Battery pack

Abstract

The present invention provides a machine assembled from battery cells in which all battery cells are immersed in a thermal management fluid during operation, and a control circuit for the machine. [Solution] The battery pack includes a charge / discharge circuit 0040 having at least one battery cell assembly 0010, a battery pack housing, a high-voltage interface connector 3063, a high-voltage switching circuit, and a battery management circuit 300. The housing is formed by vertically stacking at least one tubular casing and covering the opposite ends with two lid modules to form an insulating barrier that isolates the battery cell assembly from the outside. The battery pack can be configured in either a distributed electrical interface configuration or a single-ended terminal configuration by housing signal lines or conductor rods using vertical wall channels within the casing. This structure facilitates modular assembly, efficient thermal management, and integrated electrical control.

Description

Technical Field

[0001] 1. Field of the Invention

[0002] The present disclosure generally relates to an assembly of battery cells configured as a device capable of both storing and releasing electrical energy. Specifically, the present disclosure generally relates to a machine assembled from battery cells in which all battery cells are immersed in a thermal management fluid during operation, and to the control circuit of the machine.

Background Art

[0003] 2. Description of the Related Art

[0004] Electrical energy is widely used to power modern machines. At various stages of the life cycle of electrical energy, such as power generation, distribution, and consumption, it is important and necessary to temporarily store energy and then release it as needed.

[0005] 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 back into electrical energy (i.e., during the discharging process). Depending on the application, battery cells are assembled in various ways to meet the required electrical performance parameters.

[0006] An assembly of battery cells, i.e., a battery cell assembly, is usually considered as a subsystem of an electrical device. In the present disclosure, the phrase "electrical device" may refer to an electromechanical device, a vehicle equipped with an electric motor as a prime mover, or an electrical energy storage system electrically connected to a pipe network or a power plant, or a computing machine (e.g., a server equipped with IT gear, a circuit board, and / or integrated circuit components configured to perform a computing function or an information processing function). Therefore, it is also important to consider the integration of the battery cell assembly and the electrical device.

[0007] Furthermore, it is well known that integrating battery cells involves incorporating thermal management systems and battery management systems.

[0008] Given the design considerations mentioned above, optimizing the integration of battery cells and other functional elements (such as control circuits) becomes a crucial challenge. [Overview of the project]

[0009] Technical challenges

[0010] Conventional battery packs often rely on complex external wiring harnesses to connect high-voltage switching components (contactors, fuses) and low-voltage control signals (BMS, sensors) across different modules. This external routing increases assembly complexity, occupies valuable space, and exposes sensitive signal lines to potential damage. Furthermore, effectively managing distributed high-voltage components while maintaining centralized control (e.g., separating positive and negative terminals at opposite ends) requires a robust integrated interconnection strategy that avoids external wiring. [Means for solving the problem]

[0011] technical solution

[0012] To address the aforementioned issues, this disclosure provides a battery pack with an integrated housing and electrical architecture.

[0013] According to one aspect of the present invention, a battery pack is provided. The battery pack includes a charge / discharge circuit which includes at least one battery cell assembly which includes a plurality of mechanically and electrically integrated battery cells. A battery pack housing houses the charge / discharge circuit. At least one high-voltage interface connector is located in the battery pack housing and is configured to transmit high-voltage power between the battery pack and an external electrical device. A high-voltage switching circuit is located in the battery pack and is configured to selectively open and close the high-voltage electrical connection between the charge / discharge circuit and the external electrical device. A battery management circuit is located in the battery pack and is configured to control and drive the high-voltage switching circuit.

[0014] The battery pack housing is formed by at least one tubular casing stacked vertically as a tube stack, and two lid modules that cover the opposite ends of the tube stack, respectively. This arrangement provides the battery pack housing with an insulating barrier that isolates at least one battery cell assembly from the outside of the battery pack. The two lid modules include a first lid module and a second lid module.

[0015] In some embodiments of the present invention, at least one tubular casing is implemented as a liquid-restricting casing, and the battery pack housing is configured to be liquid-tight so as to define a battery pack space containing a thermal management fluid. When the thermal management fluid is introduced into the battery pack space, the charge / discharge circuit is immersed in the thermal management fluid.

[0016] In a further embodiment of the present invention, at least one of the first cover module and the second cover module is configured as an interface module. The battery pack further includes at least one electrical energy interface module located in at least one interface module, and the high-voltage switching circuit includes a positive contactor and a negative contactor housed within at least one electrical energy interface module.

[0017] In one embodiment, a first cover module is located at the first vertical end of the tube stack, and a second cover module is located at the second vertical end of the tube stack. Both the first and second cover modules are interface modules, with a first electrical energy interface module located in the first cover module and a second electrical energy interface module located in the second cover module. The high-voltage switching circuit and battery management circuit are functionally divided into a first circuit module and a second circuit module. The first circuit module is housed within the first electrical energy interface module and includes a positive contactor, a precharge contactor, a precharge resistor, and a high-voltage interlocking loop. The second circuit module is housed within the second electrical energy interface module and includes a negative contactor and a current shunt.

[0018] In this embodiment, each tubular casing includes a vertical wall channel, and signal lines are arranged within the vertical wall channel. The signal lines electrically connect the low-voltage loop of the first circuit module and the low-voltage loop of the second circuit module for control signal transmission. The charge / discharge circuit is electrically connected to the positive contactor and pre-charge contactor of the first circuit module and to the current shunt and negative contactor of the second circuit module.

[0019] In another embodiment of the present invention, a first cover module is located at the first vertical end of the tube stack and functions as an interface module, and a second cover module is located at the second vertical end of the tube stack and functions as a terminal module. In this configuration, the high-voltage switching circuit includes a positive contactor, a precharge contactor, a precharge resistor, a high-voltage interlocking loop, a negative contactor, and a current shunt, all housed within the electrical energy interface module. Each tubular casing includes a vertical wall channel, and signal lines are arranged within the vertical wall channel to electrically connect the low-voltage loop of the high-voltage switching circuit. The charge / discharge circuit is electrically connected to the positive contactor, precharge contactor, and current shunt housed within the electrical energy interface module.

