the cell housings 52a, 52b to the outside of the battery module 50.

[0034] An exhaust assembly including a pair of exhaust channels 57a, 57b is provided on the back surface of the battery module 50. The exhaust channels 57a, 57b extend from exhaust holes formed in the bottom and top surfaces of the battery module 50. Accordingly, the exhaust channels 57a, 57b extend from the bottom surface to the top surface of the battery module 50. The exhaust channels 57a, 57b are used to convey exhaust gas that may be formed within the cell housings 52a, 52b (e.g., in response to one or more of the battery cell stacks undergoing thermal runaway) away from the battery module 50. In particular, each exhaust channel 57a, 57b is fluidly coupled to the inside of one of the cell housings 52a, 52 such that exhaust gas emitted from one of the battery cell stacks within the cell housings 52a, 52b can be directed in a direction away from the battery module 50.

[0035] Between the cell casings 52a and 52b, a cooling assembly having a cooling channel 56 extends. The cooling channel 56 extends from cooling holes formed in each of the lower and upper surfaces of the battery module 50. Accordingly, the cooling channel 56 extends from the lower surface of the battery module 50 to the upper surface of the battery module 50. The cooling channel 56 is used to convey a cooling fluid between the cell casings 52a and 52b. The cooling channel 56 extends substantially along the entire length of the cell casings 52a and 52b and is separated from the exhaust channels 57a and 57b by a physical interface so that the cooling fluid flowing through the cooling channel 56 does not mix with the exhaust gas 57 flowing through the exhaust channels 57a and 57b. The cooling fluid may include, for example, a coolant, a forced air flow (e.g., cold air forced upward or downward through the battery module 50 via the cooling channel 56), or a passive air flow (e.g., air flowing through the battery module 50 via the cooling channel 56 by natural convection).

[0036] When two or more such battery modules 50 are stacked, the cooling channel 56 of one battery module 50 is aligned with the cooling channel 56 of an adjacent battery module 50. Also, the exhaust channels 57a and 57b of one battery module 50 are aligned with the exhaust channels 57a and 57b of an adjacent battery module 50.

[0037] In some embodiments, the exhaust channels 57a and 57b and the cooling channel 56 may be located at other locations on the battery module 50. For example, the cooling channels may be provided along each side surface of the battery module 50 extending away from the battery module 50. As another example, the battery module 50 may include a single exhaust channel useful for both of the cell casings 52a and 52b. Those skilled in the art will recognize that any number of cooling channels and exhaust channels may be included within the battery module 50 and that the number can be varied according to the desires of those skilled in the art provided that the cooling channel(s) and the exhaust channel(s) extend through the battery module 50 from one side surface of the battery module 50 to another side surface of the battery module 50.

[0038] Module 50 has several male or female self - locking members 59. The self - locking members 59 are configured to engage or fit with corresponding self - locking members 51 provided on the lower surface of another battery module 50. Each self - locking member 51 has a tapered portion to facilitate engagement with the mating self - locking member 59 of an adjacent battery module 50. The tapered portion allows for a certain tolerance deviation between the battery modules 50 so that they can be more easily "self - aligned" when the battery modules 50 are engaged with each other.

[0039] Power connectors 83 are provided one each on the upper and lower surfaces of the battery module 50 in front of it. The power connectors 83 include a pair of conductive pins and a ground connection part. The conductive pins can be retractable as described in relation to the power pins 67 of FIGS. 24A and 24B. Each power connector 83 has a tapered portion to facilitate engagement with the power connector 83 of an adjacent battery module 50. Thus, the male power connector 83 on the upper part of the battery module 50 has a tapered portion to facilitate engagement with the tapered female power connector 83 on the lower surface of the adjacent upper battery module 50. The tapered portion allows for a certain tolerance deviation between the battery modules 50 so that they can be more easily "self - aligned" when the battery modules 50 are engaged with each other.

