Battery pack, vehicle, and battery pack assembly process

Abstract

We provide battery packs and battery pack assembly processes that optimize the integration of battery cells. [Solution] The battery pack includes a bottom cell holder having a receiving structure that provides lateral and vertical forces to hold the battery cells. The bottom cell holder includes a layer of lateral retaining structures, a layer of vertical retaining structures, and a plurality of ventilation structures. The lateral retaining structures are configured to receive the battery cells. The vertical retaining structures are configured to support the weight of the battery cells. The vertical retaining structures have a plurality of lateral channels that divide the vertical retaining structures into discrete islands, and between these discrete islands, the lateral channels form a gap between the bottom cell holder and the bottom wall. When a thermal event causes the battery cells to release gas from their bottom, the gas passes through the lateral channels between the discrete islands, then enters through holes in the ventilation structures, and moves vertically toward the upper end of the ventilation structures.

Description

Technical Field

[0001] 〔Cross - Reference to Related Applications〕 This application claims the benefit of U.S. Provisional Application No. 63 / 716,203, filed on November 4, 2024. Further, this application claims the benefit of U.S. Provisional Application No. 63 / 735,305, filed on December 17, 2024. The contents of these applications are hereby incorporated by reference into this specification.

Background Art

[0002] 1. Field of the Invention

[0003] This disclosure generally relates to the integration of battery cells configured as devices capable of both storing and releasing electrical energy. Specifically, this disclosure generally relates to machines assembled from battery cells, where during operation, all battery cells are immersed in a thermal management fluid.

[0004] 2. Description of the Related Art

[0005] 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. To optimize the integration of battery cells, it is necessary to simultaneously manage thermal performance, electrical interfaces, mechanical stacking, and manufacturability.

[0006] 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.

[0007] The integration of battery cells, or in other words, the battery cell assembly, is typically considered a subsystem of an electrical device. In this disclosure, the term “electrical device” 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 between the battery cell assembly and the electrical device.

[0008] Furthermore, it is well known that integrating battery cells involves incorporating thermal management systems and battery management systems.

[0009] Given the design considerations mentioned above, optimizing the integration of battery cells presents a significant challenge. [Overview of the project]

[0010] I. Problems addressed To optimize battery cell integration, it is necessary to simultaneously manage thermal performance, electrical interfaces, mechanical stack-up, and manufacturability. In an immersion system, the thermal management fluid is configured to be in direct contact with the battery cells while its movement is restricted, so that modules can be stacked and sealed in a liquid-tight battery pack housing. Coolant inlets and outlets may be provided on at least one side wall of the housing and configured to serve as interfaces for introducing the thermal management fluid into and discharging it from the thermal management system. The battery cell assembly may include cell monitoring circuits, temperature sensors, and voltage sensors to facilitate battery management functions. The battery cell assembly includes a bottom cell holder that is in close contact with the bottom wall of the housing. The bottom cell holder includes a receiving structure that provides lateral and vertical forces to hold the battery cells. The bottom cell holder is a rectangular plate and may include layers of lateral retaining structures, layers of vertical retaining structures, and multiple ventilation structures. The battery cells may be positioned in the bottom cell holder by a lateral stopping structure and a vertical stopping structure. The ventilation structure may include through holes extending from the lowest end of the lateral stopping structure to the highest end of the ventilation structure, thereby allowing gas or liquid to flow vertically through the through holes. The bottom cell holder may have a connecting structure for connecting to other bottom cell holders.

[0011] II. Effects of the Invention Immersion cooling can maintain the temperature of the battery cell within a predetermined range and reduce combustion. The receiving structure of the bottom cell holder can provide lateral and vertical forces to hold the battery cell. The battery cell may be positioned in the bottom cell holder by lateral and vertical retaining structures. The inner wall of the receiving hole restricts the lateral movement of the battery cell. The vertical retaining structure restricts the downward vertical movement of the battery cell by supporting the battery cell by protruding radially inward from the receiving hole. Through-holes in the ventilation structure allow a flow of gas or liquid to pass vertically. The vertical retaining structure may have multiple lateral channels that divide the vertical retaining structure into discrete islands. Laterally distributed channels are formed between these discrete islands, allowing liquid or gas released from the bottom of the battery cell to pass through.

[0012] III. Dependencies and Problem Area Structure Regarding the route system architecture → battery pack layout, sealing and manufacturing, claim 1 establishes a battery cell assembly, and the liquid-tight battery pack housing is configured to integrate with passages for electrical equipment, high-voltage electrical connections, low-voltage signal connections, and thermal management fluid to flow into and out of the housing. Claim 2 provides a signal-opening structure for a signal communication interface. Claim 4 provides a bottom cell holder having projections for positioning a holder connecting member, claim 6 provides a bottom cell holder having a lateral stopper structure, a vertical stopper structure and a ventilation structure, claim 9 provides a battery cell connecting member for connecting a plurality of BCs in parallel to form a plurality of parallel connected BC groups, and connecting these plurality of parallel connected BC groups in series to at least one adjacent BC, claim 10 provides a housing having side walls with internal passages for thermal management fluid, claim 12 establishes a vehicle having a battery pack integrated into a chassis, and claim 14 establishes a battery pack assembly process.

[0013] IV. Embodiments corresponding to each claim The first embodiment provides a battery pack comprising: at least one battery cell assembly having a plurality of battery cells, cell holders and at least one battery cell connector; a housing integrated as a liquid-tight housing, comprising a front side wall, right side wall, left side wall, rear side wall, bottom wall and top wall combined to define a space for housing the battery cells, at least one battery cell connector and a thermal management fluid; a coolant inlet and coolant outlet provided on the right side wall and left side wall, respectively; at least one high-voltage connector provided on the front side wall; and at least one busbar connected to the high-voltage connector and the battery cell connector; and a battery management system comprising at least one cell monitoring unit. The housing is configured to be integrated with electrical equipment. The battery cell assembly is monitored by the cell monitoring unit. An external connection interface of the cell monitoring unit is assembled into the housing and is configured to connect to a low-voltage connector of a downstream signal circuit.

[0014] Another embodiment provides that the housing further includes a signal-opening structure, which is a through-hole extending from the inner surface of the front wall to the outer surface of the front wall, and such a through-hole provides a channel for housing a signal communication interface.

[0015] Another embodiment provides that the through-hole may further include a cylindrical channel structure and a square channel structure. The cylindrical channel structure provides a through-hole extending from the inner surface of the side wall to the middle portion of the front side wall, such a through-hole having a rounded-edged inner opening facing the BCA space and a rounded-edged outer opening facing the external space of the housing. The cross-section of the rounded-edged inner opening is smaller than the cross-section of the rounded-edged outer opening, thereby allowing a portion of the middle portion of the side wall to be seen from the outside of the housing.

[0016] Another embodiment provides that the battery pack includes a holder connector and the cell holder includes a bottom cell holder. The bottom cell holder is mounted on the surface of the bottom wall. The bottom cell holder has a projection, and the holder connector has a positioning hole, the projection being inserted into the positioning hole to position the holder connector on the bottom cell holder. The holder connector is configured to function as a support chassis providing vertical support and is configured to function as a partition between the battery cell assemblies.

[0017] Another embodiment provides that the holder connecting member includes a plurality of fence structures, the plurality of fence structures configured as lateral channels through which fluid passes between the fence structures.

[0018] Another embodiment provides that the cell holder includes a bottom cell holder. The bottom cell holder includes a layer of lateral retaining structures, a layer of vertical retaining structures, and a plurality of ventilation structures. The lateral retaining structures are planar structures having receiving holes configured to receive battery cells. The vertical retaining structures are attached to the bottom of the lateral retaining structures and are configured to support the weight of the battery cells. The vertical retaining structures have a plurality of lateral channels that divide the vertical retaining structures into discrete islands, between which the lateral channels form gaps between the bottom cell holder and the bottom wall. Laterally distributed lateral channels are formed, allowing liquid or gas released from the bottom of the battery cells to pass through. The ventilation structures are located above the lateral channels of the vertical retaining structures and include through holes extending from the lowest end of the lateral retaining structures to the uppermost end of the ventilation structures, thereby allowing gas or liquid to flow vertically through the through holes. When a thermal event causes a battery cell to release gas from its bottom, the gas passes through lateral channels between discrete islands, then enters through holes in the ventilation structure, and moves vertically toward the upper end of the ventilation structure.

[0019] Another embodiment provides that the bottom cell holder further includes a plurality of vertical fluid channel structures located on both sides of the bottom cell holder, wherein the lateral channels are fluidly connected to the vertical fluid channel structures.

[0020] Another embodiment provides that the horizontal projection area of ​​the vertical stopper structure is smaller than the horizontal projection area of ​​the bottom cell holder.

