Battery pack

Abstract

We will provide a battery pack. [Solution] The immersion-cooled battery pack includes at least one battery module having a plurality of battery cells held by cell holders and electrically connected by battery cell connecting members within a liquid-restricting casing. The liquid-restricting casing provides a peripheral wall, as well as an upper and lower wall surface, with an interlocking structure for vertical stacking. The liquid-restricting casing, together with an interface module and a terminal module or a second interface module, forms a liquid-tight battery pack housing that contains a thermal management liquid. A liquid tank module functions as a buffer for liquid volume changes and as an external liquid interface, and is positioned above the liquid-tight battery pack housing to provide a gravity head. An electrical energy interface module relays high-voltage energy from the battery pack to a downstream load.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application is a partial continuation of U.S. application Ser. No. 18 / 211,417, filed Jun. 19, 2023. Further, this application claims the benefit of U.S. Provisional Application No. 63 / 735,305, filed Dec. 17, 2024. Further, this application claims the benefit of U.S. Provisional Application No. 63 / 696,991, filed Sep. 20, 2024. The contents of these applications are incorporated herein by reference.

[0002] The present disclosure generally relates to the integration of battery cells configured as devices capable of both storing and releasing electrical energy. Specifically, the present disclosure generally relates to a machine assembled from battery cells in which all battery cells are immersed in a thermal - management liquid during operation.

Background Art

[0003] Electrical energy is widely used to power modern machines. At various stages of the life cycle of electrical energy, such as generation, distribution, and consumption, the temporary storage and subsequent release of energy as needed are important and necessary.

[0004] A rechargeable battery cell is a device that stores electrical energy by converting electrical energy into chemical energy (i.e., during the charging process) and then converting it back into electrical energy (i.e., during the discharging process). Depending on the application, battery cells are integrated in various ways to meet the required electrical performance parameters.

[0005] The integration of battery cells, or in other words, the battery cell assembly, is typically considered a subsystem of electrical equipment. In this disclosure, the term “electric equipment” may refer to electric machinery, vehicles having electric motors as prime movers, or electrical energy storage systems electrically connected to a grid or power plant, or computing machines (e.g., servers having IT gear, circuit boards, and / or integrated circuit components configured to perform computing or information processing functions). Therefore, it is also important to consider the integration of battery cell assemblies with electrical equipment.

[0006] Furthermore, it is well known that integrating battery cells involves incorporating thermal management systems and battery management systems.

[0007] Given the design considerations mentioned above, optimizing the integration of battery cells presents a significant challenge. [Overview of the project]

[0008] I. Problems to be solved

[0009] To optimize battery cell integration, it is necessary to simultaneously manage thermal performance, electrical interfaces, mechanical stack-up, and manufacturability. In immersion systems, the thermal control liquid is configured to be in direct contact with the battery cells, but its movement is restricted, allowing modules to be stacked and sealed within a liquid-tight battery pack housing. The packs may be mounted in different orientations, and as the volume of the liquid changes with temperature, the liquid tank modules are positioned higher than the battery pack housing, so the liquid in the tanks has a higher gravitational potential than the liquid in the housing, thereby avoiding trapped air and supporting filling / venting functions. Intermodule interfaces use interlocking structures that create lateral constraints under vertical stacking and sealing member mechanisms that prevent leakage at the interfaces between liquid-restricting casings. Electrical integration allows for the relaying of high-voltage energy to downstream loads and the co-location of terminals by sealing vertical wall channels within vertical through-holes and arranging conductor rods within them, thus enabling both electrodes to be positioned at one vertical end. Cell positioning is achieved using stopping structures that provide vertical reaction forces and arbitrary fixing structures to limit displacement in any direction. Manufacturability can be achieved through integral molding (e.g., injection molding or die casting) or assembly from separate sidewalls.

[0010] II. Technical Effects

[0011] Immersion cooling can maintain the temperature of the battery cells within a predetermined range and reduce combustion. Interlocking mechanisms of the upper and lower walls at the vertical ends of the casing provide lateral forces that limit relative displacement between stacked casings, improving stack stability. Sealing member housing (and, in some embodiments, positioning) structures reduce leakage at the casing-to-casing interface. Higher-mounted liquid tank modules buffer volume changes and function as a liquid interface to external channels. Vertical through-holes with conductive rods allow for joint placement of terminals at one vertical end of the stack to simplify external connections. Cell holder retaining and fixing structures restrain motion while maintaining component space. Alternative manufacturing routes enable robust sealing and stacking while providing flexibility in terms of cost and tolerances.

[0012] III. Dependencies and Inclusion of Problem Areas

[0013] Route system architecture → LTM layout, sealing, manufacturing: Claim 1 establishes immersable modules, interlocking, liquid-tight battery pack housings, interface modules, and higher-mounted liquid tank modules; Claim 2 provides hose-based LTM connections; Claim 11 provides an LTM integrated with a first interface module; Claim 19 adds an interface liquid connector for external circulation. Co-location chain of terminals: Claim 1 → Claim 5 (vertical wall channel sealed within vertical through-holes) → Claim 6 (conductor rod within through-holes) → Claim 7 (enabling co-located terminals by rod connection at first vertical end and projection at second vertical end). Cell restraint chain: Claim 1 → Claims 8-10 (retaining structure and deformation of inner boundary) → Claim 14 (fixing structure with fasteners). Policy of liquid areas: Claim 1 → Claim 12 (hydraulically continuous EEIM space and BP space) or Claim 13 (hydraulically isolated by sealed electrical channels). Inclusion: System-level immersion / integration encompasses module-level lamination / encapsulation / manufacturing, which in turn encompasses cell-level constraints and electrical mechanisms within modules. Policies regarding the liquid domain and the joint placement of terminals intersect with both system integration and safety.

[0014] IV. Embodiments corresponding to each claim

[0015] The first embodiment provides a battery pack comprising at least one battery module, a first interface module as a first vertical lid, a terminal module or second interface module as a second vertical lid, and a liquid tank module, wherein at least one of the battery modules includes a plurality of cells, a cell holder having a cell receiving structure, a battery cell connecting member, and a liquid-restricting casing having a peripheral wall that laterally surrounds a space and extends vertically, an inner wall surface to which the cell holder is fixed, and an upper and lower wall surface at a vertical end having an interlocking structure that restricts lateral displacement when the casings are stacked, wherein a first (and optionally second) electrical energy interface module relays high-voltage energy, a liquid-tight battery pack housing is assembled from the casing and the vertical lids, and the liquid tank module is positioned higher than the battery pack housing such that the tank liquid has a greater gravitational potential than the housing liquid, buffering the volume and providing an external liquid interface.

[0016] Another embodiment provides a flexible hose having hose connectors on the first interface module and the liquid tank module.

[0017] Another embodiment provides that the second vertical cover is a second interface module, and the housing includes the casing, the first interface module, and the second interface module.

[0018] Another embodiment provides that the second vertical cover is the terminal module, and the housing includes the casing, the first interface module, and the terminal module.

[0019] Another embodiment provides vertical wall channels within the casing, which are sealed to one another to form vertical through-holes extending through stacked modules.

[0020] Another embodiment provides a conductor rod disposed within the vertical through-hole.

[0021] Another aspect provides that the conductor rod is connected to the first electrode at a first vertical end adjacent to the terminal module, protrudes from a second vertical end adjacent to the first interface module, and enables a common arrangement of terminals at the second end.

[0022] Another aspect provides at least one cell holder stop structure configured to extend inward from the inner surface of the peripheral wall and limit the vertical movement of the cell holder by providing a vertical force.

[0023] Another aspect provides that the stop structure has an inner boundary parallel to the side wall on which it is disposed and the transverse cross-sectional view is a line or a curve.

[0024] Another aspect provides that the transverse cross-sectional view is a curve having a radius of curvature greater than or equal to the radius of the battery cell in the cross-section.

[0025] Another aspect provides that the liquid tank module is directly integrated with the first interface module, so that no hose is required between them.

[0026] In another aspect, the electrical energy interface module space and the battery pack space are hydraulically continuous such that the thermal management liquid immerses components in both spaces.