[0020] In an additional embodiment, vertical wall channels of a tubular casing are aligned to form a series of vertical through-holes penetrating the tube stack. Conductor rods are housed within these series of vertical through-holes and configured to electrically connect the electrodes of a charge / discharge circuit located at the second vertical end to an electrical energy interface module located at the first vertical end, thereby providing a compact vertical bus structure for high-voltage power routing.

[0021] In another embodiment of the present invention, each battery cell assembly includes a cell monitoring circuit located within a tubular casing. The cell monitoring circuit includes a vertical interface connector located at the vertical end of the tubular casing. The vertical interface connector is configured to electrically connect the cell monitoring circuit to a battery management circuit housed within an electrical energy interface module in order to transmit status data of multiple battery cells, such as voltage, temperature, and other monitoring data.

[0022] In a further embodiment, the battery pack further includes sealing members arranged at the interface between two adjacent stacked tubular casings, or at the interface between a tubular casing and one of two lid modules. At least one of the tubular casings or lid modules includes a sealing member housing structure configured to house and position a sealing member that seals the battery pack space, thereby supporting immersion cooling while maintaining liquid-tight integrity.

[0023] In a further embodiment of the present invention, the battery management circuit is housed within a first electrical energy interface module. The tubular casing includes vertical wall channels with signal lines arranged inside, which electrically connect the first electrical energy interface module and the second electrical energy interface module. The battery management circuit is configured to transmit control signals via the signal lines to the second electrical energy interface module to control the open or closed state of the negative contactor. This allows for centralized control at one end of the pack while distributing high-voltage switching and measurement components at multiple locations.

[0024] These and other aspects of the present invention provide a immersable modular battery pack architecture that improves the implementation efficiency, safety, and reliability of a high-voltage energy storage system by integrating mechanical structure, sealing design, high-voltage switching, current detection, cell monitoring, and control signal routing into a tube stack and lid module configuration.

[0025] 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]

[0026] [Figure 1A] 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).

[0027] [Figure 1B] This is a system functional block circuit diagram of a battery pack according to an embodiment of the present invention.

[0028] [Figure 2A] This is a perspective view of an embodiment of a battery cell assembly (0010). [Figure 2B] This is a perspective view of an embodiment of a battery cell assembly (0010), and is an exploded view showing a cell holder (0050), a cell receiving structure (0060), and an electrode surface (0024).

[0029] [Figure 2C] This is an exploded perspective view of a battery cell assembly (0010) showing a battery cell connection member (0026) and a cell holder (0050).

[0030] [Figure 2D] This is a detailed view showing a plate hole (0029) of a battery cell connection member (0026) engaged with a vertical direction limiting structure (0070) of a cell holder (0050).

[0031] [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.

[0032] [Figure 4A] This is a top view of a tube-shaped liquid limiting casing (0080) having a peripheral wall (0090). [Figure 4B] This is a top view of a tube-shaped liquid limiting casing (0080) having a peripheral wall (0090). [Figure 4C] This is a top view of a tube-shaped liquid limiting casing (0080) having a peripheral wall (0090).

[0033] [Figure 5A] This is a perspective view of a battery cell assembly (0010) arranged within a liquid-restricting casing (0080). [Figure 5B] This is a vertical exploded view showing the top opening (0094), the bottom opening (0095), and the two cell holders (0050).

[0034] [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).

[0035] [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).

[0036] [Figure 6C] This is a diagram of a perimeter wall (0090) assembled from two partially enclosing walls.

[0037] [Figure 6D] This is a diagram of a perimeter wall (0090) assembled from four independent side walls (0091).

[0038] [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 battery cell assembly (0010) having a cell holder (0050) and a cross-sectional line A-A'.

[0039] [Figure 7D] This is a vertical cross-sectional view along line 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.

[0040] [Figure 7E] This is a diagram of a liquid-restricting casing (0080) showing individual cell holder retaining structures (0140) on the inner north face (0105) of the north side wall (0099).

[0041] [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 the line 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).

[0042] [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).

[0043] [Figure 10A]This is a diagram of a liquid-restricting casing (0080) showing the top wall surface (0160), bottom wall surface (0170), top surface interlocking structure (0180), and bottom surface interlocking structure (0190).

[0044] [Figure 10B] This figure shows two liquid-limiting casings (0080) stacked with interlocking structures (0180, 0190) engaged.

[0045] [Figure 11A] The sealing features at the interface between the liquid-restricting casings (0080) are shown, along with the sealing member housing structure (0220) and the sealing member positioning structure (0210). [Figure 11B] The sealing features at the interface between liquid-restricting casings (0080) are shown, and sealing members (0200), such as O-rings, are shown arranged within the housing structure.

[0046] [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).

[0047] [Figure 12B] This figure shows a vertical wall channel (0230) having a conductor rod (0280).

[0048] [Figure 13] This is a cross-sectional view of a battery pack (3030) including a battery module (3010), a terminal module (3040), an interface module (3050), and an interface. [Figure 14A] This is a conceptual diagram of a battery pack architecture, showing multiple battery modules (3010) stacked between a first interface module and a second interface module (3050a, 3050b), with electrical energy interface modules (3060a, 3060b) and a high-voltage interface connector (3063) provided at the opposite vertical end. [Figure 14B]This is a conceptual diagram of a battery pack architecture, showing a battery module positioned between a terminal module (3040) and an interface module (3050), with an electrical energy interface module (3060) and two high-voltage interface connectors (3063) located at the same vertical end, and a vertical wall channel (0230) sealed to form a vertical through-hole for housing a conductor rod (0280).

[0049] [Figure 15A] This is a conceptual diagram showing the direction relative to the gravity vector. [Figure 15B] This is a conceptual diagram showing the direction relative to the gravity vector.

[0050] [Figure 16A] This is a conceptual side view of a battery pack, illustrating the flow field and stacked architecture.