[0021] Another embodiment provides a battery cell connecting member that electrically connects multiple BCs in parallel and connects multiple BCs in series to at least one adjacent BC.

[0022] Another embodiment provides that the right and left walls each have at least one internal port, and the right and left walls each define an internal passage through which a thermal management fluid can flow, and each passage is in fluid communication with an internal port and a coolant inlet or coolant outlet. The internal port allows the space to be in fluid communication with the internal passage.

[0023] Another embodiment provides that a plurality of internal ports are evenly distributed on the inner wall surfaces of the right and left walls, along the sides defined by the intersection of the inner wall surface and the top wall surface. The evenly distributed internal ports are configured to provide a uniform flow of the heat management fluid through the space.

[0024] The second aspect provides a vehicle comprising a chassis and a battery system including the aforementioned battery pack integrated into the chassis to form a cell-to-chassis integration.

[0025] Another embodiment provides that the battery system includes at least one battery cell assembly, a battery management system, and a thermal management system, wherein the at least one battery cell assembly is formed of battery cells electrically connected by at least one battery cell connecting member.

[0026] The third aspect is an assembly process of a battery pack, including steps of assembling a plurality of side walls of a housing that includes a front side wall, a rear side wall, a right side wall, and a left side wall, and a high-voltage connector and a signal interface circuit board are provided on the front side wall; providing a coolant inlet and a coolant outlet on the right side wall and the left side wall respectively; arranging a bottom cell holder inside the housing; assembling a holder connection member to the bottom cell holder; assembling two barriers to the right side wall and the left side wall respectively; assembling a plurality of battery cells to the bottom cell holder inside the housing; connecting a part of the high-voltage connector inside the housing to a contactor inside the housing; assembling a plurality of connecting rods to a plurality of insertion holes of the bottom cell holder, where the connecting rods are located between the battery cells and protrude from above the battery cells; assembling a top cell holder to the connecting rods and above the battery cells; filling a gap material inside the housing to fix the battery cells; arranging a plurality of battery cell connection members on a top cell holder and assembling the battery cell connection members to the battery cells; providing two busbars in the housing in sequence to provide a high-voltage electrical connection from the inside to the outside of the battery pack; providing a battery management system in the housing to provide a signal connection from the inside to the outside of the battery pack; providing a circuit layout of a temperature sensor; providing a bottom wall at the bottom of the housing; providing a top wall at the top of the housing and providing a plurality of signal outlets on the top wall, so as to provide an assembly process of the battery pack.

[0027] Another aspect provides that before arranging the bottom cell holder inside the housing, a plurality of positioning members are arranged at the corners of the housing for the bottom cell holder, and after arranging the bottom cell holder inside the housing, the corners of the bottom cell holder abut against the positioning members.

[0028] Another aspect provides that the bottom cell holder has protrusions, the holder connection member has positioning holes, and the protrusions are inserted into the positioning holes to position the holder connection member to the bottom cell holder.

[0029] Another embodiment provides a bottom cell holder comprising a layer of lateral restraint structure having a receiving hole and a layer of vertical restraint structure, wherein the battery cell is received in the receiving hole of the lateral restraint structure and supported by the vertical restraint structure, so that the inner wall of the receiving hole restricts the lateral movement of the battery cell and the vertical restraint structure restricts the downward vertical movement of the battery cell.

[0030] Another embodiment provides that the thickness of the interstitial material is less than or equal to the height of the ventilation structure above the lateral retaining structure, thereby preventing the interstitial material from filling the through-holes of the ventilation structure.

[0031] Another embodiment provides that a thermocouple is attached to the bottom of the battery cell before the battery cell is assembled into the bottom cell holder.

[0032] Another embodiment provides a top cell holder having a plurality of assembly holes, into which connecting rods are inserted to position the top cell holder above the battery cell.

[0033] Another embodiment provides that battery cells are connected in parallel by one battery cell connecting member for every three cells.

[0034] Another embodiment provides that battery cells are electrically connected by battery cell connecting members to form a plurality of electrically series-connected battery cell assemblies, and the electrodes of the plurality of battery cell assemblies are assembled on the right and left walls, respectively, so as to connect the battery cell assemblies in series to form a battery system.

[0035] Another embodiment provides that the battery management system includes a plurality of cell monitoring units and a plurality of flexible printed circuit boards, the flexible printed circuit boards being assembled to the battery cell assemblies, and the cell monitoring units being assembled to the flexible printed circuit boards.

[0036] Another embodiment provides that multiple signal interface circuit boards of the cell monitoring unit are assembled in a housing and configured to connect to low-voltage connectors of downstream signal circuits.

[0037] Another embodiment provides that each busbar has one end that contacts a battery cell connecting member and the other end that connects a contactor.

[0038] Another embodiment provides that a sealing ring is positioned between the bottom wall and the side wall to prevent leakage of the heat management fluid, and a sealing ring is positioned between the top wall and the side wall to prevent leakage of the heat management fluid.

[0039] This summary is provided for technical information and convenience of understanding and is not intended to be used to identify essential features, define the scope of protection, or interpret the claims.

[0040] These and other objects of the present invention will become undoubtedly apparent to those skilled in the art after reading the following detailed description of preferred embodiments shown in various figures and drawings. [Brief explanation of the drawing]

[0041] [Figure 1] This 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).

[0042] [Figure 2A] This is a perspective view of one embodiment of a battery cell assembly (0010). [Figure 2B] This is a perspective view of one embodiment of a battery cell assembly (0010), and is an exploded view showing the cell holder (0050), the cell receiving structure (0060), and the electrode surface (0024).

[0043] [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).

[0044] [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).

[0045] [Figure 3A] This is a conceptual perspective view showing two battery cell assemblies (0010) arranged in a stacked configuration. [Figure 3B] This is a conceptual perspective view showing two battery cell assemblies (0010) arranged in a parallel configuration (Figure 3B).

[0046] [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).

[0047] [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 the top opening (0094), the bottom opening (0095), and two cell holders (0050).

[0048] [Figure 6A] This is a top view of a rectangular liquid-restricting casing (0080) having side walls (0091) indicated by an east wall (0096), a south wall (0097), a west wall (0098), and a north wall (0099).

[0049] [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), corner column (0130), and side wall (0091).

[0050] [Figure 6C] This is a diagram of a surrounding wall (0090) assembled from two walls that partially enclose it.

[0051] [Figure 6D] This is a diagram of a peripheral wall (0090) assembled from four independent side walls (0091).

[0052] [Figure 7A] This is a top view of a liquid-restricting casing (0080) showing the inner surface of the peripheral wall (0090) and a cell holder retaining structure (0140) extending inward from the inner boundary (0141). [Figure 7B] This is a top view of a liquid-restricting casing (0080) showing the inner surface of the peripheral wall (0090) and a cell holder retaining structure (0140) extending inward from the inner boundary (0141). [Figure 7C] This is a top view of a liquid-restricting casing (0080) showing the inner surface of the peripheral wall (0090) and a cell holder retaining structure (0140) extending inward from the inner boundary (0141), and showing a cell holder (0050) and a battery cell assembly (0010) having a cross section line A-A'.

[0053] [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.

[0054] [Figure 7E] This is a diagram of the liquid limiting casing (0080), showing individual cell holder retaining structures (0140) on the inner north face (0105) of the north side wall (0099).

[0055] [Figure 8A] This is a top view showing the cell holder fixing structure (0150) inside the liquid limiting casing (0080), and 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).

[0056] [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).

[0057] [Figure 10A] This is a diagram of a liquid-restricting casing (0080) showing the top wall surface (0160), bottom wall surface (0170), top surface connecting structure (0180), and bottom surface connecting structure (0190).

[0058] [Figure 10B] This diagram shows two liquid limiting casings (0080) stacked together with connecting structures (0180, 0190) engaged.

[0059] [Figure 11A] The sealing feature portion at the interface between the liquid-restricting casings (0080) is shown, along with the sealing member housing structure (0220) and the sealing member positioning structure (0210). [Figure 11B] The sealing feature portion 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.

[0060] [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).

[0061] [Figure 12B] This figure shows a vertical wall channel (0230) having a conductor rod (0280).

[0062] [Figure 13] This is a conceptual block diagram of an electric vehicle (3010) designed using a cell-to-chassis integrated battery system (3030).

[0063] [Figure 14] This is a conceptual side view of an EV (3010) with a CTC integrated BS (3030).

[0064] [Figure 15] This is a conceptual block diagram of the CTC integrated BS (3030).

[0065] [Figure 16A] This is a perspective view of BS(3030) of this disclosure.

[0066] [Figure 16B] This is a perspective view showing the inside of the BCA enclosure (3080).

[0067] [Figure 17A] This is a perspective view showing that four BCAs (0010) are integrated into the BCA space (3120) defined by the BCA enclosure (3080).