[0027] Another aspect provides a sealed electrical channel in which the electrical energy interface module space and the battery pack space are hydraulically isolated and the first interface module has a sealing member that fits tightly with the bus bar.

[0028] Another aspect provides at least one cell holder fixing structure including a fastener hole such that the cell holder is mechanically fixed to the casing by a fixing fastener.

[0029] Another aspect provides that the battery cell connection member includes a cell contact plate and a current transport plate, and a melting structure that melts under an overload current is provided on the cell contact plate.

[0030] Another aspect provides that at least one of the upper wall surface and the lower wall surface includes a sealing member accommodation structure for receiving an O-ring to prevent leakage between the stacked casings.

[0031] Another aspect provides that the liquid confinement casing is integrally formed by injection molding or die casting.

[0032] Another aspect provides that the peripheral wall is assembled from four separate side walls or two partially surrounding walls.

[0033] Another aspect provides that the liquid tank module includes an interface liquid connector for connecting the battery pack to an external liquid circulation system.

[0034] This summary is provided for purposes of technical information and convenience of understanding, and is not intended to identify essential features, define the scope of protection, or be used to interpret the claims.

[0035] These and other objects of the present invention will become clearly apparent to those skilled in the art after reading the following detailed description of the preferred embodiments shown in various figures and drawings.

Brief Description of the Drawings

[0036] [Figure 1] It is a conceptual circuit diagram showing a charge-discharge circuit (0040) including a battery cell assembly (0010), a battery cell (0020), and a battery cell string (0030).

[0037] [Figure 2A] It is a perspective view of an embodiment of a battery cell assembly (0010).

[0038] [Figure 2B] This is a perspective view of one embodiment of a battery cell assembly (0010), and an exploded view showing the cell holder (0050), the cell receiving structure (0060), and the electrode surface (0024).

[0039] [Figure 2C] This is an exploded perspective view of a battery cell assembly (0010) showing the battery cell connecting member (0026) and the cell holder (0050).

[0040] [Figure 2D] This is a detailed diagram showing the plate hole (0029) of the battery cell connecting member (0026) that engages with the vertical limiting structure (0070) of the cell holder (0050).

[0041] [Figure 3A] This is a conceptual perspective view showing two battery cell assemblies (0010) arranged in a stacked configuration.

[0042] [Figure 3B] This is a conceptual perspective view showing two battery cell assemblies (0010) arranged in a parallel configuration.

[0043] [Figure 4A] This is a top view of a liquid-restricting casing (0080) in the form of a tube having a peripheral wall (0090). [Figure 4B] This is a top view of a liquid-restricting casing (0080) in the form of a tube having a peripheral wall (0090). [Figure 4C] This is a top view of a liquid-restricting casing (0080) in the form of a tube having a peripheral wall (0090).

[0044] [Figure 5A] This is a perspective view of a battery cell assembly (0010) located within a liquid-restricting casing (0080). [Figure 5B]This is a perspective view of a battery cell assembly (0010) located within a liquid-restricting casing (0080), and a vertical exploded view showing an upper opening (0094), a lower opening (0095), and two cell holders (0050).

[0045] [Figure 6A] This is a top view of a rectangular liquid limiting casing (0080) having side walls (0091) indicated to the east (0096), south (0097), west (0098), and north (0099).

[0046] [Figure 6B] This is a diagram of a liquid-restricting casing (0080) showing the inner wall surface (0101), outer wall surface (0106), inner corner (0120), outer corner (0125), prism (0130), and side wall (0091).

[0047] [Figure 6C] This is a diagram of a perimeter wall (0090) assembled from two partially surrounding walls.

[0048] [Figure 6D] This is a diagram of a peripheral wall (0090) assembled from four independent side walls (0091).

[0049] [Figure 7A] This is a top view of a liquid-restricting casing (0080) showing a cell holder retaining structure (0140) and an inner boundary (0141) extending inward from the inner surface of the peripheral wall (0090). [Figure 7B] This is a top view of a liquid-restricting casing (0080) showing a cell holder retaining structure (0140) and an inner boundary (0141) extending inward from the inner surface of the peripheral wall (0090). [Figure 7C] This is a top view of a liquid-restricting casing (0080) showing a cell holder retaining structure (0140) and an inner boundary (0141) extending inward from the inner surface of the peripheral wall (0090), and also includes a cell holder (0050) and a battery cell assembly (0010) having a cross section line A-A'.

[0050] [Figure 7D] This is a vertical cross-sectional view along A-A' in Figure 7C, showing the relative positions of the peripheral wall (0090), the cell holder retaining structure (0140), and the space above and below the retaining structure.

[0051] [Figure 7E] This is a diagram of the liquid limiting casing (0080) showing the individual cell holder retaining structure (0140) on the inner north face (0105) of the north wall (0099).

[0052] [Figure 8A] This diagram shows the cell holder fixing structure (0150) within the liquid limiting casing (0080), and is a top view showing the fixing structure (0150) having fastening holes (0151). [Figure 8B] This is a top view showing the cell holder fixing structure (0150) within the liquid limiting casing (0080), and a cell holder (0050) having a fixing fastener (0152). [Figure 8C] This is a cross-sectional view along B-B' showing the cell holder fixing structure (0150) within the liquid limiting casing (0080), the cell holder (0050), the retaining structure (0140), and the fixing fastener (0152).

[0053] [Figure 9A] This is a perspective view showing two stacked battery cell assemblies (0010). [Figure 9B] This is a perspective view showing two stacked battery cell assemblies (0010).

[0054] [Figure 10A] This is a diagram of a liquid limiting casing (0080) showing the upper wall surface (0160), the lower wall surface (0170), the upper interlocking structure (0180), and the lower interlocking structure (0190).

[0055] [Figure 10B] This diagram shows the two stacked liquid limiting casings (0080) when the interlocking structures (0180, 0190) are engaged.

[0056] [Figure 11A] The sealing mechanism at the interface between liquid-restricting casings (0080) is shown, and the sealing member housing structure (0220) and the sealing member positioning structure (0210) are also shown. [Figure 11B] The sealing mechanism at the interface between liquid-restricting casings (0080) is shown, and a sealing member (0200) such as an O-ring is shown arranged within the housing structure.

[0057] [Figure 12A] This figure shows a vertical wall channel (0230) having a PCB of a cell monitoring device (0260) related to a battery cell connecting member (0026).

[0058] [Figure 12B] This figure shows a vertical wall channel (0230) having a conductor rod (0280).

[0059] [Figure 13] This is a perspective view of a battery pack (3030) including a battery module (3010), a terminal module (3040), an interface module (3050), and an electrical energy interface module (3060).

[0060] [Figure 14A] This is a conceptual diagram of a battery pack (3030) with the electrical energy interface module omitted, showing different mounting orientations with respect to gravity vectors and the arrangement of the liquid tank module (3070) and hose (3071). [Figure 14B] This is a conceptual diagram of a battery pack (3030) with the electrical energy interface module omitted, showing different mounting orientations with respect to gravity vectors and the arrangement of the liquid tank module (3070) and hose (3071).

[0061] [Figure 15]This is a diagram of an integrated interface module (3050) with a liquid tank module (3070) including an LTM-casing (3074) and an LTM-space (3075).

[0062] [Figure 16A] This is a conceptual diagram of a battery pack architecture, showing a plurality of battery modules (3010) stacked between first and second interface modules (3050a, 3050b), each having electrical energy interface modules (3060a, 3060b) and a high-voltage interface connector (3063) at their opposing vertical ends. [Figure 16B] This is a conceptual diagram of a battery pack architecture, showing the battery module between the terminal module (3040) and the interface module (3050), with the electrical energy interface module (3060) and two high-voltage interface connectors (3063) at the same vertical end, and the vertical wall channel (0230) is sealed to form a vertical through-hole with a conductor rod (0280).