[0051] [Figure 16B] This is a conceptual diagram showing the detailed configuration of the battery module.

[0052] [Figure 17] This is a conceptual diagram showing the physical configuration of a battery pack (3030) according to one embodiment of the present invention.

[0053] [Figure 18A] This is a perspective view of a battery pack (3030) according to an exemplary embodiment of the present disclosure.

[0054] [Figure 18B] Figure 18A shows the electronic connection structure of the cell monitoring circuit (3110 and 3120) as an exemplary embodiment of the present disclosure.

[0055] [Figure 19] Figures 18A and 18B show circuit diagrams of BC(0020), a cell monitoring circuit (3110), and a cell detection circuit (3111) as shown in exemplary embodiments of the present disclosure. [Modes for carrying out the invention]

[0056] Before describing this disclosure in more detail, it should be noted that, where appropriate, reference numbers may be repeated between figures to indicate corresponding or similar elements that may have similar characteristics.

[0057] To facilitate the explanation of this disclosure, directional terms (e.g., front, back, left, right, top, bottom, etc.) may be used in this specification and in the claims to describe parts of this disclosure. Unless otherwise specifically defined, these definitions of directions are for the purpose of describing and claiming this disclosure and are not intended to limit it.

[0058] The following contains specific information relating to exemplary embodiments of this disclosure. The drawings and accompanying detailed disclosures are only for illustrative embodiments of this disclosure. However, this disclosure is not limited to these exemplary embodiments. Those skilled in the art will be able to conceive of other variations and embodiments of this disclosure. Unless otherwise specified, identical or corresponding elements in the drawings may be indicated by the same or corresponding reference numerals. Also, the drawings and illustrations of this disclosure are generally not to scale and do not correspond to actual relative dimensions.

[0059] For the sake of consistency and ease of understanding, similar features are identified by numbers in the illustrative figures (although not shown in some examples). However, features in different embodiments should not be narrowly limited to those shown in the figures, as they may differ in other respects.

[0060] 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 it 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 described certain features, structures, or characteristics. The term “combination” is defined as a direct or indirect connection by intervening parts, and is not necessarily limited to a physical connection. The term “includes,” when used, means “includes, but is not necessarily limited to,” specifically indicating an open-ended inclusion or membership in the disclosed combinations, groups, series, and equivalents.

[0061] Furthermore, for the sake of non-exclusive explanation, specific details such as functional entities, technologies, protocols, and standards are included to provide an understanding of the disclosed technology. In other instances, detailed disclosures such as well-known methods, technologies, systems, and architectures are omitted so as not to obscure the disclosure with unnecessary details.

[0062] Figure 1A is a conceptual circuit diagram of a charge / discharge circuit 0040. In Figure 1A, 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 the required target output voltage, amperes, or power. To meet these requirements, battery cells can be mechanically and electrically integrated into the BCA0010, for example, by being assembled to provide collective performance.

[0063] As shown in Figure 1A, in some embodiments, the BCA0010 may include one or more battery cell strings 0030 (hereinafter referred to as BCS) electrically connected in parallel. The number of parallel-connected BCS0030 determines the overall current output of the BCA0010. Furthermore, each BCS0030 may include one or more battery cells 0020 (hereinafter referred to as BC) electrically connected in series. The number of series-connected BC0020 within each BCS0030 determines the overall voltage output of the BCS0030 and BCA0010.

[0064] 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 consumption device such as the engine of an electric vehicle to supply power to the engine.

[0065] In some embodiments (not shown in Figure 1A), the charge / discharge circuit 0040 may include two or more BCAs 0010 to satisfy specific 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.

[0066] Referring back to Figure 1A, 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.

[0067] BC0020 is configured as a basic component for converting electrical energy to chemical energy or vice versa, and may include 1) a charge / discharge circuit 0040 to which BC0020 is connected, and 2) a positive electrode and a negative electrode as interfaces between the cathode material and anode material enclosed in BC0020.

[0068] Furthermore, BC0020, which constitutes the basic energy storage construction block of BCA0010 and the charge / discharge circuit 0040, must be electrically connected. Regardless of whether BC0020 is cylindrical, prismatic, or pouch-shaped, the electrodes of BC0020 are typically located at the top, bottom, or both ends of the body of BC0020, respectively. In such cases, since BC0020 is typically mechanically aligned, 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.

[0069] In some embodiments, BCA0010 may include a battery cell connecting member 0026 (hereinafter referred to as BCCM), which is an electrical conductor configured to connect to the electrodes of BC0020. The BCCM0026 connects BC0020 electrically in parallel or in series. For example, planar conductive plates may be arranged on the electrode surface 0024 to connect to the electrodes of BC0020.

[0070] In this disclosure, the term “Battery Pack” (hereinafter, BP) 3030 refers to an energy storage system designed, assembled, manufactured, and enclosed to be integrated into an electrical device (e.g., an EV, BESS, or other) powered by electrical energy discharged from the BP 3030. This is typically produced as a separate product by an entity supplying the final device to an original equipment manufacturer (hereinafter, OEM). The BP 3030 is mechanically stable to ensure its integrity during transport and of the final device. For example, the integration and assembly processes may be those of an EV assembly process. Furthermore, the BP 3030 features standardized interfaces to facilitate electrical and mechanical integration with systems larger than the system to which it is installed. The spatial dimensions of the BP 3030 are also designed to take into account the available space for the electrical device below.

[0071] Figure 1B is a system function block diagram of a BP3030 according to one embodiment of the present disclosure. As shown in Figure 1B, thick solid lines represent the high-voltage loop of the BP3030, thin dashed lines represent the communication paths for low-voltage control signals or detection signals, and thin solid lines represent the low-voltage power supply paths. As shown in Figure 1B, the BP3030 includes a charge / discharge circuit (CDC) 0040 consisting of at least one battery cell assembly (BCA) 0010, and other function blocks configured to control or manage the CDC 0040, such as a battery management circuit 300.