[0068] [Figure 17B] This is an exploded view of the BS(3030).

[0069] [Figure 18A] This is a perspective view showing the bottom cell holder (0520).

[0070] [Figure 18B] This is a top view showing the bottom cell holder (0520).

[0071] [Figure 18C] This is a perspective view showing the bottom of the bottom cell holder (0520).

[0072] [Figure 18D] This is a conceptual side view of the bottom cell holder (0520), BC (0020), and bottom wall (3100).

[0073] [Figure 19A] This shows the assembly process for BS(3030). [Figure 19B] This shows the assembly process for BS(3030). [Figure 19C] This shows the assembly process for BS(3030). [Figure 19D] This shows the assembly process for BS(3030). [Figure 19E] This shows the assembly process for BS(3030). [Figure 19F] This shows the assembly process for BS(3030). [Figure 19G] This shows the assembly process for BS(3030). [Figure 19H] This shows the assembly process for BS(3030). [Figure 19I] This shows the assembly process for BS(3030). [Figure 19J] This shows the assembly process for BS(3030). [Figure 19K] This shows the assembly process for BS(3030). [Figure 19L] This shows the assembly process for BS(3030). [Modes for carrying out the invention]

[0074] Before describing this disclosure in more detail, note that, where appropriate, reference numerals are repeated in the figures to indicate, optionally, corresponding or similar elements that may have similar characteristics.

[0075] To facilitate the description of this disclosure, directional terms may be used in this specification and in the claims to describe parts of the disclosure (e.g., front, back, left, right, top, bottom, etc.). Unless specifically defined otherwise, these definitions of directions are intended solely to assist in describing and claiming this disclosure and are not intended in any way to limit the disclosure.

[0076] The following contains specific information relating to exemplary embodiments in this disclosure. The detailed disclosure of the drawings and accompanying drawings is limited to exemplary embodiments of this disclosure. However, this disclosure is not limited to these exemplary embodiments. Those skilled in the art will be able to envision other variations and embodiments of this disclosure. Unless otherwise noted, similar or corresponding elements in the drawings may be indicated by similar or corresponding reference numerals. Furthermore, the drawings and illustrations in this disclosure are generally not intended to correspond to actual relative dimensions and are not to scale.

[0077] For consistency and ease of understanding, similar features are identified by numbers in the illustrative figures (although some examples are not illustrated). However, features in different embodiments should not be narrowly limited to those shown in the figures, as they may differ in other respects.

[0078] References to “one embodiment,” “embodiment,” “exemplary embodiment,” “various embodiments,” “several embodiments,” and “embodiments of the Disclosure” may indicate that embodiments of the Disclosure may include certain features, structures, or characteristics, but not all possible embodiments of the Disclosure necessarily include certain features, structures, or characteristics. Furthermore, repeated use of the phrases “in one embodiment,” “in an exemplary embodiment,” or “embodiment” does not necessarily refer to the same embodiment, although they may refer to the same embodiment. Also, any use of phrases such as “embodiment” in relation to “the Disclosure” should be understood not as meaning that all embodiments of the Disclosure must include certain features, structures, or characteristics, but rather as meaning that “at least some embodiments of the Disclosure” include the specific features, structures, or characteristics described. The term “coupled” is defined as a direct connection or an indirect connection through 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 refers to an open form of inclusion or membership in a disclosed combination, group, series, and equivalent.

[0079] 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 to avoid obscuring the disclosure with unnecessary details.

[0080] 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 in mechanical and electrical ways, for example, assembled to provide collective performance.

[0081] As shown in Figure 1, in some embodiments, the BCA0010 may include one or more battery cell strings 0030 (hereinafter referred to as BCS) that are electrically connected in parallel. The number of BCS0030 connected in parallel determines the overall current output of the BCA0010. Furthermore, each of the BCS0030 may include one or more battery cells 0020 (hereinafter referred to as BC) that are electrically connected in series. The number of BC0020 in each of the series-connected BCS0030 determines the overall voltage output of the BCS0030 and the BCA0010.

[0082] The charge / discharge circuit 0040 may 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-consuming device such as the motor of an electric vehicle, thereby supplying power to the motor.

[0083] In some embodiments (not shown in Figure 1), the charge / discharge circuit 0040 may include two or more BCAs 0010 to satisfy certain design considerations, such as the manufacturing and / or assembly process of the charge / discharge circuit 0040 itself, or design considerations relating to the assembly of the charge / discharge circuit 0040 with electrical equipment.

[0084] Referring back to Figure 1, depending on the technology used, the BC0020 may have different specifications in aspects such as shape, electrical performance (output voltage, current, power, charging speed, discharging speed, or operating temperature, etc.), material, and other properties. For example, the BC0020 can be enclosed in various forms such as cylindrical, prismatic, or pouch. Unless otherwise specifically specified, those skilled in the art should understand that the technical features disclosed herein are not necessarily limited to any particular type of BC0020.

[0085] BC0020 is configured as a fundamental element for converting electrical energy to chemical energy or vice versa. 1. A charge / discharge circuit 0040 to which BC0020 is connected, 2. The interface between the cathode material and the anode material enclosed in BC0020 may include a positive electrode and a negative electrode.

[0086] Furthermore, BC0020, which is configured as the fundamental energy-storing building blocks for BCA0010 and the charge / discharge circuit 0040, must 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 BC0020 body, respectively. In such cases, since BC0020 is usually mechanically parallel, each electrode of BC0020 may 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 located and distributed.

[0087] In some embodiments, BCA0010 may include a battery cell connecting member 0026 (hereinafter referred to as BCCM), which is a conductor configured to connect to the electrodes of BC0020. BC0020 is electrically connected in parallel or series by the BCCM0026. For example, a planar conductive plate can be placed on the electrode surface 0024 to connect the electrodes of BC0020.

[0088] In this disclosure, when referring to direction, the terms "lateral direction" and "in the lateral direction" refer to the direction on the plane in which the electrodes of BC0020 of BCA0010 are arranged, and the direction parallel to the lines on the plane in which the BC0020 of BCA0010 are distributed in parallel. In the figures of this disclosure, the lateral direction is expressed as the direction parallel to the lines on the yz plane. The term "top view" refers to a cross-section viewed from the positive x direction toward the negative x direction.

[0089] In this disclosure, the terms “vertical” 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, “vertical” refers to the direction along the x-direction.

[0090] For example, refer to Figures 2A and 2B, perspective views of an embodiment of BCA0010 (not all components of BCA0010 are shown), where Figure 2B is an exploded view of Figure 2A. In Figures 2A and 2B, the body of BC0020 may extend vertically (along the x-direction). Furthermore, the vertical axis of BC0020 is parallel to the x-direction, and BC0020 is parallel along the yz-plane.

[0091] In some embodiments, to mechanically or structurally integrate BC0020, 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 BC0020 is: 1. Restricting the relative position of a particular BC0020 to any other BC0020 belonging to the same BCA0010, and 2. The relative position of a specific BC0020 with respect to the main body of BCA0010 may be restricted. For example, in Figure 2A, a portion of the body of each BC0020 is placed within the corresponding cell receiving structure (cell receiving structure) 0060 of the cell holder 0050. The cell receiving structures 0060 are periodically distributed along the lateral direction. Therefore, when BC0020 are placed within the cell receiving structures 0060, these BC0020 may be arranged laterally in such a periodic spatial distribution.

[0092] In some embodiments, the cell holder 0050 may include vertical limiting structures 0070 to restrict the vertical movement of the BC0020. All the bodies and electrodes of the BC0020 of the BCA0010 may 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.

[0093] In some embodiments, adhesive may be used to provide a displacement limiting function. For example, after placing BC0020 in the supporting holes of the cell holder 0050, adhesive can be introduced to further secure BC0020.

[0094] 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 maintain the relative position between the electrode surface 0024 and BCCM0026 in a stationary state. For example, if BC0020 is mechanically fixed to the cell holder 0050, BCCM0026 may be mechanically connected to the cell holder 0050.

[0095] For example, in Figure 2C, an exploded perspective view of an exemplary BCA0010 (BC and some components not shown), the BCA0010 includes a cell holder 0050 and a BCCM0026. The BCCM0026 is a plate-shaped conductive material. The BCCM0026 is positioned in the cell holder 0050 and is also configured to be positioned on the electrode surface 0024 of the BCA0010.

[0096] In some embodiments, BCCM0026 may include a cell-contact-plate 0027 and a current-transport-plate 0028.

[0097] The cell contact plate 0027 may be configured to make direct contact with the electrodes of BC. Connection processes such as welding, crimping, fastening, or the use of conductive adhesives may be used to connect the cell contact plate 0027 to the electrodes of BC. Furthermore, in some cases, the cell contact plate 0027 may include a fusing welding structure 0025 configured to melt when the current becomes overloaded.