[0063] [Figure 17A] This is a conceptual diagram showing the orientation of the liquid tank module (3070) with respect to the gravity vector when it is placed on the interface module (3050). [Figure 17B] This is a conceptual diagram showing the orientation of the liquid tank module (3070) with respect to the gravity vector when it is placed on the interface module (3050). [Modes for carrying out the invention]

[0064] Before describing this disclosure in more detail, note that reference numbers are repeated between drawings where appropriate to indicate corresponding or similar elements that may have similar characteristics.

[0065] To facilitate the description of this disclosure, directional terms may be used in this specification and the claims to describe parts of the disclosure (e.g., front, back, left, right, up, down, etc.). Unless otherwise defined, these definitions of directions are intended solely to aid in describing and claiming this disclosure and not to limit it in any way.

[0066] The following contains specific information relating to exemplary implementations in this disclosure. The detailed disclosures in the drawings and their appendices only cover exemplary implementations in this disclosure. However, this disclosure is not limited to these exemplary implementations. Those skilled in the art will be able to imagine other modifications and implementations of this disclosure. Unless otherwise noted, similar or corresponding elements in the drawings may be indicated by similar or corresponding reference numbers. Furthermore, the drawings and examples in this disclosure are generally not to scale and are not intended to correspond to actual relative dimensions.

[0067] For consistency and ease of understanding, similar mechanisms are identified by numbers in the illustrative diagrams (although some examples are not illustrated). However, mechanisms in different implementations may differ in other respects and should therefore not be narrowly limited to those shown in the diagrams.

[0068] References to “one implementation,” “implementation,” “exemplary implementation,” “various implementations,” “several implementations,” and “implementation of the disclosure” may indicate that an implementation of the disclosure may include a particular mechanism, structure, or characteristic, but not all possible implementations of the disclosure may include a particular mechanism, structure, or characteristic. Furthermore, repeated use of the phrases “in one implementation,” “in an exemplary implementation,” or “implementation” does not necessarily refer to the same implementation, although they may be identical. Also, any use of phrases such as “implementation” in relation to “the disclosure” should never mean that all implementations of the disclosure must include a particular mechanism, structure, or characteristic; rather, “at least some implementations of the disclosure” should be understood to mean that they include the described particular mechanism, structure, or characteristic. The term “coupled” is defined as a direct or indirect connection by intervening components, and is not necessarily limited to a physical connection. The term "comprising" means, when used, "including, but not necessarily limited to," and specifically indicates an open inclusion or affiliation with the disclosed combinations, groups, series, and equivalents.

[0069] Furthermore, for non-exclusive purposes, certain details such as functional entities, technologies, protocols, and standards are included to provide an understanding of the disclosed technology. In other cases, detailed disclosures such as well-known methods, technologies, systems, and architectures are omitted so as not to obscure the disclosure with unnecessary details.

[0070] Figure 1 is a conceptual circuit diagram of a charge-discharge circuit 0040. In Figure 1, the charge-discharge circuit includes a "battery cell assembly" 0010 (hereinafter referred to as BCA). The BCA0010 is configured to meet required electrical performance, such as a required target output voltage, amperage, or power. To meet such requirements, battery cells can be integrated into the BCA0010, for example, assembled to provide collective performance.

[0071] As shown in Figure 1, in some embodiments, the BCA0010 may include one or more electrically connected battery cell strings 0030 (hereinafter referred to as BCS) in parallel. The number of BCS0030 connected in parallel determines the overall current output of the BCA0010. Furthermore, each BCS0030 may include one or more electrically connected battery cells 0020 (hereinafter referred to as BC) in series. The number of BC0020 in each BCS0030 connected in series determines the overall voltage output of the BCS0030 and BCA0010.

[0072] The charge-discharge circuit 0040 can be connected to an energy source such as a charging station to charge the BCA0010. The charge-discharge circuit may also be connected to an energy consumer such as the prime mover of an electric vehicle, and thus supply power to the prime mover.

[0073] In some embodiments (not shown in Figure 1), the charge-discharge circuit 0040 may include multiple BCAs 0010.

[0074] Referring back to Figure 1, depending on the technology used, the BC0020 may have different specifications in terms of shape, electrical performance (e.g., output voltage, current, power, charging rate, discharging rate, or operating temperature), material, and other properties. For example, the BC0020 can be encapsulated in various forms such as cylindrical, prismatic, or pouch. Unless otherwise specifically stated, those skilled in the art should understand that the technical features disclosed herein are not necessarily limited to any particular type of BC0020.

[0075] BC0020 may include a positive electrode and a negative electrode as an interface between the charge-discharge circuit 0040(1) to which BC0020 is connected and the cathode material and anode material (2) enclosed in BC0020, in order to be configured as a basic component that converts electrical energy to chemical energy or vice versa.

[0076] Furthermore, BC0020, which constitutes the basic energy storage components of BCA0010 and the charge-discharge circuit 0040, needs to be electrically connected. Whether BC0020 is cylindrical, prismatic, or pouch-shaped, the electrodes of BC0020 are typically located at the top, bottom, or both ends of the body of BC0020, respectively. In such cases, BC0020 is usually mechanically aligned so that each electrode of BC0020 can be aligned in substantially the same plane. As a result, the body of BCA0010 may include at least one electrode surface 0024 on which the electrodes of BC0020 are positioned and distributed.

[0077] In some embodiments, BCA0010 may include a battery cell connecting member 0026 (hereinafter referred to as BCCM), which is an electrical conductor configured to connect to the electrodes of BC0020. Through BCCM0026, BC0020 is electrically connected in parallel or in series. For example, a planar conductive plate can be placed on the electrode surface 0024 to connect the electrodes of BC0020.

[0078] In this disclosure, when referring to direction, the terms “lateral direction” and “in the lateral direction” refer to the direction in the plane where the electrodes of BCA0010 and BC0020 are positioned, and the direction parallel to the lines in the plane where the BC0020s of BCA0010 are distributed side by side. In the figures of this disclosure, the lateral direction is marked as the direction parallel to the lines in the yz plane. The term “top view” means a cross-section viewed from the positive x direction toward the negative x direction.

[0079] In this disclosure, the terms “perpendicular” and “perpendicular” mean a direction orthogonal to any “lateral direction,” not “lateral direction.” By this definition, the electrodes of the BC0020 are typically located at at least one vertical end of the body of the BC0020. In the figures of this disclosure, the vertical direction refers to the direction along the x-direction.

[0080] For example, see Figures 2A and 2B, perspective views of an embodiment of BCA0010 (not all components of BCA0010 are shown). Figure 2B is an exploded view of Figure 2A. In Figures 2A and 2B, the body of BC0020 can extend vertically (along the x-direction). Furthermore, the vertical axis of BC0020 is parallel to the x-direction, and BC0020 aligns along the yz-plane.

[0081] To mechanically or structurally integrate the BC0020, in some embodiments, the BCA0010 may include at least one cell holder 0050 which may have the primary function of restricting the position of each BC0020 in a particular configuration. For example, the restriction of the position of the BC0020 may be 1. restricting the relative position of a particular BC0020 to any other BC0020 belonging to the same BCA0010, and 2. restricting the relative position of a particular BC0020 to the body of the BCA0010. For example, in Figure 2A, a portion of the body of each BC0020 is placed within the corresponding cell receiving structure 0060 of the cell holder 0050. The cell receiving structure 0060 is periodically distributed along the lateral direction. Therefore, when the BC0020s are placed within the cell receiving structure 0060, these BC0020s may be arranged laterally in such a periodic spatial distribution.

[0082] In some embodiments, the cell holder 0050 may include a vertical limiting structure 0070 to restrict the vertical movement of the BC0020. All the bodies and electrodes of the BC0020 of the BCA0010 can be formed as electrode surfaces 0024 of the BCA0010 so that they are aligned in the same vertical position. For example, in Figure 2A, the BCA0010 includes two electrode surfaces 0024 on both sides in the x-direction.

[0083] In some embodiments, an adhesive can be used to provide a displacement limiting function. For example, after placing the BC0020 within the cell receiving structure 0060 of the cell holder 0050, an adhesive (glues) can be introduced to further fix the BC0020 in place.