[0040] In conjunction with the tapered portions of one or both of the male and female power connectors 83, the power connector 83 can "float" with respect to the cell housings 52a, 52b, and additional tolerance can be formed when the power connector 83 of the battery module 50 is mated with the power connector 83 of an adjacent battery module.

[0041] Returning to FIGS. 4A - 4D, various exemplary methods for interconnecting the battery modules 50 of the battery module stack 100 are shown.

[0042] Figure 4A shows a battery pack 200 in which a pack controller 202 is integrated with a module stack 100. In particular, Figure 4A shows a first left column 206 of battery modules positioned adjacent to a right column 208 of battery modules on the right side of the battery module. The orientation of the battery modules in the right column 208 is reversed with respect to the orientation of the battery modules in the left column 206, and the power connection parts of one column are provided adjacent to the power connection parts of the other column, thereby minimizing the electrical path length of the string of battery modules.

[0043] Figure 4B shows an alternative exemplary configuration having a single column of interconnected battery modules. A return conduction path 210 is provided to return from the cover 212 to the pack controller 202. Figure 4C shows another similar configuration having a single column of interconnected battery modules. However, each battery module 50 includes two adjacent stacks of battery cells (similar to the embodiment of Figure 2). Figure 4D shows a configuration identical to that of Figure 4C except that a wireless communication transceiver or module 214 is used to enable communication between the battery modules instead of an optical communication port. As described above, a wired connection may be used instead for communication.

[0044] Figure 5 shows an alternative configuration including a plurality of module stacks 100 and a single pack controller 202 configured to control the module stacks 100. Each battery module includes two battery cell stacks. The return conduction path 210 connects the top of each module stack 100 to an interface base 95, and then the electrical path is directed to the pack controller 202. A wireless communication transceiver or module 214 is used to provide communication between the battery modules 50. In some embodiments, two or more module stacks 100 are connected in series before being connected to the pack controller 202, thereby improving the configurability of the height and installation area of the battery pack. Split stack

[0045] Referring now to FIGS. 6A and 6B, there are shown exemplary schematic views of battery module 50 and intermediate module 612, which can be used to assemble an assembly of battery module stack 100 that collectively has a higher energy density than a similar assembly of battery module stack 100 assembled without using intermediate module 612.

[0046] Module 50 of FIG. 6A includes a module housing 614 (shown in FIG. 7). In at least some embodiments, housing 614 includes cell housings 52a, 52b and a module chassis, which supports cell housings 52a, 52b and functions as the front wall, rear wall, left side wall, and right side wall of housing 614, as shown in FIG. 7. An upper power connector 83a is provided on the upper surface of housing 614, and a lower power connector 83b is provided at a corresponding position on the lower surface of housing 614. One of upper power connector 83a and lower power connector 83b is a male connector, and the other of upper power connector 83a and lower power connector 83b is a female connector. This allows a plurality of modules 50 to be stacked on top of each other, such that with a second module 50 placed on top of a first module 50, the upper power connector 83a of the first module 50 mates with the lower power connector 83b of the second module 50.

[0047] The upper power connector 83a of the module 50 in FIG. 6A includes first to fifth upper electrical contacts 604a to 604e, which are each connected in series with first to fifth lower electrical contacts 606a to 606e that form part of the lower power connector 83b via first to fifth conductive paths 608a to 608e. Accordingly, the first to fifth conductive paths 608a to 608e each terminate at the first to fifth upper electrical contacts 604a to 604e and the first to fifth lower electrical contacts 606a to 606e. The first conductive path 608a is in series with a battery cell 602 that forms part of the module 50. The fifth conductive path 608b and electrical contacts 604e, 608e are for joining the housing 614 of the module 50 together to reduce the risk of electric shock. Accordingly, the housing 614 is conductive and is short-circuited to the fifth conductive path 608b and electrical contacts 604e, 606e. In at least some different exemplary embodiments, the connectors 83a, 83b may include different combinations of electrical contacts. For example, the connectors 83a, 83b may include a ground electrical contact connected to ground and one or both of the contacts used for wired communication between modules 50, and these contacts may be added to or alternatively used in place of at least some of the first to fifth upper electrical contacts 604a to 604e and lower electrical contacts 606a to 606e.