[0098] The current transport plate 0028 may be configured to transport the combined 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.

[0099] 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 a hollow structure on the cell holder 0050. In another example, the BCCM0026 may include a hole configured to engage with a projection or protrusion on 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 may be limited.

[0100] Figures 3A and 3B are conceptual perspective views of the integration of two BCA0010s. Depending on the available space for installing the BCA0010s in the electrical equipment, the BCA0010s may be integrated in a stacked or parallel (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 parallel manner, suitable for placement in spaces with sufficient width but limited height, such as the floor space under a cabinet in a passenger car.

[0101] In this disclosure, the terms “vertical” and “perpendicular” also refer to the stacking direction of a stacking-type integration BCA. For example, in Figure 3A, the stacking-type integration BCA is stacked along the vertical direction and along the x-direction.

[0102] 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 heat management fluid so that the heat management fluid 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 entirely immersed in the heat management fluid. If the entire BCA0010 is immersed, BCA0010 and several other components intended to be integrated into BCA0010 may be in direct contact with the heat management fluid, thereby providing a greater effect on thermal management.

[0103] To immerse BCA0010 in a heat management fluid, BCA0010 can be integrated into a liquid-restricting casing 0080 (hereinafter, LLC). LLC0080 may be configured to restrict the movement of the heat management fluid. For example, in a space described by Cartesian coordinates, a particular volume of heat management fluid may have a displacement or velocity that can be described by a vector containing components obtained by multiplying unit vectors in the x, y, or z directions by coefficients, respectively. To maintain the relative position between BCA0010 and the heat management fluid while BCA0010 is immersed in the heat management fluid, LLC0080 may include means to restrict the movement of the heat management fluid in at least some of those six directions.

[0104] In some embodiments, impervious materials can be used to form a specific structure that completely or partially encloses the heat management fluid, thereby restricting the movement of the heat management fluid in all or some directions. For example, LLC0080 may be formed as a tubing shape having two openings, such as a triangular tube, a square tube, or a circular tube. The tubing-shaped LLC0080 may include a circumferential wall 0090 (or in other words, a circumferential wall).

[0105] In some embodiments, the peripheral walls of LLC0080 may include impervious membranes to restrict the movement of the heat management fluid.

[0106] In some embodiments, LLC0080 may include rigid structures such as impervious walls to restrict the movement of the heat management fluid.

[0107] 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 be asymmetrical geomatics. In Figures 4A, 4B, and 4C, each of the illustrated LLC0080 includes a peripheral wall 0090 enclosing the space laterally. In Figures 4A, 4B, and 4C, the peripheral wall 0090 can extend vertically, i.e., along the x-direction. Thus, the three-dimensional space enclosed by the LLC0080 can be used to accommodate a heat management fluid, a BCA0010, and several components intended to be integrated into the BCA0010. Due to the impervious property of the peripheral wall 0090, the heat management fluid contained within the LLC0080 can only move vertically.

[0108] Figures 5A and 5B are perspective views of an exemplary embodiment of BCA0010, and not all components of BCA0010 are shown in order to clearly specify the means for immersing BCA0010 in the heat management fluid. For example, BC0020 is not shown in Figures 5A and 5B.

[0109] 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 into BC0020 (BC0020 is not shown in Figures 5A and 5B). Several other components, not shown, intended to be integrated into cell holders 0050, BC0020, and BCA0010 may be located within the space enclosed by LLC0080.

[0110] In embodiments in which LLC0080 is formed in a tubular shape, the peripheral wall 0090 may be formed as a material extending vertically between a top vertical position 0092 and a bottom vertical position 0093. At the top vertical position 0092, the inner edge of the peripheral wall 0090 may define a top opening 0094 of LLC0080, and at the bottom vertical position 0093, the inner edge of the peripheral wall 0090 may define a bottom opening 0095 of LLC0080. The top opening 0094 and the bottom opening 0095 may be configured as entrances or exits to the space enclosed by the peripheral wall 0090. Components such as BC0020, cell holders 0050, and other components intended to be placed inside LLC0080 may be placed within the internal space of LLC0080 through at least one of the top opening 0094 and the bottom opening 0095.

[0111] For example, in the embodiment shown in Figure 5B, the peripheral wall extends between the top vertical position 0092 and the bottom vertical position 0093. The vertical length (i.e., height) of LLC0080 is equal to the vertical distance between the top vertical position 0092 and the bottom vertical position 0093 H1. The two cell holders are positioned within the space enclosed by the peripheral wall 0090 through the top opening 0094 and the bottom opening 0095.

[0112] 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 that surround the vertical axis in the circumferential direction and are arranged parallel to the vertical axis. For example, Figure 6A shows an exemplary top view of the LLC0080. The LLC0080 includes four side walls 0091, namely the east side wall 0096, the south side wall 0097, the west side wall 0098, and the north side wall 0099, which are arranged to surround the vertical axis in the circumferential direction.

[0113] In some embodiments, LLC0080 may be manufactured by an integral molding process such as injection molding or die casting. Alternatively, LLC0080 may be manufactured using a turning process.

[0114] Referring to 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.

[0115] 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 extends between one of the two outer corners of the corresponding side wall 0091. For example, in Figure 6B, the east side wall 0096 includes an outer east surface 0107 extending between the outer northeast corner 0126 and the outer southeast corner 0127, the south side wall 0097 includes an outer south surface 0108 extending between the outer southeast corner 0127 and the outer southwest corner 0128, the west side wall 0098 includes an outer west surface 0109 extending between the outer southwest corner 0128 and the outer northwest corner 0129, and the north side wall 0099 includes an outer north surface 0110 extending between the outer northwest corner 0129 and the outer northeast corner 0126.

[0116] Furthermore, the inner wall surface 0101 of each side wall 0091 may be an inner plane extending between one of two adjacent inner corners of the lower side wall 0091. For example, in Figure 6B, the east side wall 0096 includes an inner east surface 0102 extending between the inner northeast corner 0121 and the inner southeast corner 0122, the south side wall 0097 includes an inner south surface 0103 extending between the inner southeast corner 0122 and the inner southwest corner 0123, the west side wall 0098 includes an inner west surface 0104 extending between the inner southwest corner 0123 and the inner northwest corner 0124, and the north side wall 0099 includes an inner north surface 0105 extending between the inner northwest corner 0124 and the inner northeast corner 0121.

[0117] In some embodiments, the perimeter wall 0090 may be assembled from separate components. For example, in Figure 6B, LLC 0080 includes four corner pillars 0130, which are independent components assembled with side walls 0091 (i.e., the east side wall 0096, the south side wall 0097, the west side wall 0098, and the north side wall 0099) to form the perimeter wall 0090. In another example, referring to Figure 6C, the perimeter wall 0090 may be assembled from two partially enclosing walls. In yet another example, referring to Figure 6D, the perimeter wall 0090 may be assembled from four independent side walls 0091.

[0118] 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 the space enclosed by LLC0080 through one of the top openings 0094 and bottom openings 0095 at the two vertical ends of the tubular structure. LLC0080 may include at least one cell holder retaining structure 0140 extending from one of the inner surfaces of the peripheral wall 0090 and extending inward along the lateral direction.

[0119] The vertical relative 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 vertically reach within the space enclosed 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 enclosed by the peripheral wall 0090.

[0120] 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 (hidden in Figure 7A) is integrated into 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.

[0121] 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.

[0122] 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, BC0020 may be placed within a space partially enclosed by the curved portion of the inner boundary 0141 of the cell holder retaining structure 0140.

[0123] Figure 7C shows an exemplary BCA0010. BCA0010 includes a cell holder 0050 located within the space enclosed by the peripheral wall 0090 of LLC0080. The dashed line A-A' indicates the cross-section shown in Figure 7D.

[0124] Figure 7D shows a vertical cross-sectional view along the dashed line A-A' in Figure 7C. BCA0010 is integrated into 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 located 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.

[0125] 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 may be accommodated in the space between the top opening 0094 of the LLC 0080 and the cell holder retaining structure 0140, such a space having a height equal to H3, and the cell holder 0050 may also be accommodated in the space between the bottom opening 0095 of the LLC 0080 and the cell holder retaining structure 0140, such a space having a height equal to H3.

[0126] In some embodiments, LLC0080 may include individual cell holder retaining structures 0140 located on the inner surface of the side wall 0091. For example, referring to Figure 7E, LLC0080 includes a north side wall 0099 and two cell holder retaining structures located on the inner north surface 0105.

[0127] 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, referring to Figure 8A, the LLC0080 in 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 fastener holes 0151 that use fasteners to restrict relative movement between the LLC0080 and the cell holder 0050. 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.