[0072] In some embodiments, the battery pack (BP) may be electrically connected to a power supply 301. The power supply 301 is configured to supply operating electrical energy to the battery management circuit 300. In one embodiment, the power supply 301 is an external power source independent of the battery pack (e.g., a 12V power supply from the vehicle). For example, the power supply 301 may supply operating electrical energy to the battery management circuit 300 via a connector (e.g., a 32-pin connector). Furthermore, the power supply 301 also supplies operating electrical energy to the pump 302 and pulse width modulation (PWM) control 303 via a low-voltage power supply path.

[0073] The battery management circuit 300 is configured to control the high-voltage switching circuit. In one embodiment, the battery management circuit 300 includes a printed circuit board (PCB) having an electronically controlled integrated circuit (IC) configured as a computing core, called a battery management unit (BMU). The BMU is generally a microcontroller having computing and memory functions. In addition to the BMU, the PCB of the battery management circuit 300 may further include communication circuits, voltage and current detection circuits, power-related circuits, drive-related circuits (e.g., relays for driving contactors) or other functional circuits. The battery management circuit 300 may internally receive signals from the CDC0040, the cell monitoring circuit 305, and the high-voltage switching circuit. The battery management circuit 300 may externally receive signals from the power supply 301 and the energy source or energy consumption device 304. Based on the calculation results, the battery management circuit 300 internally transmits control signals to control the operation of the cell monitoring circuit 305 and the high-voltage switching circuit, and externally transmits and / or receives signals to the energy source or energy consumption device 304.

[0074] The cell monitoring circuit 305 may be configured to detect the operating status at the level of the BCA0010 or at the level of the battery cell. For example, the cell monitoring circuit 305 monitors parameters such as temperature, voltage, and current of the object under test, performs open-circuit / short-circuit diagnostics, collects health information (e.g., metrics required for State of Charge (SoC) / State of Health (SOH)) and sends it back to the battery management circuit 300. In one embodiment, the cell monitoring circuit 305 includes one or more PCBs located near the battery cells, each PCB including a cell monitoring IC or analog front-end (AFE) configured as a measurement core. The cell monitoring IC or AFE is also called a cell monitoring unit (CMU). The cell monitoring circuit 305 may further include necessary communication circuits, isolated power supply circuits, and protection circuits. The cell monitoring circuit 305 may be internally and directly connected to each BCA0010. The cell monitoring circuit 305 may be externally interconnected with the battery management circuit 300 via isolated communication to return measurement / diagnostic data and receive measurement setting and balance commands. The power for the cell monitoring circuit 305 may be supplied by the battery management circuit 300 or an independent isolated power supply. With respect to the control path, the cell monitoring circuit 305 schedules measurements and balancing based on the strategy of the battery management circuit 300. If the cell monitoring circuit 305 detects an overvoltage, undervoltage, open circuit, or detection anomaly, it can immediately report the anomaly and locally stop protective operations such as balancing.

[0075] Pump 302 may be configured to drive the flow of thermal management fluid within the battery pack to regulate the temperature of the BCA0010. In one embodiment, pump 302 is an electric pump powered from power supply 301 via a low-voltage (e.g., 12V) power supply path. Pump 302 may be hydraulically connected to the fluid circulation loop of the battery pack. For example, pump 302 may be positioned at the inlet or outlet of the fluid limiting casing of the BCA0010 to circulate the thermal management fluid through the battery cells. The operation of pump 302, such as the start timing or flow rate, is controlled by PWM control 303.

[0076] The PWM control 303 may be configured to generate a pulse-width modulated signal that drives the pump 302. The PWM control 303 may be electrically connected to a power supply 301 to receive operating power and signal-connected to a battery management circuit 300 to receive control signals. Based on the control signals from the battery management circuit 300 (for example, based on temperature readings returned by the cell monitoring circuit 305), the PWM control 303 modulates the duty cycle of the pulse-width modulated signal. By adjusting the duty cycle, the rotational speed of the pump 302 is adjusted linearly or dynamically, thereby controlling the flow rate of the thermal management fluid and achieving precise thermal management.

[0077] The high-voltage switching circuit may include a contactor (POS) 307, a contactor (PRE) 309, a resistor (PRE) 310, a contactor (NEG) 312, a current shunt 311, a fuse 308, and a high-voltage interlocking loop (HVIL) 306.

[0078] The contactor (POS) 307 may be considered a switch for determining whether the positive terminal of the CDC0040 is electrically connected to an external circuit. In one embodiment, the contactor (POS) 307 includes a commercially available contactor component which is a high-voltage switch whose switching can be controlled by a small current. With regard to high-voltage circuit connections, the contactor (POS) 307 may be internally connected to the positive terminal of the CDC0040, then externally connected to a fuse 308 (optional), then to the positive terminal of a battery system (e.g., a battery pack) (e.g., a high-voltage interface connector (HVIC) 3063), and then indirectly connected to an energy source or energy consumption device 304. With regard to low-voltage circuit connections, the contactor (POS) 307 may be connected to a battery management circuit 300 to receive control signals and return an operating status.

[0079] The contactor (PRE) 309 may be considered a switch for determining whether the positive terminal of the CDC0040 is electrically connected to an external circuit. PRE stands for pre-charge. In one embodiment, the contactor (PRE) 309 includes a commercially available contactor component. During pre-charging, the CDC0040 releases electrical energy to the energy consumer 304 with a smaller current. The pre-charge step is essential. In particular, if there is a large voltage difference between the entire CDC0040 and the energy consumer 304, a large inrush current may be generated if the contactor (POS) 307 is used directly to discharge to the energy consumer 304, potentially damaging the circuitry of the energy consumer 304. Regarding high-voltage circuit connections, the contactor (PRE) 309 may be internally connected to the positive terminal of CDC0040, then externally connected to resistor (PRE) 310, then to fuse 308 (optional), then to the positive terminal of the battery pack (e.g., HVIC3063), and then indirectly connected to the energy source or energy consumption device 304. Regarding low-voltage circuit connections, the contactor (PRE) 309 may be connected to the battery management circuit 300 to receive control signals and return operating status.