[0084] In some embodiments, to electrically integrate BC0020, BCA0010 may include BCCM0026 located on the electrode surface 0024. Furthermore, BCA0010 may include mechanical means configured to statically maintain the relative position between the electrode surface 0024 and BCCM0026. For example, if BC0020 is mechanically fixed to the cell holder 0050, BCCM0026 can be mechanically connected to the cell holder 0050.

[0085] For example, in Figure 2C, an exploded perspective view of an exemplary BCA0010 (BC and some components are not shown), the BCA0010 includes a cell holder 0050 and a BCCM0026. The BCCM0026 is a conductive material formed in a plate shape. The BCCM0026 is positioned in the cell holder 0050 and is also configured to be positioned on the electrode surface 0024 of the BCA0010.

[0086] In some embodiments, the BCCM0026 may include a cell contact plate 0027 and a current transport plate 0028.

[0087] The cell contact plate 0027 may be configured to directly contact the electrodes of BC. The cell contact plate 0027 and the electrodes of BC can be connected using a connection process such as welding, crimping, fastening, or the use of a conductive adhesive. Furthermore, the cell contact plate 0027 may optionally include a fusing welding structure 0025 configured to melt when the current becomes overloaded.

[0088] The current transport plate 0028 may be configured to transport the total current of multiple BC0020s. For this purpose, the current transport plate 0028 may have a greater thickness than the cell contact plate 0027. Furthermore, the current transport plate 0028 may have a higher conductivity than the cell contact plate 0027. For example, the cell contact plate 0027 may be a nickel plate, and the current transport plate 0028 may be a copper plate.

[0089] In some embodiments, the BCCM0026 may include a structure configured to position the BCCM0026 on the cell holder 0050. For example, the BCCM0026 may include a projection or protrusion configured to engage with the hollow structure of the cell holder 0050. In another example, the BCCM0026 may include a hole configured to engage with the projection or protrusion of the cell holder 0050. For example, in Figures 2C and 2D, the BCCM0026 includes a plate hole 0029 that engages with a vertical limiting structure 0070 of the cell holder 0050. The vertical limiting structure 0070 penetrates the plate hole 0029 of the BCCM0026 and limits the relative movement of the BCCM0026 with respect to the cell holder 0050. For example, the lateral and vertical relative movement of the BCCM0026 with respect to the cell holder 0050 can be limited.

[0090] Figures 3A and 3B are conceptual perspective views of the integration of two BCA0010s. Depending on the available space for mounting the BCA0010s in the electrical equipment, the BCA0010s may be integrated in a stacked or side-by-side manner. For example, in Figure 3A, the BCA0010s are integrated in a stacked manner, suitable for placement in narrow, long spaces such as the front and rear compartments of a passenger car. In another example, in Figure 3B, the BCA0010s are integrated in a side-by-side manner, suitable for placement in spaces that are wide enough but have limited height, such as the floor space under a cabinet in a passenger car.

[0091] In this disclosure, the terms “vertical” and “perpendicular” also refer to the stacking direction of the stacked BCA. For example, in Figure 3A, the stacked BCA is stacked along the vertical direction and along the x-direction.

[0092] To prevent thermal runaway events, the operating temperatures of BCA0010 and BC0020, or both, are maintained. It is known that BC0020 is brought into direct contact with the thermal management liquid so that the thermal management liquid can transport heat to maintain the operating temperature of BC0020 within a predetermined range or prevent combustion reactions. For example, BCA0010 or BC0020 may be partially or completely immersed in the thermal management liquid. If the entire BCA0010 is immersed, BCA0010 and several other components intended to integrate with BCA0010 may come into direct contact with the thermal management liquid, thus providing a better thermal management effect.

[0093] To immerse BCA0010 in a thermal control liquid, BCA0010 can be integrated with a liquid-restricting casing 0080 (hereinafter, LLC). LLC0080 may be configured to restrict the movement of the thermal control liquid. For example, in a space described by Cartesian coordinates, a constant volume of the thermal control liquid may have a displacement or velocity that can be represented by a vector consisting of components obtained by multiplying a unit vector in the x, y, or z direction by a coefficient. LLC0080 may include means to restrict the movement of the thermal control liquid in at least some of those six directions in order to maintain the relative position between BCA0010 and the thermal control liquid while BCA0010 is immersed in the thermal control liquid.

[0094] In some embodiments, an impermeable material can be used to form a specific structure that completely seals or partially covers the thermal management liquid, thereby restricting the movement of the thermal management liquid in all directions or in certain directions. For example, LLC0080 may be formed as a tubular shape having two openings, such as a triangular tube, a square tube, or a circular tube. The tubular LLC0080 may include a circumferential wall 0090 (or in other words, a circumferential wall).

[0095] In some embodiments, the peripheral wall of LLC0080 may include an impermeable membrane to restrict the movement of the thermal management fluid.

[0096] In some embodiments, LLC0080 may include rigid structures such as impermeable walls to restrict the movement of the thermal management fluid.

[0097] For example, Figures 4A, 4B, and 4C show a conceptual LLC0080 in a tubular structure shown in a top view. In other examples, the side view (i.e., top view) of the tubular structure may have an asymmetrical geometric shape. In Figures 4A, 4B, and 4C, each shown LLC0080 includes a peripheral wall 0090 that encloses the space laterally. The peripheral wall 0090 can extend vertically, i.e., along the x-direction, in Figures 4A, 4B, and 4C. Thus, the three-dimensional space enclosed by the LLC0080 can be used to accommodate a thermal management liquid, BCA0010, and several components to be integrated with the BCA0010. Due to the impermeability of the peripheral wall 0090, the thermal management liquid contained in the LLC0080 can only move in the vertical direction.

[0098] Figures 5A and 5B are perspective views of an exemplary embodiment of BCA0010, and not all components of BCA0010 are shown, for the purpose of clearly specifying the means for immersing BCA0010 in a heat-controlled liquid. For example, BC0020 is not shown in Figures 5A and 5B.

[0099] Figure 5B is a vertical exploded perspective view of Figure 5A. In the embodiments of Figures 5A and 5B, BCA0010 includes two cell holders 0050 integrated with BC0020 (BC0020 is not shown in Figures 5A and 5B). Several other components not shown that intend to integrate with cell holders 0050, BC0020, and BCA0010 may be located within the space surrounded by LLC0080.

[0100] In embodiments in which LLC0080 is formed in a tubular shape, the peripheral wall 0090 may be formed as a material extending vertically between an upper vertical position 0092 and a lower vertical position 0093. At the upper vertical position 0092, the inner edge of the peripheral wall 0090 may define the upper opening 0094 of LLC0080, and at the lower vertical position 0093, the inner edge of the peripheral wall 0090 may define the lower opening 0095 of LLC0080. The upper opening 0094 and the lower opening 0095 may be configured as entrances or exits to the space surrounded by the peripheral wall 0090. Components such as BC0020, cell holders 0050, and other components to be placed inside LLC0080 may be placed in the internal space of LLC0080 through at least one of the upper opening 0094 and the lower opening 0095.

[0101] For example, in the embodiment shown in Figure 5B, the peripheral wall extends between the upper vertical position 0092 and the lower vertical position 0093. The vertical length (i.e., height) of LLC 0080 is equal to the vertical distance between the upper vertical position 0092 and the lower vertical position 0093 H1. The two cell holders are positioned within the space enclosed by the peripheral wall 0090, passing through the upper opening 0094 and the lower opening 0095.

[0102] In some embodiments in which the LLC0080 is formed in a rectangular tubular shape, the circumferential wall 0090 of the LLC0080 may further include four planar side walls 0091 arranged to surround the vertical axis in a circumferential direction. For example, Figure 6A shows an exemplary top view of the LLC0080. The LLC0080 includes four side walls 0091 arranged to surround the vertical axis in a circumferential direction, namely the east wall 0096, the south wall 0097, the west wall 0098, and the north wall 0099.

[0103] In some embodiments, LLC0080 may be manufactured using an integral molding process such as injection molding or die casting. Alternatively, LLC0080 can be manufactured using a turning process.