[0128] Referring to Figure 8B, a top view of LLC0080 is shown. In Figure 8B, the cell holder 0050 is positioned within the space enclosed by the peripheral wall of LLC0080. LLC0080 includes the cell holder 0050 and four fixing fasteners 0152 inserted perpendicularly into the cell holder fixing structure 0150 (not shown in Figure 8B).

[0129] Referring to Figure 8C, Figure 8B shows a cross-sectional view of LLC0080 along the dashed line B-B'. 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 to LLC0080 with the fixing fastener 0152.

[0130] Figures 9A and 9B are perspective views of the stacked BCAs.

[0131] In some embodiments, as shown in Figure 10A, LLC0080 may include a top wall surface 0160 and a bottom wall surface 0170, which are surfaces extending laterally along the vertical end of LLC0080.

[0132] In some embodiments, the top wall surface 0160 and the bottom wall surface 0170 may include complementary interlocking features configured to resist lateral shear when stacked vertically. For example, as shown in Figure 10A, the top wall surface 0160 may include at least one top interlocking structure 0180, and the bottom wall surface 0170 may include at least one bottom interlocking structure 0190. The top interlocking structures 0180 and the bottom interlocking structures 0190 may be located in specific lateral positions so that when two LLCs 0080 are stacked vertically (as shown in Figure 10B), the combination of the top interlocking structures 0180 and the bottom interlocking structures 0190 can provide a lateral force to limit the relative displacement between the two stacked LLCs 0080. For example, the pair of top interlocking structures 0180 and the bottom interlocking structures 0190 may be a projection structure and a receiving structure.

[0133] Referring to Figures 11A and 11B, in some embodiments, at least one of the top wall surface 0160, the bottom wall surface 0170, or both thereof may include at least one sealing-member-accommodating structure 0220 configured to provide a space for accommodating a sealing member that is positioned at the interface of two LLCs 0080 to prevent liquid leakage from the interface of the two LLCs. For example, the sealing member 0200 may be an O-ring or an adhesive material. In some embodiments, the bottom 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 to restrict the lateral movement of the sealing member 0200. As shown in Figure 11B, the sealing member 0200 can fill the space provided by the sealing member housing structure 0220 to provide a sealing effect.

[0134] 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.

[0135] 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.

[0136] Referring to Figure 13, Figure 13 is a conceptual block diagram of an electric vehicle (EV) 3010 designed using a cell-to-chassis (CTC) integrated battery system (BS) 3030. As shown in the figure, the EV 3010 may include a chassis 3020. The chassis 3020 may include a BS 3030. In this disclosure, BS 3030 may refer to one or more battery packs (BP) having other necessary systems related to the operation of the BP, or, in the case of CTC integration, BS may refer to a cell integrated into the chassis 3020 of the chassis 3020 having other necessary systems related to the operation of the cell. For example, BS 3030 may include, but is not limited to, one or more BPs, a battery management system (BMS), a thermal management system (TMS), etc. In the CTC example, BS 3030 may have a cell integrated into the chassis 3020, a battery management system, a thermal management system, etc.

[0137] Referring to Figure 14, which is a conceptual side view of EV3010 having a CTC integrated BS3030. As shown, EV3010 may include a body 3040 and a chassis 3020. The chassis 3020 may be integrated with the body 3040, BS3030, transaction motor (not shown), transmission system (not shown), and drive wheels 3050 (only two wheels 3050 are shown in Figure 14 because it is a side view of EV3010).

[0138] Referring to Figure 15, which is a conceptual block diagram of the CTC integrated BS3030, the chassis 3020 of the EV3010 may include the BS3030. The BS3030 may include at least one BCA0010, BMS3060, and TMS3070 as described above. From the standpoint of system integration, the chassis 3020 may include accommodation spaces for at least one BCA0010, BMS3060, and TMS3070. For example, the chassis 3020 may include a BCA space for at least one BCA0010, a BMS space for BMS3060, and a TMS space for TMS3070. For example, the chassis 3020 may include structures that define these accommodation spaces.

[0139] In some cases, the BCA0010 is integrated with other components to form a battery module (hereinafter referred to as BM). For example, in this disclosure, the BM may be an assembly comprising the BCA0010 and other components such as the housing of the BCA0010, heat-regulating components such as heat dissipation components, battery management components and other components. The manufacture of the BM is typically an intermediate step in the production of the entire system. That is, the BM is considered an intermediate building block that forms a higher level of integrated energy storage system, while the BM is also integrated by the more basic building block, the BC0020, as described above. Thus, the BM may also include a modular interface configured to integrate the BM with other BMs and / or other modules of a larger energy storage system below. For example, the BM may include a modular electrical energy interface (hereinafter referred to as MEEI) configured to provide electrical connections for the transfer (charging or discharging) of electrical energy stored in or released from the BM. The MEEI may be electrodes or connectors located in the BM. For example, the BM may include interfaces for thermal control components such as liquid connectors through which thermal control fluid flows into and out of the BM and into another liquid container or channel. For example, the BM may include interfaces for mechanically connecting to another BM and / or other modules.

[0140] In this disclosure, the term “Battery Pack” (hereinafter, BP) refers to an energy storage system that is independently manufactured and encapsulated, designed to be integrated into electrical equipment (e.g., EVs, battery energy storage systems (hereinafter, BESS), or others) powered by the electrical energy discharged from the BP. This is typically produced as a separate product by a separate entity, usually separate from the original equipment manufacturer (hereinafter, OEM) of the electrical equipment. The BP ensures its integrity in transportation and integration processes, such as the EV assembly process, by being mechanically stable. The BP is also equipped with a standardized interface to facilitate electrical and mechanical integration with larger systems to be provided. In some embodiments, the BP may be integrated into the chassis by welding, adhesive bonding, or bolting. The spatial dimensions of the BP are also designed to take into account the available space for the underlying electrical equipment. In some cases, a BC0020 may be integrated to directly form the BP. For example, the BP may include a structure that can be directly integrated into a BC0020. Therefore, there is no need to manufacture BCA0010 or BM before assembling BP. This concept is known as cell-to-pack (CTP) integration.

[0141] In other cases, a BP is assembled by integrating multiple BMs. In some cases, electrical equipment, such as a passenger car, may consist of only one BP. In other cases, electrical equipment may consist of multiple BPs.

[0142] In some cases, the BC0020 may be directly integrated into the electrical equipment. For example, some passenger EVs are designed using a chassis 3020 that can be directly integrated into the BC0020. This concept is known as CTC integration. CTC integration provides a simplified manufacturing process for OEMs of electrical equipment, reducing costs.

[0143] Referring to Figures 16A and 16B, Figure 16A is a perspective view of the BS3030 of the present disclosure, and Figure 16B is a perspective view showing the interior of the BCA enclosure 3080. In Figures 16A and 16B, the BCA enclosure 3080 of the BS3030 may include four side walls 3090 (including a front side wall 3091, a rear side wall 3092, a right side wall 3093, and a left side wall 3094), a bottom wall 3100, and a top wall 3110, which are combined to define the BCA space 3120. Thus, the BCA space 3120 is enclosed by the four side walls 3090, the bottom wall 3100, and the top wall 3110 of the BCA enclosure 3080, with the top wall 3110 covering the BCA space 3120.

[0144] In some embodiments, at least a portion of the BCA enclosure 3080 may be formed together with the chassis 3020. For example, the BCA enclosure 3080 may be formed in a casting process that manufactures the chassis 3020. In some embodiments, at least a portion of the box-like BCA enclosure 3080 may be formed integrally with the chassis 3020. For example, the top wall 3110, the bottom wall 3100, or at least one side wall 3090 may be formed together with the chassis 3020.

[0145] In some embodiments, the entire BCA enclosure 3080 may be formed independently rather than together with the chassis 3020. Therefore, in such cases, the integration of the BCA enclosure 3080 with the chassis 3020 is a separate step from the manufacturing process of the chassis 3020. An independently formed BCA enclosure 3080 offers the advantage of being able to be manufactured and qualified independently of the chassis 3020, rather than being formed integrally with it, and being more easily removable for replacement or repair.

[0146] In some embodiments, the heat management fluid is introduced into the BCA housing 3080 such that at least one BCA 0010 in the BCA space 3120 is immersed in the heat management fluid. In such cases, the side walls 3090, bottom wall 3100, and top wall 3110 are integrated as a liquid-tight housing. The mechanical interfaces of these walls 3090, 3100, and 3110 may include sealing structures, sealing components, or both sealing structures and sealing components to prevent leakage of the heat management fluid from the BCA space 3120. For example, the side wall 3090 of the BCA housing 3080 may include a sealing member receiving structure 0220 (shown in Figures 11A and 11B) that receives an O-ring, or a sealing member positioning structure 0210 (shown in Figures 11A and 11B) that restricts the movement of the O-ring.