[0080] The fuse 308 provides overcurrent power-off protection. In the event of an overcurrent, the fuse 308 may blow to disconnect the contactor (POS) 307 from the downstream energy source or energy consumption device 304. In some embodiments, the fuse 308 is integrated into a manual service disconnect (MSD) component. With respect to high-voltage circuit connections, the fuse 308 may be internally connected to the contactor (POS) 307 or the resistor (PRE) 310. The fuse 308 may first be externally connected to the positive terminal of the battery pack (e.g., HVIC 3063) and indirectly connected to the energy source or energy consumption device 304. With respect to low-voltage circuit connections, the fuse 308 is internally connected to HVIL 306 and loops back to the battery management circuit 300.

[0081] HVIL306 may be a low-voltage signal loop (for logic / monitoring) configured to signally connect to various high-voltage interfaces that may be exposed to high voltage (high potential energy) or accidentally opened, for example, these high-voltage interfaces may be MSD, maintenance cover switch, high-voltage connector, contactor box cover, charging port, etc. The BMU may continuously monitor HVIL306. If HVIL306 opens or has an abnormal resistance value, the system provides a request to disconnect the main contactors (e.g., contactor (POS) 307 and contactor (NEG) 312) and prevents power-on. Regarding low-voltage circuit connections, HVIL306 is connected to fuse 308 / MSD and HVIC3063 for detection, and the detection signal is returned to the battery management circuit 300.

[0082] The contactor (NEG) 312 may be considered a switch for determining whether the negative terminal of CDC0040 is electrically connected to an external circuit. In one embodiment, the contactor (NEG) 312 may include a commercially available contactor component. With regard to high-voltage circuit connections, the contactor (NEG) 312 is internally connected to the current shunt 311 and then to the negative terminal of CDC0040. The contactor (NEG) 312 may first be externally connected to the negative terminal of the battery pack (e.g., HVIC3063) and then indirectly connected to the energy source or energy consumption device 304. With regard to low-voltage circuit connections, the contactor (NEG) 312 may be connected to the battery management circuit 300 to receive control signals and return an operating status.

[0083] The current shunt 311 may be configured to measure high-voltage current values ​​and provide them to the battery management circuit 300 for calculation and control. The current shunt 311 may include a low-resistance, high-precision resistor and may be configured to convert the current to a voltage for measurement. The battery management system (BMS) or current sensing amplifier reads the load voltage and calculates the current flowing through the load. With respect to high-voltage circuit connections, the current shunt 311 may be arranged before or after the contactor, and is generally arranged at the terminals of the contactor (NEG) 312. Taking Figure 1B as an example, the current shunt 311 may be arranged between the contactor (NEG) 312 and the CDC0040. With respect to low-voltage circuit connections, the current shunt 311 may be configured to provide the measurement signal to the battery management circuit 300 for calculation and control.

[0084] In this disclosure, when referring to direction, the terms “lateral” and “laterally” refer to the direction on the plane in which the electrodes of BCA0010 and BC0020 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 marked as the direction parallel to the lines on the yz plane. The term “top view” means a cross-section viewed from the positive x direction toward the negative x direction.

[0085] In this disclosure, the terms “vertical” and “vertically” mean a direction orthogonal to any “lateral direction,” not “lateral direction.” By this definition, the electrodes of the BC0020 are typically located at at least one vertical end of the body of the BC0020. In the figures of this disclosure, the vertical direction refers to the direction along the x-direction.

[0086] For example, see Figures 2A and 2B, which are perspective views of an embodiment of BCA0010 (not all parts 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 aligned along the yz-plane.

[0087] To mechanically or structurally integrate the BC0020s, in some embodiments, the BCA0010 may include at least one cell holder 0050 which may have the primary function of restricting the position of each BC0020 in a particular configuration. For example, the restriction of the position of the BC0020s may be 1) restricting the relative position of a particular BC0020 to any other BC0020 belonging to the same BCA0010, and 2) restricting the relative position of a particular BC0020 to the body of the BCA0010. For example, in Figure 2A, a portion of the body of each BC0020 is placed within the corresponding cell receiving structure 0060 of the cell holder 0050. The cell receiving structure 0060 is periodically distributed along the lateral direction. Therefore, once the BC0020s are placed within the cell receiving structure 0060, these BC0020s may be arranged laterally in such a periodic spatial distribution.

[0088] In some embodiments, the cell holder 0050 may include a vertical limiting structure 0070 that restricts the vertical movement of the BC0020. All the bodies and electrodes of the BC0020 of the BCA0010 may be aligned in the same vertical position and may be formed as electrode surfaces 0024 of the BCA0010. For example, in Figure 2A, the BCA0010 includes two electrode surfaces 0024 on both sides in the x-direction.

[0089] In some embodiments, adhesive may be used to provide a displacement limiting function. For example, after BC0020 is placed in the support hole of the cell holder 0050, adhesive may be further introduced to fix BC0020 in place.

[0090] 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.

[0091] For example, in Figure 2C, an exploded perspective view of an exemplary BCA0010 (BC and some components are not shown), the BCA0010 includes a cell holder 0050 and a BCCM0026. The BCCM0026 is a conductive material formed in a plate shape. The BCCM0026 is positioned in the cell holder 0050 and is also configured to be positioned on the electrode surface 0024 of the BCA0010.

[0092] In some embodiments, the BCCM0026 may include a cell contact plate 0027 and a current transport plate 0028.

[0093] 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 molten weld structure 0025 configured to melt when the current becomes overloaded.

[0094] 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.

[0095] In some embodiments, the BCCM0026 may include structures configured to position the BCCM0026 on the cell holder 0050. For example, the BCCM0026 may include protrusions or projections configured to engage with hollow structures on the cell holder 0050. In another example, the BCCM0026 may include holes configured to engage with protrusions or projections 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. In various embodiments, mechanical engagement may be achieved by interlocking features such as interlocking fits, snap-fits, fasteners, or arrangements of holes and posts as described herein.