[0104] As shown in Figures 6A to 6B, in some embodiments in which LLC0080 is formed in a rectangular tube shape, the peripheral wall 0090 of LLC0080 may include four inner corners 0120 and four outer corners 0125. The four inner corners 0120 may further include an inner northeast corner 0121, an inner southeast corner 0122, an inner southwest corner 0123, and an inner northwest corner 0124. The four outer corners 0125 may further include an outer northeast corner 0126, an outer southeast corner 0127, an outer southwest corner 0128, and an outer northwest corner 0129.

[0105] In some embodiments, each side wall may include an inner wall surface 0101 and an outer wall surface 0106. The outer wall surface 0106 of each side wall 0091 may be an outer plane that can extend between one of the two outer corners of the corresponding side wall 0091. For example, in Figure 6B, the east wall 0096 includes an outer east surface 0107 extending between the outer northeast corner 0126 and the outer southeast corner 0127, the south wall 0097 includes an outer south surface 0108 extending between the outer southeast corner 0127 and the outer southwest corner 0128, the west wall 0098 includes an outer west surface 0109 extending between the outer southwest corner 0128 and the outer northwest corner 0129, and the north wall 0099 includes an outer north surface 0110 extending between the outer northwest corner 0129 and the outer northeast corner 0126.

[0106] Furthermore, the inner wall surface 0101 of each side wall 0091 may be an inner plane that extends between one of the two inner corners of the corresponding side wall 0091. For example, in Figure 6B, the east wall 0096 includes an inner east surface 0102 extending between the inner northeast corner 0121 and the inner southeast corner 0122; the south wall 0097 includes an inner south surface 0103 extending between the inner southeast corner 0122 and the inner southwest corner 0123; the west wall 0098 includes an inner west surface 0104 extending between the inner southwest corner 0123 and the inner northwest corner 0123; and the north wall 0099 includes an inner north surface 0105 extending between the inner northwest corner 0124 and the inner northeast corner 0121.

[0107] In some embodiments, the perimeter wall 0090 may be assembled from separate components. For example, in Figure 6B, LLC 0080 includes four prisms 0130 which are independent components assembled with side walls 0091 (i.e., east wall 0096, south wall 0097, west wall 0098, and north wall 0099) to form the perimeter wall 0090. In other examples, as shown in Figure 6C, the perimeter wall 0090 may be assembled from two partially enclosing walls. In other examples, as shown in Figure 6D, the perimeter wall 0090 may be assembled from four independent side walls 0091.

[0108] In some embodiments, LLC0080 may include a structure configured for integration of the cell holder 0050 with LLC0080. If LLC0080 is tubular in shape as shown in Figures 4A, 4B, and 4C, the cell holder 0050 may be positioned in a space surrounded by LLC0080 through one of the upper openings 0094 and lower openings 0095 at the two vertical ends of the tubular structure. LLC0080 may include at least one cell holder retaining structure 0140 extending inward along the lateral direction from one of the inner surfaces of the circumferential wall 0090.

[0109] The relative vertical position on the inner surface of the peripheral wall 0090 and the vertical size of the cell holder retaining structure 0140 define the vertical depth (vertical range) that the cell holder 0050 can reach vertically within the space surrounded by the LLC. Thus, such a lateral structure (i.e., the cell holder retaining structure 0140) can restrict the vertical movement of the cell holder 0050 by providing a vertical force to the cell holder 0050. Such a vertical force counteracts the vertical movement of the cell holder 0050 within the space surrounded by the peripheral wall 0090.

[0110] For example, Figures 7A, 7B, 7C, 7D, and 7E are conceptual diagrams of an exemplary BCA0010. Figures 7A, 7B, and 7C are top views of an exemplary BCA0010. In Figure 7A, BCA0010 includes LLC0080, which includes a perimeter wall 0090. The perimeter wall includes four side walls 0091. LLC0080 further includes two cell holder retaining structures 0140 extending laterally and inward from the inner surface of the perimeter wall 0090. Each of the two cell holder retaining structures 0140 may include an inner boundary 0141. A lateral cross-sectional view (top view) of the inner boundary 0141 may be a line on a lateral plane. In the embodiment shown in Figure 7A, each of the inner boundaries 0141 is a plane parallel to the side wall on which the cell holder retaining structure 0140 is located, and the lateral cross-sectional view of the inner boundary 0141 is a straight line along the y-direction. In Figure 7A, the maximum distance between the inner boundary 0141 and the inner surface of the side wall 0091 on which the cell holder retaining structure 0140 is located is a constant number, for example, in Figure 7A, such a constant distance is equal to W2.

[0111] In other embodiments, the inner boundary 0141 does not have to be a plane; that is, the distance between the inner boundary 0141 and the inner surface of the side wall 0091 on which the cell holder retaining structure 0140 is located does not have to be a constant number. For example, in Figure 7B, the inner boundary 0141 is a curved surface, and the lateral cross-sectional view of the inner boundary 0141 is a curve on a lateral plane.

[0112] In some embodiments, as shown in Figure 7B, the curved inner boundary 0141 of the cell holder retaining structure 0140 can provide additional space for accommodating components of the BCA0010, such as BC0020. In some cases, the curved portion of the inner boundary 0141 may include a lateral cross-sectional view in which the curve has a radius of curvature greater than or equal to the radius viewed from the lateral cross-section of the BC. Thus, the BC0020 can be positioned within the space partially enclosed by the curved portion of the inner boundary 0141 of the cell holder retaining structure 0140.

[0113] Figure 7C shows an exemplary BCA0010. BCA0010 includes a cell holder 0050 located in the space surrounded by the peripheral wall 0090 of LLC0080. The dashed line A-A' marks the cross-section shown in Figure 7D.

[0114] Figure 7D shows a vertical cross-sectional view along the dashed line A-A' in Figure 7C. BCA0010 includes LLC0080, which further includes a peripheral wall 0090. LLC also includes two cell holders 0050 and two cell holder retaining structures 0140 (only one is shown). The cell holder retaining structures 0140 are positioned on the inner surface of the peripheral wall 0090. Vertically, the center of the cell holder retaining structure 0140 aligns with the center of the peripheral wall 0090.

[0115] In some embodiments, the vertical length (hereinafter referred to as height) of the cell holder retaining structure 0140 is smaller than the height of the peripheral wall 0090, so the difference between the height of the cell holder retaining structure 0140 and the height of the peripheral wall 0090 can provide space for accommodating the cell holder 0050. For example, in Figure 7D, the height of the cell holder retaining structure 0140 is equal to H4, and the height of the peripheral wall 0090 is equal to H1. The difference between H1 and H4 is equal to twice H3. Therefore, the cell holder 0050 is accommodated in the space between the upper opening 0094 of the LLC 0080 and the cell holder retaining structure 0140, and such space has a height equal to H3. The cell holder 0050 is also accommodated in the space between the lower opening 0095 of the LLC 0080 and the cell holder retaining structure 0140, and such space has a height equal to H3.

[0116] In some embodiments, LLC0080 may include individual cell holder retaining structures 0140 located on the inner surface of the side wall 0091. For example, as shown in Figure 7E, LLC0080 includes a north wall 0099 and two cell holder retaining structures located on the inner north surface 0105.

[0117] In some embodiments, the LLC0080 may include at least one cell holder fixing structure 0150 that provides mechanical means to restrict the displacement of the cell holder in any direction. For example, as shown in Figure 8A, the LLC0080 in the top view includes four cell holder fixing structures 0150 extending from the inner wall surface 0101 of the peripheral wall 0090. In this embodiment, the cell holder fixing structure 0150 includes fastening holes 0151 for restricting relative movement between the LLC0080 and the cell holder 0050 using fastening devices. In some embodiments, the cell holder fixing structure 0150 and the cell holder fixing structure may differ in several embodiments, such as shape, lateral position, and vertical position.

[0118] As shown in Figure 8B, a top view of LLC0080 is shown. In Figure 8B, the cell holder 0050 is located in the space enclosed by the peripheral wall of LLC0080. LLC0080 includes four fasteners 0152 inserted vertically through the cell holder 0050 and the cell holder fixing structure 0150 (not shown in Figure 8B).