[0147] Referring to Figure 17A, the four BCA0010s are integrated into the BCA space 3120 defined by the BCA housing 3080. The top wall 3110 is configured to integrate with the side wall 3090, so that the BCA housing 3080 may be liquid-tight for immersion cooling.

[0148] In some embodiments, the BCA housing 3080 may include a coolant inlet 3095 and a coolant outlet 3096 provided on the right wall 3093 and the left wall 3094, respectively, and configured to serve as interfaces for introducing and discharging the heat management fluid into and out of the TMS 3070. For example, the TMS 3070 may include a liquid tank, a pump, and a heat exchanger for immersion cooling.

[0149] In some embodiments, each right-side wall 3093 and left-side wall 3094 may include an internal passage 3098. Each internal passage 3098 may be a through-hole in the lower right-side wall 3093 and left-side wall 3094. The internal passage 3098 may function as a relay channel between the BCA space 3120 and the inlet 3095 or outlet 3096. For example, the right-side wall 3093 may include a first internal passage which is a through-hole having a first end fluidly connected to the inlet 3095 and a second end fluidly connected to the BCA space 3120, and the left-side wall 3094 may include a second internal passage which is a through-hole having a first end fluidly connected to the outlet 3096 and a second end fluidly connected to the BCA space 3120.

[0150] In some embodiments, each right-side wall 3093 and left-side wall 3094 may include at least one passage interface structure 3099 configured as a fluid interface between the internal passage 3098 and the BCA space 3120. For example, as shown in Figure 17A, the passage interface structure may include a plurality of vertical projections 3099 extending from the inside of the lower right-side wall 3093 or left-side wall 3094. The space between two adjacent vertical projections 3099 may function as a fluid channel through which fluid flows between the internal passage 3098 and the BCA space 3120. In some embodiments, the BCA 0010 may include a cell monitoring circuit 3061, a temperature sensor, and a voltage sensor to facilitate battery management functions. These circuits may be signal-connected to a BMS 3060 via a signal communication interface mounted on the BCA housing 3080. For example, as shown in Figure 16B, the BCA housing 3080 may include a signal opening structure 3081 to provide space for setting up the signal interface. For example, as shown in Figure 16A, BS3030 may include a signal interface circuit board 3190 that is attached to a signal open structure, covered by the signal open structure, and sealed.

[0151] In some embodiments, the signal opening structure 3081 may be a through-hole extending from the inner surface of the side wall 3090 (the surface adjacent to the BCA space 3120) to the outer surface of the side wall 3090, and such a through-hole provides a channel for housing a signal communication interface. The through-hole may further include a cylindrical channel structure 3082 and / or a square channel structure 3083. The cylindrical channel structure 3082 can provide a through-hole extending from the inner surface of the side wall 3090 to the middle portion of the side wall 3090, and such a through-hole has a rounded inner opening facing the BCA space 3120 and a rounded outer opening facing the external space of the BCA housing 3080. These rounded openings are suitable for fitting an O-ring and have a higher sealing effect. For example, an O-ring receiving gap 3084 may be provided in the rounded outer opening. The square channel structure 3083 may provide through-holes extending from the middle portion of the side wall 3090 to the outer surface of the BCA housing 3080. The square shape is suitable for housing the PCB board of the signal interface circuit board 3190. The signal interface circuit board 3190 may include O-ring receiving gaps used for sealing with the BCA housing 3080 by O-rings.

[0152] Refer to Figure 17B, an exploded view of BS3030. As shown in the figure, BCA0010 may include a plurality of BC0020, a top cell holder 0510, a bottom cell holder 0520, at least one BCCM0026, at least one battery cell assembly electrode (hereinafter referred to as BCAE)0031, and gap material (not shown).

[0153] In some embodiments, the bottom cell holder 0520 may be in close contact with the surface of the bottom wall 3100 of the BCA housing 3080. The bottom cell holder 0520 may include a receiving structure that provides lateral and vertical forces to hold the BC0020. For example, the receiving structure may include a receiving hole that extends vertically. In another example, the receiving structure may include a vertically extended wall or pillar-shaped structure that can guide the insertion of the BC0020 during assembly.

[0154] In some embodiments, BC0020 may be fixed within the receiving structure of the bottom cell holder 0520. In some embodiments, a gap material (not shown) may be used to provide adhesive force to fix BC0020. The gap material may be any insulating material that can harden from a liquid state to a solid state. For example, the gap material may be a resin such as epoxy or allyl.

[0155] Referring to Figures 18A to 18C, the bottom cell holder 0520 may be a rectangular plate and may include a layer of lateral restraint structure 0521, a layer of vertical restraint structure 0522, a plurality of ventilation structures 0523, and a plurality of vertical fluid channel structures 0524. The lateral restraint structure 0521 is a planar structure having a receiving hole 0525. The receiving hole 0525 penetrates the upper and lower surfaces of the bottom cell holder 0520 and is configured to receive the BC0020. The inner wall of the receiving hole 0525 restricts the lateral movement of the BC0020. The vertical restraint structure 0522 is attached to the bottom of the lateral restraint structure 0521 and is configured to support the weight of the BC0020. The vertical restraint structure 0522 can restrict the downward vertical movement of the BC0020 by projecting radially inward from the receiving hole 0525 and supporting the BC0020. Therefore, BC0020 may be positioned on the bottom cell holder 0520 by the lateral stopper structure 0521 and the vertical stopper structure 0522. The horizontal projection area of ​​the vertical stopper structure 0522 is smaller than the horizontal projection area of ​​the bottom cell holder 0520.

[0156] Refer to Figure 18C, which shows the bottom of the bottom cell holder 0520. The vertical stopper structure 0522 is formed of discrete islands. In this embodiment, the vertical stopper structure 0522 may have a plurality of lateral channels 0526 that divide the vertical stopper structure 0522 into discrete islands. Laterally distributed channels 0526 are formed between these discrete islands, allowing liquid or gas released from the bottom of BC0020 to pass through. These lateral channels 0526 are fluidly connected to a ventilation structure 0523 or a vertical fluid channel structure 0524.

[0157] Referring to Figures 18A to 18C, the ventilation structure 0523 and the vertical fluid channel structure 0524 are tubular structures extending upward from the lateral sealing structure 0521. The ventilation structure 0523 is located above the lateral channel 0526 of the vertical sealing structure 0522. These tubular structures include through-holes extending from the lowest end of the lateral sealing structure 0521 to the uppermost end of the tubular structures, thereby allowing gas or liquid to flow vertically through the through-holes.

[0158] Referring to Figure 18D, the lateral channel 0526 forms a gap between the bottom cell holder 0520 and the bottom wall 3100. For example, when a thermal event causes BC0020 to release gas from its bottom, the gas may pass through the lateral channel 0526 between the discrete islands of the vertical stopper structure 0522, then enter the through-holes of the ventilation structure 0523, and move vertically toward the upper end of the ventilation structure 0523 (the arrows shown in Figure 6D represent the movement of gas). Thus, BC0020 does not expand due to the gas, thereby ensuring the safe operation of BC0020. In some embodiments, the thickness of the gap material (not shown in Figure 18D) is less than or equal to the height h of the ventilation structure 0523 above the lateral stopper structure 0521, so that the gap material does not fill the through-holes of the ventilation structure 0523.

[0159] In some embodiments, the bottom cell holder 0520 may have a connecting structure 0527 for connecting to other bottom cell holders 0520. The connecting structure 0527 may be an engaging structure having a concave joint and a convex joint. The connecting structure 0527 and the vertical fluid channel structure 0524 may be located on both sides of the bottom cell holder 0520.

[0160] Referring to Figures 19A to 19L, these figures illustrate the assembly process of the BS3030. When assembling the BCA enclosure 3080, the side walls 3090 are assembled first. As shown in Figure 19A, the high-voltage connector 3097 and the signal interface circuit board 3190 are mounted on the front side wall 3091, and the gap between the high-voltage connector 3097 and the front side wall 3091 is sealed with structural adhesive (e.g., DP100). Next, the front side wall 3091, rear side wall 3092, right side wall 3093, and left side wall 3094 are assembled, and their joints are sealed with structural adhesive to form the BCA enclosure 3080. Furthermore, the coolant inlet 3095 and coolant outlet 3096 may be provided on the right wall 3093 and left wall 3094, respectively, so that the heat management fluid can flow into the BCA housing 3080 through the coolant inlet 3095 and out of the BCA housing 3080 through the coolant outlet 3096.