[0048] Accordingly, the second to fourth conductive paths 608b to 608d may function as bypass paths to allow power and / or signals to pass through the module 50. These conductive paths 608b to 608d are shown as electrical shorts in FIG. 6A, but in at least some different exemplary embodiments, a circuit having a non-zero impedance may be disposed along one or more of the conductive paths 608b to 608d.

[0049] FIG. 7 is a front perspective view of an exemplary embodiment of module 50 with the rear plate of module 50 removed to show the electrical connections below. In FIG. 7, upper power connector 83a and lower power connector 83b are visible. In contrast to the exemplary embodiment of module 50 shown in FIG. 6A, in FIG. 7, the fifth upper electrical contact 604e and the lower electrical contact 606e do not comprise a part of the power connectors 83a, 83b. Rather, the fifth upper electrical contact 604e and the lower electrical contact 604e are replaced by conductive bond pins 616 directly connected to the housing 614 of module 50. When two of the modules 50 are stacked, the bond pins 616 on the lower surface of the upper module of the modules 50 are received by corresponding receptacles 617 on the upper surface of the other module of the modules 50, thereby positioning the housings 614 to be electrically shorted together.

[0050] An exemplary embodiment has first to fourth upper electrical contacts 604a - 604d located within the upper power connector 83a within module 50 of FIG. 7, and first to fourth lower electrical contacts 606a - 606d located within the lower power connector 83a. The second to fourth conductive paths 608a - 608d are busbars that directly connect the second to fourth upper electrical contacts 604b - 604d and lower electrical contacts 606b - 606d, respectively. In FIG. 7, only a part of the first conductive path 608a is visible. This visible part includes a first busbar that extends downward from the first upper electrical contact 604a, is fixed adjacent to one of the cell housings 52a, and connects to the cell 602 within the cell housing 52a, a second busbar that extends horizontally and connects the cells 602 within the two cell housings 52a, 52b to each other, and a third busbar that is fixed adjacent to the other of the cell housings 52b and connects the cell 602 within the cell housing 52b to the first lower electrical contact 606a. Thus, the first conductive path 608a connects the first upper electrical contact 604a and the lower electrical contact 606a to the battery cells 602 within the cell housings 52a, 52b.

[0051] The intermediate module 612 in FIG. 6B has a housing 614, an upper power connector 83a and a lower power connector 83b, first to fifth upper electrical contacts 604a to 604e, and first to fifth lower electrical contacts 606a to 606e similar to those shown in the module 50 of FIG. 6A. However, the intermediate module 612 in FIG. 6B has only four conductive paths 608a to 608d instead of the five conductive paths 608a to 608e that the module 50 in FIG. 6A has. The first conductive path 608a connects the first upper electrical contact 604a on the upper surface of the intermediate module 612 in series with some cells and then in series with the third conductive path 608c, and terminates at the first lower electrical contact 606a on the lower surface of the intermediate module 612.