[0119] Figure 8C is a cross-sectional view of LLC0080 along the dashed line B-B' shown in Figure 8B. As shown, the cell holder 0050 is fixed to LLC0080 by being secured vertically by the cell holder stopper structure 0140 and fastening the cell holder 0050 and LLC0080 together with the fixing fastener 0152.

[0120] Figures 9A and 9B are perspective views of the stacked BCAs.

[0121] In some embodiments, as shown in Figure 10A, LLC0080 may include an upper wall surface 0160 and a lower wall surface 0170, which are the sides of the vertical end of LLC0080.

[0122] In some embodiments, the upper wall surface 0160 and the lower wall surface may include complementary interlocking mechanisms configured to resist lateral shear when stacked vertically. For example, as shown in Figure 10A, the upper wall surface 0160 may include at least one upper interlocking structure 0180, and the lower wall surface 0170 may include at least one lower interlocking structure 0190. The upper interlocking structure 0180 and the lower interlocking structure 0190 may be positioned in specific lateral locations so that when two LLCs 0080 are stacked vertically (as shown in Figure 10B), the upper interlocking structure 0180 and the lower interlocking structure 0190 combine to provide a lateral force that limits the relative displacement between the two stacked LLCs 0080. For example, the pair of upper interlocking structures 0180 and the lower interlocking structure 0190 may be a projection structure and a receiving structure.

[0123] As shown in Figures 11A and 11B, in some embodiments, at least one of the upper wall surface 0160, the lower wall surface 0170, or both thereof may include at least one sealing member housing structure 0220 configured to provide space for housing a sealing member positioned at the interface of two LLCs 0080 to prevent liquid leakage from the interface of two LLCs. For example, the sealing member 0200 may be an O-ring or adhesive materials. In some embodiments, the lower wall surface 0170 or both thereof may further include at least one sealing member positioning structure 0210 configured to restrict the lateral movement of the sealing member 0200. For example, in Figures 11A and 11B, the sealing member positioning structure 0210 is a gap configured to provide a lateral force that restricts the lateral movement of the sealing member 0200. As shown in Figure 11B, the sealing member 0200 can be filled in the space provided by the sealing member housing structure 0220 to provide a sealing effect.

[0124] In some embodiments, the peripheral wall 0090 may include a vertical wall channel 0230, which is a hollow space within the peripheral wall 0090. The vertical wall channel 0230 may be a through-hole that penetrates the peripheral wall 0090 vertically. The vertical wall channel 0230 may be used to house the PCB of a cell monitoring device 0260 signal-connected to BCCM0026 of BCA0010, as shown in Figure 12A. The vertical wall channel 0230 may be used to house a conductor rod 0280 used to position both the positive electrode 0271 and the negative electrode 0272 at the same terminal of BCA0010, as shown in Figure 12B.

[0125] As disclosed in application '417 (i.e., application number 18 / 211,417), the vertical wall channel 0230 may be used to provide a vertical channel that allows a liquid to flow vertically. For example, the vertical wall channel 0230 may refer to the “inlet channel” and “outlet channel” disclosed in application '417.

[0126] In some embodiments, BCA0010 is integrated with other components to form a battery module (hereinafter, BM) 3010. For example, BM3010 may be an assembly comprising BCA0010 and other components such as LLC0080, thermal control components such as heat dissipation components, battery management circuits, and other components. Manufacturing BM3010 is typically an intermediate step in the manufacturing of the entire system. That is, BM3010 is considered an intermediate component block for forming a higher level energy storage system, and BM3010 is also integrated by BC0020, which is a more basic component block. Therefore, BM3010 may also include a modular interface configured to integrate BM3010 with other BM3010s and / or other modules of the underlying larger energy storage system. For example, BM3010 may include a modular electrical energy interface 3020 (hereinafter, MEEI) configured to provide electrical connections for the transfer (charging or discharging) of electrical energy stored in or released from BM3010. MEEI3020 may be an electrode or connector positioned on the BM3010. For example, MEEI3020 may be a conductor that directly contacts one of the current transport plates 0028 of the first BM3010 and also directly contacts one of the current transport plates 0028 of the second BCA0010. Such MEEI3020 functions as an electrical connector between the two BM3010s.

[0127] For example, BM3010 may include interfaces for heat-regulating components, such as liquid connectors, for heat-regulating fluid to enter and exit BM3010 and flow into other liquid containers or channels, such as the upper opening 0094 and lower opening 0095 of LLC0080. For example, BM3010 may include interfaces for mechanically connecting to other BMs and / or other modules, such as the upper interlocking structure 0180 and the lower interlocking structure 0190.

[0128] In this disclosure, the term “Battery Pack” (hereinafter, BP) 3030 refers to an assembled, manufactured, and enclosed energy storage system designed for integration into electrical equipment (such as EVs, BESSs, or others) powered by electrical energy discharged from the BP 3030. This is typically manufactured as a separate product by an entity supplying the final equipment to the original equipment manufacturer (hereinafter, OEM). The BP 3030 is mechanically stable to ensure its integrity during transport and of the final equipment. The integration and assembly process may include the EV assembly process. Furthermore, the BP 3030 is equipped with a standardized interface to facilitate electrical and mechanical integration with larger systems in which it is provided. The spatial dimensions of the BP 3030 are also designed to take into account the available space of the underlying electrical equipment.

[0129] Figure 13 is a perspective view of BP3030. In some embodiments, as shown in Figure 13, BP3030 may include two BM3010 assembled together in a stacked manner. In other cases, BP3030 may include only one BM3010 or three or more BM3010. BP may also include a terminal module (hereinafter, TM) 3040 that functions as a cover for BP3030. TM3040 provides electrical insulation so that BC0020 (not shown in Figure 13) is electrically isolated from the outside of BP3030. BP3030 may also include an interface module (hereinafter, IM) 3050. IM3050 functions not only as a cover but also as an interface for BP3030. Note that each of the BM3010 in Figure 13 may be formed (assembled) from LLC0080 and BCA0010 as previously disclosed in this disclosure.

[0130] In some embodiments, the BP3030 may be liquid-tight so that the BCA0010 of the BM3010 sealed within the BP3030 can be immersed in a thermal control liquid. For example, the LLC0080 of each BM3010, TM3040, and IM3050 can be assembled to form a liquid-tight "battery pack housing" 3031 (hereinafter referred to as the BP housing). In such an example, the BP housing 3031 is assembled by the LLC0080 providing a lateral fluid barrier, and a lid at the vertical end provides a vertical fluid barrier. For example, the lid may be TM3040 or IM3050. These lateral and vertical fluid barriers define the BP space 3032 enclosed by the BP housing 3031 (while being enclosed by these vertical and lateral fluid barriers).

[0131] In some embodiments, TM3040 and IM3050 may also include mechanical interfaces for mating, connecting, or sealing with the corresponding BM3010 or the corresponding LLC0080. For example, TM3040 may include an upper interlocking structure 0180, and IM3050 may include a lower interlocking structure 0190. For example, TM and IM may include a sealing member housing structure 0220 as described above in this disclosure.

[0132] As shown in Figure 13, BP3030 may also include an "Electrical Energy Interface Module" (EEIM) 3060. The EEIM 3060 may include an EEIM casing 3062 that encloses or surrounds an EEIM space 3061 (not shown in Figure 13) configured to house circuits for battery management, high-voltage circuits (e.g., circuits for relaying the high-voltage electrical energy of BP3030 to downstream loads such as EVs), or both. The EEIM casing 3062 may be formed integrally or may be formed from a plurality of EEIM walls 3065. For example, the EEIM walls 3065 may be part of the integrally formed EEIM casing 3062 or may be independent components. The EEIM 3060 may be placed in IM3050 by an assembly process.

[0133] In some embodiments, the IM3050 may include an IM casing 3052 surrounding or enclosing an IM space 3054 (not shown in Figure 13) configured to accommodate components configured to interface the BM3010 and EEIM3060.