[0161] Next, the components of the BCA0010 are sequentially provided within the BCA housing 3080. As shown in Figure 19B, the two bottom cell holders 0520 may be connected to each other by a connecting structure 0527. Before positioning the two bottom cell holders 0520 within the BCA housing 3080, four positioning members 3130 are positioned at the four corners of the bottom of the BCA housing 3080 for the two bottom cell holders 0520. Note that, due to viewing angle, only one positioning member 3130 is shown in Figure 19B. Two of the four corners of each bottom cell holder 0520 may be designed as planar corners that accommodate the positioning members 3130. Therefore, after the two bottom cell holders 0520 are placed inside the BCA housing 3080, the corners of each bottom cell holder 0520 abut against the corresponding positioning member 3130 to position the two bottom cell holders 0520 against the bottom wall 3100 of the BCA housing 3080.

[0162] Next, the holder connecting member 3140 is assembled to the bottom cell holder 0520. The holder connecting member 3140 may also function as a support chassis that provides vertical support force to support the components located at the top of the holder connecting member 3140. The holder connecting member 3140 may also function as a partition between the BCAs 0010, for example, the holder connecting member 3140 may be an insulator to provide an electrical barrier between multiple BCAs 0010 in the BCA space 3080. The holder connecting member 3140 may include multiple fence structures 3142, which are configured as lateral channels through which fluid passes between the fence structures 3142. As shown in Figures 19B and 19C, the bottom cell holder 0520 may have projections 0528, and the holder connecting member 3140 may have positioning holes 3141. The projection 0528 is inserted into the positioning hole 3141 to position the holder connecting member 3140 on the bottom cell holder 0520. Next, as shown in Figure 19D, the two barriers 3150 are assembled on the right wall 3093 and the left wall 3094, respectively. The two barriers 3150 are made of insulating material and are fixed to the inner wall surfaces 0101 of the right wall 3093 and the left wall 3094, respectively, to provide vertical support. Next, as shown in Figure 19E, the BC0020 is assembled on the bottom cell holder 0520 within the BCA housing 3080. As described above, BC0020 is received in the receiving hole 0525 of the lateral restraining structure 0521 and supported by the vertical restraining structure 0522, so that the inner wall of the receiving hole 0525 restricts the lateral movement of BC0020, and the vertical restraining structure 0052 restricts the downward vertical movement of BC0020. Note that the thermocouple is bonded to the bottom of BC0020 before BC0020 is assembled to the bottom cell holder 0520. Next, as shown in Figure 19F, a portion of the high-voltage connector 3097 in the BCA housing 3080 is connected to the contactor 3160 in the BCA housing 3080.

[0163] Next, as shown in Figures 17B and 19G, the multiple connecting rods 3170 are assembled into the multiple insertion holes 0529 of the bottom cell holder 0520 (as shown in Figure 18A). After the connecting rods 3170 are assembled into the bottom cell holder 0520, they are positioned between the BC0020s and protrude from above the BC0020s. Next, the four top cell holders 0510 are assembled into the connecting rods 3170s and assembled above the BC0020s. In this embodiment, each of the top cell holders 0510s has multiple assembly holes 0511, so that the connecting rods 3170 can be inserted into the assembly holes 0511s and positioned above the BC0020s, as shown in Figure 19H. Next, the gap material described above is filled into the BCA housing 3080 to fix the BCs in place. As shown in Figure 18D, the thickness of the gap material (not shown in Figure 18D) is less than or equal to the height h of the ventilation structure 0523 above the lateral retaining structure 0521, so that the gap material does not fill the through-holes of the ventilation structure 0523.

[0164] Next, as shown in Figure 19I, a plurality of BCCM0026s are arranged on four top cell holders 0510 and assembled into BC0020s, where three BC0020s are connected in parallel by one BCCM0026. In this embodiment, the positive and negative electrodes are located at the same end of each BC0020. Each BCCM0026 includes a first conductive portion and three second conductive portions located on one side of the first conductive portion. Each of the second conductive portions is electrically coupled to the first conductive portion via a corresponding neck portion. The first conductive portion of each BCCM0026 contacts the negative electrode of the BC0020. The second conductive portions of each BCCM0026 contact the positive electrode of the adjacent BC0020. BCCM0026 electrically connects multiple BC0020s in parallel to form a group of multiple parallel-connected BC0020s, and connects the group of multiple parallel-connected BC0020s in series to at least one adjacent BC0020. The design of BCCM0026 enables a reduction in the manufacturing steps required to assemble the BC0020s into BCA0010s.

[0165] For example, the first conductive portion of each BCCM0026 contacts the negative electrodes of three BC0020s, and the second conductive portion of each BCCM0026 contacts the positive electrodes of three adjacent BCs, thereby electrically connecting all three BC0020s in parallel and connecting the three groups of BC0020s in series. In this embodiment, the BC0020s are electrically connected by the BCCM0026s to form four electrically series-connected BCA0010s.

[0166] Furthermore, each of the four BCAE0031s is positioned in the barrier 3150 and assembled on the right wall 3093 and the left wall 3094 to electrically connect two sets of BCA0010 in series, each set containing two BCA0010s. The fifth BCAE0031 electrically connects each set of BCA0010s to form BS3030. During the assembly of the BCAE0031s, the barrier 3150 can provide vertical support to the BCAE0031s and prevent short-circuit contacts.

[0167] Next, as shown in Figure 19J, two busbars 3181 and 3182 are provided sequentially within the BCA housing 3080 to provide high-voltage electrical connections from the inside (i.e., the BCA) of the BP to the outside. The two busbars 3181 and 3182 are provided along the side of the BCA, which is also adjacent to another BCA, thereby achieving a reduction in the overall volume of the BP or a simplified layout within the BP. For example, each of the busbars 3181 and 3182 may have one end that contacts the BCCM0026 of the BCA0010 and the other end that connects to the contactor 3160. The two busbars 3181 and 3182 may be high-voltage busbars. In this embodiment, busbar 3181 may be connected to the high-voltage connector 3097 on the right side of Figure 19J and to BCCM0026 of BCA0010, and busbar 3182 may be connected to contactor 3160 and another BCCM0026 of BCA0010.

[0168] Next, the components related to the BMS3060 are housed within the BCA enclosure 3080 to provide signal connections from the inside (i.e., BCA) of the BP to the outside. As shown in Figure 19K, the BMS3060 may include four cell monitoring circuits (hereinafter referred to as CMCs)3061 and four flexible printed circuit boards (hereinafter referred to as FPCs)3062. Each of the four FPCs3062 is assembled into four BCAs0010, and each of the four CMCs3061 is assembled into four FPCs3062. Next, two external connection interfaces of the CMCs3061, for example, signal interface circuit boards 3190, are assembled into the BCA enclosure 3080. The external connection interfaces (e.g., signal interface circuit boards 3190) are configured to connect low-voltage connectors (not shown) of downstream signal circuits such as the system's battery monitoring unit (BMU) or the vehicle's controller area network (CAN) bus or electronic control unit (ECU). Next, a circuit layout for a temperature sensor (not shown) is provided. In this embodiment, one BCA0010 is monitored by one CMC3061. The CMC3061 is configured to monitor the voltage and temperature of the BC0020 of the BCA0010.

[0169] Next, as shown in Figure 19L, the bottom wall 3100 is provided at the bottom of the BCA housing 3080. In this embodiment, a sealing ring (e.g., an O-ring) may be placed between the bottom wall 3100 and the side wall 3090 to prevent leakage of the heat management fluid. The bottom wall 3100 may be fixed to the bottom of the BCA housing 3080 by a number of screws or the like.

[0170] Next, as shown in Figure 16A, the top wall 3110 is provided on the top of the BCA housing 3080, and the multiple signal outlets 3200 are provided on the top wall 3110. In this embodiment, a sealing ring (e.g., an O-ring) may be placed between the top wall 3110 and the side wall 3090 to prevent leakage of the heat management fluid. The top wall 3110 may be fixed to the top of the BCA housing 3080 by multiple screws or the like. Thus, the assembly of the BS3030 is completed.

[0171] The embodiments described and shown above are merely examples. Many details are often found in the art. Therefore, many such details are not shown or described. Although several features and advantages of the disclosure, along with details of its structure and function, are described above, the disclosure is only illustrative and may be modified in detail. Therefore, it should be understood that the embodiments described above can be modified in various ways within the scope of the claims.

[0172] 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 boundaries and scope of the appended claims.

Claims

1. At least one battery cell assembly (BCA), Multiple battery cells (BC), A cell holder configured to restrict the position of the battery cell, A battery cell assembly (BCA) includes at least one battery cell connecting member (BCCM) which is a conductor configured to connect to the electrodes of the battery cell, A liquid-tight enclosure configured to restrict the movement of a heat management fluid, The liquid-tight housing comprises a front wall, left wall, right wall, rear wall, bottom wall, and top wall, which are combined to define a space for housing the battery cell, the at least one cell holder, the at least one battery cell connecting member, and the heat management fluid. Coolant inlet and coolant outlet are provided on the right and left walls, respectively, and are configured to serve as interfaces for introducing and discharging the heat management fluid, The front wall is provided with at least one high-voltage connector for electrically connecting to electrical equipment, To provide a high-voltage electrical connection between the BCA and the electrical equipment, the high-voltage connector and at least one busbar connected to the BCCM are included, The housing is configured to be welded, bonded, or bolted to the electrical equipment, and is a liquid-tight housing, A battery management system including at least one cell monitoring circuit (CMC), One BCA is monitored by one CMC. A battery pack wherein the external connection interface of the CMC is assembled in the housing and the external connection interface is configured to connect to a low-voltage connector of a downstream signal circuit.