[0052] The fourth conductive path 608d terminates at a second upper electrical contact 604b on the upper surface of the intermediate module 612 and a second lower electrical contact 606b on the lower surface of the intermediate module 612. The first upper electrical contact 604a, the second upper electrical contact 604b, the first lower electrical contact 606a, and the second lower electrical contact 606b are positioned such that when the intermediate module 612 is stacked between a first module 50 (on the upper surface of the intermediate module 612) and a second module 50 (on the lower surface of the intermediate module 612) of the type shown in FIG. 6A, the first lower electrical contact 606a of the first module 50 contacts the first upper electrical contact 604a of the intermediate module 612, the first lower electrical contact 606a of the intermediate module 612 contacts the third upper electrical contact 604c of the lower module 50, the second lower electrical contact 606b of the first module 50 contacts the second upper electrical contact 604b of the upper module 50, and the second lower electrical contact 606b of the intermediate module contacts the fourth upper electrical contact 604d of the lower module 50. As a result, by using the intermediate module 612, the first conductive path 602a (in series with the cell 602) of the first module 50 is routed to the third conductive path 608c of the lower module 50. When the first module 50 is placed directly on top of the second module 50, the first conductive path 604a of the first module 50 and the first conductive path 604a of the second module 50 are in series. Similarly, by using the intermediate module 612, the second conductive path 608b of the first module 50 is routed to the fourth conductive path 608d of the second module 50. When the first module 50 is placed directly on top of the second module 50, the second conductive path 604b of the first module 50 and the second conductive path 604b of the second module 50 are in series. This rerouting of the paths makes it possible to increase the power density when the modules 50, 612 are deployed, as will be further explained below. Similar to the module 50 of FIG. 7, busbars may be used for the conductive paths 608a - 608e of the intermediate module 612.

[0053] FIG. 6C shows three stacks 100, namely, a left stack 100, a central stack 100, and a right stack 100. Each of the stacks 100 is placed on an interface base 95 and covered by a module stack cover 80. Each of the left stack and the right stack includes four modules 50 of FIG. 6A stacked between the interface base 95 and the cover 80. The central stack includes four modules 50 of FIG. 6A and one intermediate module 612 of FIG. 6B. The intermediate module 612 is located at the center of the stack 100, with two modules 50 of FIG. 6A located between the intermediate module 612 and the cover 80, and the other two modules 50 of FIG. 6A located between the intermediate module 612 and the base 95. Each of the covers 80 includes a return path 210 that connects a first conductive path 604a to a second conductive path 604b of the module 50 on which the cover 80 is placed.

[0054] The first conductive path 608a of the left stack 100 and the second conductive path 608b of the right stack 100 are connected to an electrical load (not shown) via the first wire 618a and the fourth wire 618d. Similarly, the first conductive path 608a and the fourth conductive path 608d of the lowermost module 50 of the central stack 100 are connected to an electrical load (not shown) via the second wire 618b and the third wire 618c. The second conductive path 608b of the left stack 100 is connected to the third conductive path 608c of the lowermost module 50 within the central stack via the fifth wire 618e. The second conductive path 608b of the lowermost module 50 of the central stack 100 is connected to the first conductive path 608a of the right stack 100 via the wire 618f. The intermediate module 612 in the center of the central stack 100 reroutes the first conductive path 608a and the second conductive path 608b of the upper two modules 50 of the central stack 100 such that they are electrically in series with the left stack 100, in contrast to the lower two modules 50 of the central stack 100. As a result, the left stack 100 and the upper two modules 50 of the central stack 100 are connected in series, and the right stack 100 and the lower two modules 50 of the central stack are connected in series, whereby two stacks 100 of six modules 50 in series become available for one or more electrical loads (not shown). When the intermediate module 612 is replaced with another module 50 of FIG. 6A, FIG. 6C results in a configuration of two stacks 100 of four modules 50 and one stack 100 of five modules 100.

[0055] Figures 9A - 9C show various exemplary configurations that are possible using the combination of module 50 of FIG. 6A and module 612 of FIG. 6B. FIG. 9A shows three stacks 100 electrically connected using an intermediate module 612 in the center of the central stack 100, which form two groups of twelve modules 50 connected in series respectively, and the central stack 100 is divided such that four of its modules 50 are grouped with eight modules 50 of the left - hand stack 100 and four of its modules 50 are grouped with eight modules 50 of the right - hand stack 100. FIG. 9B shows a similar configuration where three stacks 100 are electrically connected together using an intermediate module 612 in the center of the central stack 100, forming two groups of thirteen modules connected in series respectively, and the central stack 100 is again divided. FIG. 9C shows a similar configuration used to form two groups of fourteen modules 50 each.