[0096] Figures 3A and 3B are conceptual perspective views of two BCA0010 assemblies. Depending on the available space for mounting the BCA0010 in electrical equipment, the BCA0010 may be assembled in a stacked or parallel configuration. For example, in Figure 3A, the BCA0010 is assembled in a stacked configuration and is suitable for arrangement in narrow, long spaces such as the front and rear compartments of a passenger car. In another example, in Figure 3B, the BCA0010 is assembled in a parallel configuration and is suitable for arrangement in spaces that are wide but have limited height, such as the floor space under a cabinet in a passenger car.

[0097] In this disclosure, the terms “vertical” and “vertically” also refer to the stacking direction of the stacked BCA. For example, in Figure 3A, the stacked BCA is stacked vertically and along the x-direction.

[0098] 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 completely immersed in the heat management fluid. If the entire BCA0010 is immersed, BCA0010 and several other components integrated into BCA0010 may be in direct contact with the heat management fluid, thereby providing a higher level of thermal management.

[0099] To immerse BCA0010 in a heat management fluid, BCA0010 may be contained in 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 a Cartesian coordinate system, 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 the 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.

[0100] In some embodiments, the waterproofing material may be used to form a specific structure that completely seals or partially covers 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 tube shape having two openings, such as a triangular tube, a square tube, or a circular tube. The tube-shaped LLC0080 may include a circumferential wall 0090 (i.e., a circumferential wall).

[0101] In some embodiments, the peripheral wall of LLC0080 may include a water-impermeable film to restrict the movement of the heat management fluid.

[0102] In some embodiments, LLC0080 may include rigid structures such as watertight walls to restrict the movement of the heat management fluid.

[0103] For example, Figures 4A, 4B, and 4C show a conceptual LLC0080 in a tube structure shown in a top view. In other examples, the side view (i.e., top view) of the tube structure may have an asymmetric geometric shape. In Figures 4A, 4B, and 4C, each of the LLC0080 shown includes a peripheral wall 0090 that encloses the space laterally. In Figures 4A, 4B, and 4C, the peripheral wall 0090 may extend vertically, i.e., along the x-direction. Thus, the three-dimensional space enclosed by the LLC0080 may be used to house a heat management fluid, a BCA0010, and several components that are accumulated in the BCA0010. Due to the watertightness of the peripheral wall 0090, the heat management fluid housed within the LLC0080 can only move vertically.

[0104] 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.

[0105] 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 unshown components integrated into the cell holders 0050, BC0020, and BCA0010 may be arranged within the space enclosed by LLC0080.

[0106] In embodiments where 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 arranged within LLC0080 may be arranged within the internal space of LLC0080 through at least one of the top opening 0094 and the bottom opening 0095.

[0107] 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 H1 between the top vertical position 0092 and the bottom vertical position 0093. 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.

[0108] In some embodiments in which LLC0080 is formed in a rectangular tubular shape, the circumferential wall 0090 of LLC0080 may further include four planar side walls 0091 arranged circumferentially around a vertical axis and parallel to the vertical axis. For example, Figure 6A shows an exemplary top view of LLC0080. LLC0080 includes four side walls 0091: an east side wall 0096, a south side wall 0097, a west side wall 0098, and a north side wall 0099, arranged circumferentially around a vertical axis.

[0109] In some embodiments, LLC0080 may be manufactured by an integral molding process such as injection molding or die casting. Alternatively, a turning process may be used to manufacture LLC0080.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] In some embodiments, the perimeter wall 0090 may be assembled from separate components. For example, in Figure 6B, LLC 0080 includes four corner columns 0130, which are independent components assembled with side walls 0091 (i.e., east side wall 0096, south side wall 0097, west side wall 0098, and 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.

[0114] In some embodiments, LLC0080 may include a structure configured for the integration of the cell holder 0050 and 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 located 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.

[0115] 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.

[0116] 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 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, for example, in Figure 7A, such a constant distance is equal to W2.

[0117] 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. 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.

[0118] Furthermore, the inner wall surface 0101 of the peripheral wall 0090 may be a curved surface whose shape conforms to the curved outer circumference of the cell holder 0050 or the curved outer circumference of the battery cell 0020. Because the inner wall surface 0101 is a curved surface that fits the curved outer circumference of the cell holder 0050 or the battery cell 0020, the volume of the battery module can be reduced. The curved inner wall surface 0101 can also function as a guide structure when the cell holder 0050 is placed in the LLC 0080 during the assembly process of the battery module.

[0119] In some embodiments, as shown in Figure 7B, the curved inner boundary 0141 of the cell holder retaining structure 0140 may 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 positioned within a space partially enclosed by the curved portion of the inner boundary 0141 of the cell holder retaining structure 0140.

[0120] 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' is marked with respect to the cross-section shown in Figure 7D.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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 a top view includes four cell holder fixing structures 0150 extending from the inner wall surface 0101 of the peripheral wall 0090. In this embodiment, the cell holder fixing structure 0150 includes fastening holes 0151 that use fastening devices to restrict the 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.

[0125] 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 four fasteners 0152 inserted perpendicularly to the cell holder 0050 and the cell holder fixing structure 0150 (not shown in Figure 8B).

[0126] 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 retaining structure 0140 and fastening the cell holder 0050 to LLC0080 with the fixing fastener 0152.

[0127] Refer to Figures 9A and 9B for a perspective view of the stack of two BCAs (in which LLC0080 is integrated).

[0128] In some embodiments, as shown in Figure 10A, the LLC0080 may include a top wall surface 0160 and a bottom wall surface 0170, which are the vertical end surfaces of the LLC0080 and extend along the lateral direction.

[0129] 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 provides a lateral force that limits the relative displacement of 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.

[0130] 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 housing structure 0220 configured to provide a space for housing a sealing member that is arranged 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 that restricts the lateral movement of the sealing member 0200. As shown in Figure 11B, the sealing member 0200 can be filled into the space provided by the sealing member housing structure 0220 to provide a sealing effect.