[0134] In some embodiments, IM3050 may further include an IM busbar 3053 (not shown in Figure 13). One terminal of the IM busbar 3053 is configured to be electrically connected to the MEEI 3020 of BM3010, and the other terminal end of the IM busbar 3053 is configured to be electrically connected to a high-voltage circuit located in the EEIM space 3061. EEIM3060 may include a “high-voltage interface connector” 3063 (hereinafter referred to as HVIC) which may be located in the EEIM casing 3062. The HVIC 3063 is configured to make direct contact with a high-voltage circuit located in the EEIM space 3061. For example, such an electrical connector may be a terminal of a charge-discharge circuit 0040.

[0135] In some embodiments, the EEIM space 3061 and the BP space 3032 may be hydraulically continuous so that components within the EEIM space 3061 can be immersed by the thermal control liquid.

[0136] In other embodiments, the EEIM space 3061 and the BP space 3032 may be hydraulically isolated. In such cases, the IM 3050 may include at least one IM electrical channel 3051 (not shown) structure configured to provide a channel between the EEIM space 3061 and the BP space 3032. For example, the IM channel 3051 may be a through-hole located in the side wall of the IM 3050. In some embodiments, an IM busbar 3053 (not shown) may be located within the IM electrical channel 3051 and extend to the EEIM space 3061 and the BP space 3032 to provide electrical connections between components in these two containment spaces. In some embodiments, to prevent liquid from passing through the IM electrical channel 3051, the IM 3050 may further include at least one sealing member, such as an O-ring, located within the IM channel 3051 and tightly fitting with both the inner wall of the IM electrical channel 3051 and the IM busbar 3053.

[0137] In some embodiments, the BP3030 may include at least one liquid interface 3034 for introducing liquid into and / or out of the BP3030. For example, the liquid interface may be a liquid connector located on the BP housing 3031. For example, the liquid interface 3034 may be located on the wall of the IM3050 or the wall of the TM3040 as an inlet and / or outlet. In some embodiments, the BP3030 may include a first liquid interface 3034(a) (not shown) as an inlet to the BP housing 3031 and a second liquid interface 3034(b) (not shown).

[0138] In some embodiments, BP3030 may include a liquid tank module (hereinafter referred to as LTM)3070 and a hose 3071. The LTM3070 functions as a buffer tank to balance volume fluctuations of the liquid in the BP space 3032, which may be caused by changes in the operating temperature of BC0020 and the thermal management liquid. In some embodiments, during the process of introducing or filling the BP housing 3031 with liquid, the LTM3070 may be connected to an external liquid source. One end of the hose 3071 is connected to the LTM3070, and the other end of the hose 3071 is connected to the IM3050. Thus, the liquid can be introduced and flow first from the liquid source into the LTM3070, then through the hose 3071, and finally flow into and fill the entire BP space 3031. Each of the IM3050 and LTM3070 may include a hose connector 3073 that is liquid-connected to the hose 3071. LTM3070 may include an "interface liquid connector" 3072 (hereinafter referred to as ILC) configured to connect to an external liquid circulation system, such as a liquid circulation system having a liquid source or pump.

[0139] In some embodiments, the immersion-cooled BP3030 may not be connected to a liquid circulation system and may not operate in conjunction with one. In such embodiments, liquid is introduced and fills the entire BP3030. The ILC3072, configured to connect to an external liquid circulation system, may be sealed to prevent liquid from leaking out of the BP3030.

[0140] As shown in Figures 14A and 14B, which are conceptual diagrams of BP3030, EEIM3060 is not shown. In some embodiments, different situations may be considered in which electrical equipment may have various types of available space for mounting BP3030. The relative orientation of BP3030 is not always the same as the stacking direction of BM3010, TM3040, and BP housing 3031. However, considering that (1) the volume of liquid filled in BP3030 may change with its temperature, and as the volume changes, the liquid may flow between LTM3070 and IM3050 (i.e., function as a buffer tank), or (2) in the process of filling BP3030 with fluid, it is important to set LTM3070 on top of BP housing 3031 to expel air from BP3030 during filling, so that the liquid in BP housing 3031, hose 3071, and LTM space 3075 can form a single continuum. As shown in Figures 14A and 14B, the spatial conditions require that BP3030 be positioned in different orientations (in Figure 14A, gravity points in the negative y direction, and in Figure 14B, the gravity vector points in the negative x direction). In these two examples, LTM3070 is positioned to have a higher gravitational potential energy than BP enclosure 3031.

[0141] In some embodiments, the hose 3071 can be bent and flexible so that fluid connection can be achieved regardless of which side of the BP3030 body the LTM3070 is positioned on.

[0142] As shown in Figure 15, in some embodiments, the LTM 3070 can also be directly integrated with the IM 3050, thereby saving cost and space for the hose 3071 and hose connector 3073. In such embodiments, the LTM 3070 may include an LTM casing 3074 surrounding or enclosing an LTM space 3075 configured to contain a thermal management fluid. The LTM casing 3074 may be formed integrally or may be formed from a plurality of LTM walls 3076. For example, the LTM walls 3076 may be part of the integrally formed LTM casing 3074 or may be independent components. The LTM 3070 may be placed in the IM 3050 by an assembly process.

[0143] In some embodiments, the LTM casing 3074 and IM casing 3054 can be manufactured in a one-piece manner, for example by a die-casting process. Such an integrally formed "tank interface module" 3900 (hereinafter, TIM) may be a continuum. The TIM 3900 may be configured as the first vertical lid of a stacked BM 3020. The TIM 3900 may be a rectangular lid including a rectangular planar flange portion 3091 and a rectangular raised cover 3092 located in the center thereof. The rectangular raised cover 3092 includes four upright side walls rising from the flange and an upper panel that closes the cover, which define a rectangular raised cavity / gap between them and the flange.

[0144] Figures 16A, 16B, 17A, and 17B are conceptual diagrams of an embodiment of the BP3030.

[0145] In some embodiments, as shown in Figure 16A, the BP3030 may include a plurality of vertically stacked BM3010s. The BP3030 may further include, and be assembled with, a first IM3050(a) configured as a first vertical cover and a second IM3050(b) configured as a second vertical cover at the opposing vertical ends of the stacked BM3010s. The BP3030 may further include a first EEIM3060(a) and a second EEIM3060(b). The first EEIM3060(a) is positioned on the first IM3050(a), and the second EEIM3060(b) is positioned on the second IM3050(b). The first EEIM3060(a) may further include a first HVIC3063(a) positioned at one of the two vertical ends of the BP3030, and the second EEIM3060(b) may further include a second HVIC3063(b) positioned at the other vertical end of the BP3030. Such a configuration is configured to connect to a downstream load having separately positioned terminals.

[0146] In some embodiments, as shown in Figure 16B, the BP3030 may include a plurality of vertically stacked BM3010s. The BP3030 may further include, and be assembled with, a TM3040 configured as a first vertical cover and an IM3050 configured as a second vertical cover at the opposing vertical ends of the stacked BM3010s. The BP3030 may further include an EEIM3060. The EEIM3060 is positioned on the IM3050. The EEIM3060 may further include two HVIC3063s positioned at the same ends of the two opposing vertical ends of the BP3030. Such a configuration is configured to connect to a downstream load with terminals positioned in close proximity. The LLC0080 may further include vertical wall channels 0230. The vertical wall channels 0230 of each LLC0080 can be sealed to each other to form a vertical through-hole that extends vertically through the entire assembly of the stacked BM3030s. The BP3030 may further include a conductor rod 0280 located at the second vertical end of the entire stacked BM3030 assembly, configured to form first and second electrodes of a circuit formed by all battery cells connected in series and / or parallel.