[0056] As shown in FIGS. 9A - 9C, the intermediate module 612 does not necessarily have the same dimensions as the module 50 of FIG. 6A.

[0057] FIG. 8 shows another exemplary configuration that is possible using the combination of module 50 of FIG. 6A and module 612 of FIG. 6B. In FIG. 8, the intermediate module 612 is located at various positions within multiple stacks 100 such that different numbers of modules 50 can be grouped together in series. In the exemplary configuration of FIG. 8, by placing the intermediate module 612 directly above the second - from - the - bottom module 50 (the second - from - the - left stack 100), the fifth - from - the - bottom module 50 (the third - from - the - left stack 100), and the eighth - from - the - bottom module 50 (the third - from - the - left stack), three groupings of twelve modules 50 in series and one grouping of ten modules 50 in series are made possible for a maximum height of 2.75 m.

[0058] Figures 10A to 10D show an exemplary configuration of stack 100 in which the intermediate module 612 is used (Figure 10A) and a comparative configuration in which the intermediate module 612 is omitted (Figures 10B to 10D). In each of Figures 10A to 10D, stack 100 is assumed to have a length L and a height H. The length L and the height H are not necessarily the same for each of the different configurations. Stack 100 is connected to a pack controller 202 having a length of 0.8 m. Stack 100 is placed on a base having a height of 0.50 m that functions as an air plenum for stack 100, covered by a stack cover 80 of 0.4 m, and the stack requires a gap of 0.7 m above the cover 80.

[0059] Each of the configurations in Figures 10A to 10D represents eight groups of modules 50 in series, as labeled in these figures. However, their physical arrangements and the number of modules 100 in each of the stacks 100 are different. Each of the groups in the configuration of Figure 10A (the "3S split stack configuration") is formed using 1.5 modules 50 of stack 100, and stack 100 is split using an intermediate module 612 as needed. In contrast, each of the groups in the configuration of Figure 10B (the "2S standard stack configuration") is formed from two complete modules 50 of stack 100 in series, each of the groups in the configuration of Figure 10C (the "3S standard stack configuration") is formed from three complete modules 50 of stack 100 in series, and each of the groups in the configuration of Figure 10D (the "4S standard stack configuration") is formed from four complete modules 50 of stack 100 in series.

[0060] The main advantage of the split stack configuration is that by decoupling the system voltage and the number of modules from the height of the installation system, flexibility is obtained to better fill any given installation location. This allows the modules connected in series to be placed in adjacent stacks. This facilitates the efficient use of limited space that may be available for battery storage (e.g., on a ship).

[0061] In at least some exemplary embodiments, the conductive paths 608a-608e can be connected to switches that allow a single module 50, 612 to operate in different states. For example, a single module can operate as a battery module 50 when its switch is in a first state and as an intermediate module 612 when its switch is in a second state. More generally, one or both of the modules 50, 612 can include one or more switches that can route any one or more of the electrical contacts 602a-602e, 604a-604e to any other one or more of the electrical contacts 602a-602e, 604a-604e.

[0062] Further, while the above exemplary embodiments show the electrical contacts 602a-602e, 604a-604e disposed on the top and bottom surfaces of the modules 50, 612, in at least some exemplary embodiments, one or more of the electrical contacts 602a-602e, 604a-604e can be disposed on one or more different sides (e.g., left side, right side, front, or back) of the modules 50, 612. This allows the modules 50, 612 to be arranged and connected horizontally in a room rather than stacked. These horizontal connections can be made using the bottom-most modules 50, 612 (i.e., near the floor) or between any higher modules 50, 612.

[0063] In the figures, the battery module 50 and the intermediate module 612 are shown as separate modules. In at least some different exemplary embodiments, the modules 50, 612 can be combined within the same housing such that a single module has the functions of both the above-described battery module 50 and intermediate module 612.