[0131] 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 signalably connected to the BCCM 0026 of the BCA 0010, 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 the BCA 0010, as shown in Figure 12B.

[0132] As disclosed in application '417 (i.e., application number 18 / 211,417), the vertical wall channel 0230 may be used to provide a vertical fluid channel that can direct liquid flow vertically. For example, the vertical wall channel 0230 may refer to the “inlet channel” and “outlet channel” disclosed in application '417.

[0133] In some embodiments, the BCA0010 may be integrated with components to form a battery module (hereinafter referred to as BM) 3010. For example, the BM3010 may be an assembly comprising the BCA0010 and other components such as the LLC0080, thermal control components such as heat dissipation components, a battery cell monitoring circuit, and other components. The manufacture of the BM3010 is typically an intermediate step in the production of the entire system. That is, the BM3010 can be considered an intermediate building block that forms a higher level of energy storage system, while the BM3010 is also integrated with the BC0020, which is a more basic building block. Therefore, the BM3010 may also include a modular interface configured to integrate the BM3010 with other BM3010s and / or other modules of a larger energy storage system below. For example, the BM3010 may include a modular electrical energy interface (hereinafter referred to as MEEI) 3020 configured to provide electrical connections for the transfer (charging or discharging) of electrical energy stored or released within the BM3010. MEEI3020 may be an electrode or connector positioned on the BM3010. For example, MEEI3020 may be a conductor that directly contacts one of the current transport plates 0028 of the first BM3010 and also directly contacts one of the current transport plates 0028 of the second BCA0010. Such MEEI3020 functions as an electrical connector between the two BM3010s.

[0134] For example, BM3010 may include interfaces for thermal control components such as liquid connectors into which thermal control fluid flows and out of BM3010 to flow into another liquid container or channel, for example, top opening 0094 and bottom opening 0095 of LLC0080. For example, BM3010 may also include interfaces for mechanical connection to another BM and / or other modules, for example, top interlocking structure 0180 and bottom interlocking structure 0190.

[0135] In this disclosure, the term “Battery Pack” (hereinafter, BP) 3030 refers to an energy storage system designed, assembled, manufactured, and enclosed to be integrated into an electrical device (e.g., an EV, BESS, or other) powered by electrical energy discharged from the BP 3030. This is typically produced as a separate product by an entity supplying the final device to an original equipment manufacturer (hereinafter, OEM). The BP 3030 is mechanically stable to ensure its integrity during transport and of the final device. For example, the integration and assembly processes may be those of an EV assembly process. Furthermore, the BP 3030 features standardized interfaces to facilitate electrical and mechanical integration with systems larger than the system to which it is installed. The spatial dimensions of the BP 3030 are also designed to take into account the available space for the electrical device below.

[0136] Refer to Figure 13, a conceptual cross-sectional view of BP3030. In some embodiments, as shown in Figure 13, BP3030 may include two BM3010 assembled together in a stacked manner. In other cases, BP3030 may include only one BM3010 or two or more BM3010. BP may also include a terminal module (hereinafter, TM) 3040 that functions as a cover for BP3030. TM3040 provides electrical insulation so that BC0020 (not shown in Figure 13) is electrically isolated from the outside of BP3030. BP3030 may also include an interface module (hereinafter, IM) 3050. IM3050 functions not only as a cover but also as an interface for BP3030. Note that each of the BM3010 in Figure 13 may be formed (assembled) from LLC0080 and BCA0010 previously disclosed.

[0137] In some embodiments, since BP3030 is liquid-tight, the BCA0010 of BM3010 surrounded by BP3030 may be immersed in a thermal management fluid. For example, the LLC0080, TM3040, and IM3050 of each BM3010 may be assembled to form a liquid-tight "battery pack housing" (hereinafter, BP housing) 3031. In such an example, the BP housing 3031 is assembled by an LLC0080 that provides a lateral fluid barrier and a lid at the vertical end that provides a vertical fluid barrier. For example, the lid may be TM3040 or IM3050. These lateral and vertical fluid barriers define a "battery pack space" (hereinafter, BP space) 3032 surrounded by the BP housing 3031 (which is also surrounded by these lateral and vertical fluid barriers).

[0138] In some embodiments, the BP enclosure 3031 is electrically insulated so that the circuitry enclosed inside the BP enclosure 3031 does not leak to the outside. For example, the LLC0080 and the lid may be formed from an electrically insulating material and each may contain at least one layer of electrically insulating material.

[0139] In some embodiments, TM3040 and IM3050 may also include mechanical interfaces for mating, connecting, or sealing to the corresponding BM3010 or the corresponding LLC0080. For example, TM3040 may include a top interlocking structure 0180, and IM3050 may include a bottom interlocking structure 0190. For example, TM and IM may include sealing members, sealing member housing structures 0220, as described above in this disclosure.

[0140] As shown in Figure 13, BP3030 may also include an "Electrical Energy Interface Module" (EEIM) 3060. The EEIM 3060 may include an EEIM casing 3062 that encloses or surrounds an EEIM space 3061 (not shown in Figure 13) configured to house a battery management circuit, a high-voltage circuit (e.g., a circuit that relays the high-voltage electrical energy of BP3030 to a downstream load such as an EV), or both. The EEIM casing 3062 may be integrally molded or formed from a plurality of EEIM walls 3065. For example, the EEIM walls 3065 may be part of an integrally molded EEIM casing 3062 or they may be independent parts. The EEIM 3060 may be placed in IM3050 by an assembly process.

[0141] In some embodiments, the IM3050 may include an IM casing 3052 that surrounds or encloses an IM space 3054 (not shown in Figure 13) configured to house components configured to connect the BM3010 and the EEIM3060.