[0147] In some embodiments, the conductor rod 0280 may be connected to the first electrode of a circuit formed by electrically connecting all BC0020 in series and / or parallel via BCCM0026 and MEEI3020 at the first vertical end of the entire stacked BM3030 assembly, the first vertical end being adjacent to TM3040. The conductor rod may be located within a vertical through-hole, or it may extend vertically along a vertical through-hole extending vertically through the entire stacked BM3030 assembly, or it may protrude from the second vertical end of the entire stacked BM3030 assembly, the second vertical end being adjacent to IM3050. Thus, both the first and second electrodes of the circuit formed by all the battery cells connected in series and / or parallel are located at the second vertical end of the entire stacked BM3030 assembly.

[0148] In some embodiments, when both the LTM3070 and HVIC3063 of the BP3030 are located at the same vertical end of the stacked BM3020, the ILC3072 and HVIC3063 of the BP3030 may also be located at the same vertical end of the stacked BM3020. Such an arrangement facilitates system integration because both the liquid connection to the external coolant channel and the electrical connection to the downstream load can be implemented from the same side of the battery pack. This not only reduces the complexity of installation and maintenance but also improves the compactness and reliability of the battery pack assembly.

[0149] Since the gravity vectors in Figures 16A and 16B (not shown in Figures 16A and 16B) point in the y direction, each of the LTM3070s in these two examples is positioned on the negative y side of the BP enclosure 3031 to ensure that the LTM3070 has a higher gravitational potential than the BP enclosure 3031. In some embodiments, as shown in Figures 17A and 17B, if the gravity vector (not shown in Figures 17A and 17B) points in the negative x direction, the LTM3070 can be positioned on the IM3050 to ensure that the LTM3070 has a higher gravitational potential than the BP enclosure 3031.

[0150] For example, when BP3030 is installed in electrical equipment, LTM3070 is positioned higher than BP enclosure 3031, so the liquid stored in LTM3070 has a higher gravitational potential than the liquid stored in BP enclosure 3031.

[0151] The embodiments shown and described above are merely examples. Many details are commonly found in the art. Therefore, many of such details are neither illustrated nor described. Many of the features and advantages of this disclosure, along with details of its structure and function, are described above, but this disclosure is illustrative and details may be modified. Therefore, it should be understood that the embodiments described above may be modified within the claims.

[0152] Those skilled in the art will readily understand that many modifications and changes can be made to the apparatus and method while maintaining the teachings of the present invention. Accordingly, the above disclosure should be construed as being limited only by the appended claims.

Claims

1. It is a battery pack, At least one battery module, Multiple battery cells, A cell holder comprising at least one cell receiving structure, configured to restrict the position of the aforementioned battery cell, At least one battery cell connecting member which is an electrical conductor configured to be connected to the electrodes of the battery cell, Includes a liquid limiting casing configured to restrict the movement of a thermally controlled liquid, The liquid-restricting casing surrounds the space laterally and extends vertically, and includes peripheral walls including an upper wall surface, a lower wall surface, and an inner wall surface. The cell holder is fixed to the inner wall surface, The upper wall surface and the lower wall surface are the side surfaces of the vertical end of the liquid limiting casing. The aforementioned upper wall surface includes at least one upper interlocking structure, The lower wall surface includes at least one lower interlocking structure, The upper interlocking structure and the lower interlocking structure are configured to provide a lateral force that limits the relative displacement between two stacked liquid limiting casings when the two liquid limiting casings are stacked vertically, and include at least one battery module. A first interface module, configured as a first vertical cover that fits with the first vertical end of at least one of the battery modules, A second vertical cover, which fits with the second vertical end of at least one of the battery modules, The second vertical cover is a terminal module or a second interface module, The first interface module further includes a first electrical energy interface module configured to house a circuit for relaying the high-voltage electrical energy of the battery pack to a downstream load, When the second vertical cover is the second interface module, the second interface module further includes a second electrical energy interface module configured to house a circuit for relaying the high-voltage electrical energy of the battery pack to a downstream load, A liquid-tight battery pack housing, Each battery module is assembled by the liquid-limiting casing, the first interface module, and the terminal module, or The liquid-limiting casing of each battery module, the first interface module, and A liquid-tight battery pack housing assembled by the second interface module, A liquid tank module comprising a buffer tank (1) for balancing volume fluctuations of the liquid in the battery pack housing, and a liquid interface (2) for liquid connection between the battery pack and an external liquid channel, A battery pack in which, when the battery pack is attached to an electrical device, the liquid tank module is positioned higher than the battery pack housing, so that the liquid stored in the liquid tank module has a higher gravitational potential than the liquid stored in the battery pack housing.

2. Further including a flexible hose, The battery pack according to claim 1, wherein each of the first interface module and the liquid tank module further includes a hose connector that is fluidly and mechanically connected to the hose.

3. The aforementioned second vertical cover is the aforementioned second interface module, The battery pack according to claim 1, wherein the battery pack housing is assembled by the liquid-restricting casing, the first interface module, and the second interface module of each battery module.

4. The second vertical cover is the terminal module, The battery pack according to claim 1, wherein the battery pack housing is assembled by the liquid-restricting casing, the first interface module, and the terminal module of each battery module.

5. Each liquid-restricting casing of each battery module further includes a vertical wall channel, The battery pack according to claim 1, wherein the vertical wall channels of the liquid-restricting casing are sealed to each other and form vertical through-holes that extend vertically through the entire assembly of the stacked battery modules.

6. The battery pack according to claim 5, further comprising a conductor rod disposed within the vertical through hole.

7. The conductor rod is connected to a first electrode of a circuit formed by electrically connecting all the battery cells in series and / or parallel at a first vertical end adjacent to the terminal module of the entire assembly of the stacked battery modules. The battery pack according to claim 6, wherein the conductor rod protrudes from a second vertical end adjacent to the first interface module of the entire assembly of the stacked battery modules.

8. The liquid limiting casing further includes at least one cell holder retaining structure extending inward along the lateral direction from one of the inner surfaces of the peripheral wall, The battery pack according to claim 1, wherein the cell holder retaining structure is configured to restrict the vertical movement of the cell holder by providing a vertical force to the cell holder.

9. The cell holder retaining structure further includes an inner boundary, The inner boundary is the surface of the cell holder retaining structure parallel to the side wall on which the cell holder retaining structure is located. The battery pack according to claim 8, wherein the lateral cross-sectional view of the inner boundary is a line or a curve.

10. The battery pack according to claim 9, wherein the cross-section of the inner boundary is a curve having a radius of curvature greater than or equal to the radius of the battery cell in the cross-section.

11. The battery pack according to claim 1, wherein the liquid tank module is directly integrated with the first interface module, and therefore does not require a hose to connect the liquid tank module and the first interface module.

12. The battery pack according to claim 1, wherein the first electrical energy interface module defines a first electrical energy interface module space, the battery pack housing defines a battery pack space, and the first electrical energy interface module space and the battery pack space are hydraulically continuous such that a thermal management liquid immerses the components in both spaces.

13. The battery pack according to claim 1, wherein the first electrical energy interface module defines a first electrical energy interface module space, the battery pack housing defines a battery pack space, the first electrical energy interface module space and the battery pack space are hydraulically isolated, and the first interface module includes an electrical channel sealed by a sealing member that tightly fits with a busbar.

14. The battery pack according to claim 8, wherein the liquid-restricting casing further includes at least one cell holder fixing structure including fastening holes, and the cell holder is mechanically fixed to the liquid-restricting casing by a fixing fastener.

15. The battery pack according to claim 1, wherein the battery cell connecting member includes a cell contact plate and a current transport plate, and the cell contact plate includes a molten structure configured to melt when the current is overloaded.

16. The battery pack according to claim 1, wherein at least one of the upper wall surface and the lower wall surface of the liquid-restricting casing includes a sealing member housing structure configured to accommodate an O-ring to prevent liquid leakage between the two stacked liquid-restricting casings.

17. The battery pack according to claim 1, wherein the liquid-restricting casing is integrally formed by injection molding or die casting.

18. The battery pack according to claim 1, wherein the peripheral wall of the liquid-restricting casing is assembled from four separate side walls or two partially surrounding walls.

19. The battery pack according to claim 1, further comprising an interface liquid connector configured to connect the battery pack to an external liquid circulation system, wherein the liquid tank module is further comprising the liquid tank module.

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