[0064] Conductive paths 608a - 608e and / or additional conductive paths not shown in the figures are described in relation to conducting power through modules 50, 612, but additionally or alternatively, may be used to conduct other digital or analog signals. These signals may be used, for example, to communicate between modules 50, 612 and pack controller 202. Modules 50, 612 may simply relay, passively convey, or conduct a digital or analog signal received from one of modules 50, 612 to another of modules 50, 612 using the conductive paths. Alternatively, modules 50, 612 may include circuitry to relay and / or switch their digital or analog signals between different conductive paths. In at least some exemplary embodiments, in addition to or instead of conductive paths 608a - 608e, optical transmission paths may be used. The optical transmission paths may comprise, for example, optical fibers, and correspondingly, the electrical contacts on the housings of modules 50, 612 may comprise an optical fiber coupler or adapter, or an optical fiber transmitter / receiver / transceiver.

[0065] Although the present disclosure has been described in relation to specific embodiments, it is to be understood that the present disclosure is not limited to these embodiments, and that variations, modifications, and alterations of these embodiments may be made by those skilled in the art without departing from the scope of the present disclosure. Further, it is contemplated that any aspect or any portion of any embodiment described herein may be implemented or combined with any other aspect or any portion of any other embodiment described herein. For example, without limiting the generality above, the teachings of the present disclosure regarding conducting power or signals between the top and bottom of a module may be applicable to conducting power or signals between any other faces of the module.

Claims

1. (a) a housing, and (b) one or more battery cells housed within the housing and electrically connected to each other, (c) a first electrical contact and a second electrical contact located on a first surface of the housing, (d) a first electrical contact and a second electrical contact located on a second surface of the housing, (e) a first conductive path and a second conductive path each terminating at the first electrical contact and the second electrical contact, wherein the first conductive path is electrically connected in series to the one or more battery cells, the first conductive path and the second conductive path A battery module comprising.

2. The first surface of the housing is an upper surface, the first electrical contact and the second electrical contact located on the first surface of the housing are a first upper electrical contact and a second upper electrical contact, the second surface of the housing is a lower surface, and the first electrical contact and the second electrical contact located on the lower surface of the housing are a first lower electrical contact and a second lower electrical contact. The battery module according to claim 1.

3. Further comprising a third upper electrical contact located on the upper surface, a third lower electrical contact located on the lower surface, and a third conductive path terminating at the third upper electrical contact and the third lower electrical contact. The battery module according to claim 2.

4. Further comprising a fourth upper electrical contact located on the upper surface, a fourth lower electrical contact located on the lower surface, and a fourth conductive path terminating at the fourth upper electrical contact and the fourth lower electrical contact. The battery module according to claim 3.

5. The housing is conductive, and further comprises a fifth upper electrical contact located on the upper surface and a fifth lower electrical contact located on the lower surface, and each of the fifth upper electrical contact and the fifth lower electrical contact is electrically connected to the housing. The battery module according to any one of claims 2 to 4.

6. Further comprising a fifth conductive path terminating at the fifth upper electrical contact and the fifth lower electrical contact. The battery module according to claim 5.

7. One of the upper surface and the lower surface of the module is further provided with a male connector, and the other of the upper surface and the lower surface of the module is further provided with a female connector. At least one of the upper electrical contacts terminates at the connector on the upper surface of the module, and at least one of the lower electrical contacts terminates at the connector on the lower surface of the module. The battery module according to any one of claims 2 to 6.

8. All of the upper electrical contacts terminate at the connector on the upper surface of the module, and all of the lower electrical contacts terminate at the connector on the lower surface of the module. The battery module according to claim 5.