2. The enclosure includes a signal open structure, The battery pack according to claim 1, wherein the signal opening structure is a through-hole extending from the inner surface of the front wall to the outer surface of the front wall, and such a through-hole provides a channel for housing a signal communication interface.

3. The through-holes include cylindrical channel structures and square channel structures. The battery pack according to claim 2, wherein the cylindrical channel structure provides a through-hole extending from the inner surface of the side wall to the middle portion of the front side wall, and such through-hole has a rounded inner opening facing the BCA space and a rounded outer opening facing the external space of the housing.

4. Includes holder connecting member, The cell holder includes a bottom cell holder, The bottom cell holder is attached to the surface of the bottom wall, The battery pack according to claim 1, wherein the bottom cell holder has a projection, the holder connecting member has a positioning hole, and the projection is inserted into the positioning hole to position the holder connecting member on the bottom cell holder.

5. The battery pack according to claim 4, wherein the holder connecting member includes a plurality of fence structures, the plurality of fence structures define lateral channels through which a fluid passes between the fence structures.

6. The cell holder includes a bottom cell holder, The bottom cell holder is attached to the surface of the bottom wall, and the bottom cell holder includes a receiving structure that provides lateral and vertical forces to hold the battery cell, and the bottom cell holder is A layer of lateral stopping structure, wherein the lateral stopping structure is a planar structure having receiving holes, the receiving holes penetrating the upper and lower surfaces of the bottom cell holder and configured to receive the battery cells, A layer of vertical stopper structure attached to the bottom of the lateral stopper structure and configured to support the weight of the battery cell, wherein the vertical stopper structure has a plurality of lateral channels that divide the vertical stopper structure into discrete islands, and between these discrete islands, the lateral channels form a gap between the bottom cell holder and the bottom wall, and the laterally distributed lateral channels are formed to allow liquid or gas released from the bottom of the battery cell to pass through, A plurality of ventilation structures located above the lateral channel of the vertical stopper structure, each including through-holes extending from the lowest end of the lateral stopper structure to the uppermost end of the ventilation structure, thereby allowing gas or liquid to flow vertically through the through-holes, and the lateral channel being fluidly connected to the ventilation structure or vertical fluid channel structure, The battery pack according to claim 1, wherein when a thermal event causes the battery cell to release gas from its bottom, the gas passes through the lateral channels between the discrete islands, then enters the through-holes of the ventilation structure, and moves vertically toward the upper end of the ventilation structure.

7. The bottom cell holder further includes a connecting structure and a plurality of vertical fluid channel structures located on both sides of the bottom cell holder. The lateral channel is fluidly connected to the vertical fluid channel structure. The battery pack according to claim 6, wherein the bottom cell holder has a connection structure for connecting to other bottom cell holders.

8. The battery pack according to claim 6, wherein the horizontal projected area of ​​the vertical stopper structure is smaller than the horizontal projected area of ​​the bottom cell holder.

9. The battery pack according to claim 1, wherein the BCCM is configured to form a group of parallel-connected BCs by electrically connecting a plurality of BCs in parallel, and the group of parallel-connected BCs is connected in series to at least one adjacent BC.

10. The right-side wall includes a first internal passage which is a through-hole having a first end fluidly connected to the inlet and a second end fluidly connected to the BCA space. The battery pack according to claim 1, wherein the left side wall includes a second internal passage which is a through-hole having a first end fluidly connected to the outlet and a second end fluidly connected to the BCA space.

11. Each of the right and left walls further includes at least one passage interface structure configured as a flow interface between the internal passage and the BCA space, The at least one passage interface structure includes a plurality of vertical protrusions extending from the inside of the lower right side wall or the left side wall, The battery pack according to claim 10, wherein the space between two adjacent vertical protrusions functions as a fluid channel through which the fluid flows between the internal passage and the BCA space.

12. Chassis and A vehicle comprising a battery system including at least one battery pack according to claim 1, which is integrated into the chassis.

13. The battery system includes at least one battery cell assembly, a battery management system, and a thermal management system. The battery pack according to claim 12, wherein the at least one battery cell assembly is formed of the battery cells electrically connected by the at least one battery cell connecting member.

14. The battery pack assembly process, The steps include assembling multiple side walls of the enclosure, including the front wall, rear wall, right side wall, and left side wall, on which high-voltage connectors and signal interface circuit boards are provided, The steps include providing a coolant inlet and a coolant outlet in the right and left walls, respectively, The steps include: placing a bottom cell holder inside the housing; The steps include assembling the holder connecting member to the bottom cell holder, The steps include assembling the two barriers to the right wall and the left wall, respectively, The steps include assembling a plurality of battery cells in the bottom cell holder inside the housing, The steps include connecting a portion of the high-voltage connector inside the housing to a contactor inside the housing, A step of assembling a plurality of connecting rods into a plurality of insertion holes in the bottom cell holder, wherein the connecting rods are positioned between the battery cells and protrude from above the battery cells, The steps include assembling the top cell holder onto the connecting rod and above the battery cell, The steps include filling the housing with gap material to fix the battery cell, The steps include: placing multiple battery cell connecting members in the top cell holder and assembling the battery cell connecting members to the battery cell; The steps include providing two busbars in sequence within the housing to provide a high-voltage electrical connection from the inside to the outside of the battery pack, The steps include providing a battery management system within the housing to provide signal connections from the inside to the outside of the battery pack, The steps include: setting up the circuit layout for the temperature sensor, The steps include providing a bottom wall at the bottom of the housing, A battery pack assembly process comprising the steps of providing a top wall at the top of the housing and providing a plurality of signal outlets at the top wall.

15. Before the bottom cell holder is placed inside the housing, a plurality of positioning members are placed at the corners of the housing for the bottom cell holder. The assembly process according to claim 14, wherein after the bottom cell holder is placed inside the housing, the corners of the bottom cell holder come into contact with the positioning member.

16. The assembly process according to claim 14, wherein the bottom cell holder has a projection, the holder connecting member has a positioning hole, and the projection is inserted into the positioning hole to position the holder connecting member on the bottom cell holder.

17. The assembly process according to claim 14, wherein the bottom cell holder includes a layer of a lateral stopper structure having a receiving hole and a layer of a vertical stopper structure, the battery cell being received in the receiving hole of the lateral stopper structure and supported by the vertical stopper structure, so that the inner wall of the receiving hole restricts the lateral movement of the battery cell and the vertical stopper structure restricts the downward vertical movement of the battery cell.

18. The assembly process according to claim 17, wherein the thickness of the gap material is less than or equal to the height of the ventilation structure above the lateral retaining structure, so that the gap material does not fill the through-holes of the ventilation structure.

19. The assembly process according to claim 14, wherein a thermocouple is bonded to the bottom of the battery cell before the battery cell is assembled to the bottom cell holder.

20. The assembly process according to claim 14, wherein the top cell holder has a plurality of assembly holes, and the connecting rod is inserted into the assembly holes to position the top cell holder above the battery cell.

21. The assembly process according to claim 14, wherein the battery cells are connected in parallel by one battery cell connecting member for every three cells.

22. The battery cells are electrically connected by the battery cell connecting members to form a plurality of electrically series-connected battery cell assemblies. The assembly process according to claim 14, wherein the electrodes of a plurality of battery cell assemblies are assembled to the right wall and the left wall, respectively, so as to connect the battery cell assemblies in series to form a battery system.

23. The assembly process according to claim 22, wherein the battery management system includes a plurality of cell monitoring units and a plurality of flexible printed circuit boards, the flexible printed circuit boards are each assembled to the battery cell assembly, and the cell monitoring units are each assembled to the flexible printed circuit boards.

24. The assembly process according to claim 23, wherein the plurality of signal interface circuit boards of the cell monitoring unit are assembled in the housing and configured to connect to the low-voltage connectors of the downstream signal circuits.

25. The assembly process according to claim 14, wherein each of the busbars has one end that contacts the battery cell connecting member and the other end that connects the contactor.

26. To prevent leakage of the heat management fluid, a sealing ring is placed between the bottom wall and the side wall. The assembly process according to claim 14, wherein a sealing ring is positioned between the top wall and the side wall to prevent leakage of the heat management fluid.

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