9. An intermediate module for electrically connecting the upper battery module according to claim 4 and the lower battery module according to claim 4 when stacked between them, (a)A housing having opposing upper and lower surfaces, (b)A first upper electrical contact and a second upper electrical contact located on the upper surface, (c)A first lower electrical contact and a second lower electrical contact located on the lower surface, (d)A first conductive path and a second conductive path terminated by the first upper electrical contact and the first lower electrical contact and the second upper electrical contact and the second lower electrical contact respectively An intermediate module comprising: The first upper electrical contact of the intermediate module is positioned to contact the first lower electrical contact of the upper battery module, the first lower electrical contact of the intermediate module is positioned to contact the third upper electrical contact of the lower battery module, the second upper electrical contact of the intermediate module is positioned to contact the second lower electrical contact of the upper battery module, and the second lower electrical contact of the intermediate module is positioned to contact the fourth upper electrical contact of the lower battery module. Intermediate module.

10. The housing further houses one or more battery cells electrically connected to each other, and the first conductive path is electrically connected in series to the one or more battery cells. The intermediate module according to claim 9.

11. (a)A third lower electrical contact and a fourth lower electrical contact located on the lower surface, (b) a third conductive path that terminates at the third lower electrical contact and the fourth lower electrical contact; further comprising; the third lower electrical contact of the intermediate module is positioned to contact the first upper electrical contact of the lower battery module, and the fourth lower electrical contact of the intermediate module is positioned to contact the second upper electrical contact of the lower battery module, the intermediate module according to claim 9.

12. further comprising a male connector on one of the upper surface and the lower surface of the intermediate module, and a female connector on the other of the upper surface and the lower surface of the intermediate module, at least one of the upper electrical contacts of the intermediate module terminates at the connector on the upper surface of the intermediate module, and at least one of the lower electrical contacts of the intermediate module terminates at the connector on the lower surface of the intermediate module, the intermediate module according to claim 9 or claim 10.

13. all of the upper electrical contacts of the intermediate module terminate at the connector on the upper surface of the intermediate module, and all of the lower electrical contacts of the intermediate module terminate at the connector on the lower surface of the intermediate module, the intermediate module according to claim 11.

14. (a) an upper battery module according to claim 4; (b) a lower battery module according to claim 4; (c) an intermediate module stacked between the upper battery module and the lower battery module, (i) a housing having opposing upper and lower surfaces; (ii) a first upper electrical contact and a second upper electrical contact located on the upper surface; (iii) a first lower electrical contact and a second lower electrical contact located on the lower surface; (iv) a first conductive path and a second conductive path that terminate at the first upper electrical contact and the first lower electrical contact and the second upper electrical contact and the second lower electrical contact, respectively; an intermediate module comprising; The first upper electrical contact of the intermediate module is positioned to contact the first lower electrical contact of the upper battery module, the first lower electrical contact of the intermediate module is positioned to contact the third upper electrical contact of the lower battery module, the second upper electrical contact of the intermediate module is positioned to contact the second lower electrical contact of the upper battery module, and the second lower electrical contact is positioned to contact the fourth upper electrical contact of the lower battery module, an intermediate module and a battery module stack comprising the same. **Claim 15** The intermediate module further comprises a) a third lower electrical contact and a fourth lower electrical contact located on the lower surface, and b) a third conductive path terminated by the third lower electrical contact and the fourth lower electrical contact and further comprises. The third lower electrical contact of the intermediate module is positioned to contact the first upper electrical contact of the lower battery module, and the fourth lower electrical contact of the intermediate module is positioned to contact the second upper electrical contact of the lower battery module. The stack according to claim 13. **Claim 16** The intermediate module further comprises a male connector on one of the upper surface and the lower surface of the intermediate module and a female connector on the other of the upper surface and the lower surface of the intermediate module. At least one of the upper electrical contacts of the intermediate module terminates at the connector on the upper surface of the intermediate module, and at least one of the lower electrical contacts of the intermediate module terminates at the connector on the lower surface of the intermediate module. The stack according to claim 13 or claim 14. **Claim 17** All of the upper electrical contacts of the intermediate module terminate at the connector on the upper surface of the intermediate module, and all of the lower electrical contacts of the intermediate module terminate at the connector on the lower surface of the intermediate module. The stack according to claim 15.

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