[0142] In some embodiments, IM3050 may further include an IM bus 3053 (not shown in Figure 13). One terminal of the IM bus 3053 is configured to be electrically connected to the MEEI 3020 of BM3010, and the other terminal of the IM bus 3053 is configured to be electrically connected to a high-voltage circuit arranged in the EEIM space 3061. EEIM3060 may include a "high-voltage interface connector" (hereinafter, HVIC) 3063, which may be arranged in the EEIM casing 3062 or in the BP housing 3031. The HVIC 3063 is configured to directly contact the high-voltage circuit arranged in the EEIM space 3061, thereby allowing the HVIC 3063 to function as a high-voltage circuit interface between the charge / discharge circuit 0040 and the electrical equipment. Thus, the HVIC 3063 can be considered as a terminal of the charge / discharge circuit 0040.

[0143] In this disclosure, the interface module 3050 and the terminal module 3040 (which function as vertical covers and are collectively referred to as “cover modules”) may each include at least one “cover electrical interface” configured to provide an internal electrical connection path. The cover electrical interface is electrically connected between the HVIC 3063 and the MEEI 3020 of the battery module. In some embodiments, the cover electrical interface may be implemented as a rigid busbar (e.g., IM busbar 3053), a flexible busbar, a wire cable, a conductive trace on a PCB, or other suitable conductive material capable of transmitting high-voltage electrical energy.

[0144] In some embodiments, the EEIM space 3061 and the BP space 3032 are continuous via a hydraulic system, so that components in the EEIM space 3061 may be immersed in a heat management fluid.

[0145] In other embodiments, the EEIM space 3061 and the BP space 3032 may be separated by hydraulic means. In such cases, the IM 3050 may include at least one IM electrical channel 3051 (not shown) configured to provide a channel between the EEIM space 3061 and the BP space 3032. For example, the IM channel 3051 may be a through-hole located in the side wall of the IM 3050. In some embodiments, an IM busbar 3053 (not shown) is located within the IM electrical channel 3051 and extends into the EEIM space 3061 and the BP space 3032 to provide electrical connections between components in these two housing spaces. In some embodiments, to prevent liquid from passing through the IM electrical channel 3051, the IM 3050 may further include at least one sealing member, such as an O-ring, arranged within the IM channel 3051 and tightly coupled to both the inner wall of the IM electrical channel 3051 and the IM busbar 3053.

[0146] In some embodiments, the BP3030 may include at least one liquid interface 3034 for introducing liquid into and / or out of the BP3030. For example, the liquid interface may be a liquid connector located in the BP housing 3031. For example, the liquid interface 3034 may be located in the wall of the IM3050 or the wall of the TM3040 as an inlet and / or outlet. In some embodiments, the BP3030 may include a first liquid interface 3034(a) as an inlet to the BP housing 3031 and a second liquid interface 3034(b).

[0147] In some embodiments, the liquid interface 3034 may be configured to connect to an external liquid circulation system, such as a liquid circulation system equipped with a liquid source or pump.

[0148] Figures 14A, 14B, 15A, and 15B are conceptual diagrams of an embodiment of the BP3030.

[0149] In some embodiments, as shown in Figure 14A, the BP3030 may include a plurality of vertically stacked BM3010s. The BP3030 may further include and be assembled with a first IM3050(a) configured as a first vertical lid and a second IM3050(b) configured as a second vertical lid, located at the opposite vertical end of the stacked BM3010. The BP3030 may further include a first EEIM3060(a) and a second EEIM3060(b). The first EEIM3060(a) is positioned on the first IM3050(a), and the second EEIM3060(b) is positioned on the second IM3050(b). The first EEIM3060(a) may further include a first HVIC3063(a) located at one of the two vertical ends of the BP3030, and the second EEIM3060(b) may further include a second HVIC3063(b) located at the other vertical end of the BP3030. Such a configuration is set up to connect to a downstream load having separately located terminals.

[0150] In some embodiments, as shown in Figure 14B, the BP3030 may include a plurality of vertically stacked BM3010s. The BP3030 may further include and be assembled with a TM3040 configured as a first vertical cover and an IM3050 configured as a second vertical cover, located at the opposite vertical end of the stacked BM3010. The BP3030 may further include an EEIM3060. The EEIM3060 is positioned on the IM3050. The EEIM3060 may further include two HVIC3063s positioned at the same end of the two opposite vertical ends of the BP3030. Such a configuration is configured for connection to a downstream load with closely spaced terminals. The LLC0080 may further include vertical wall channels 0230. The vertical wall channels 0230 of each LLC0080 may be sealed together to form a vertical through-hole that vertically penetrates the entire assembly of the stacked BM3030. The BP3030 may further include a conductor rod 0280 configured such that both the first and second electrodes of the circuit formed by all the series-connected and / or parallel-connected battery cells are located at the second vertical end of the entire assembly of the stacked BM3030.

[0151] In some embodiments, the conductor rod 0280 may be connected to the first electrode of a circuit formed by electrically connecting all BC0020 in series and / or parallel via BCCM0026 and MEEI3020 at a first vertical end adjacent to TM3040 of the entire assembly of the laminated BM3030. The conductor rod may be arranged within a vertical through hole, extend vertically along a vertical through hole that vertically penetrates the entire assembly of the laminated BM3030, or protrude from a second vertical end adjacent to IM3050 of the entire assembly of the laminated BM3030. Thus, both the first and second electrodes of the circuit formed by all the series-and- / parallel-connected battery cells are located at the second vertical end of the entire assembly of the laminated BM3030.

[0152] In some embodiments, the HVIC3063 of the BP3030 may be arranged on the same vertical end of the stacked BM3020, while the HVIC3063 of the BP3030 may be arranged on the same vertical end of the stacked BM3020. Such arrangement facilitates system integration because both the liquid connection to the external coolant channel and the electrical connection to the downstream load can be realized on the same side of the battery pack. This not only reduces the complexity of installation and maintenance but also improves the compactness and reliability of the battery pack assembly.

[0153] Refer to Figure 16A, a conceptual perspective view of a cross-sectional view of the BP3030. Parts described in both this embodiment and the previously described embodiments, or parts with similar reference numerals, represent parts having similar structure or function, and related explanations are omitted here. Note that Figures 16A and 16B are not precise cross-sectional views of the BP3030. Figure 16A shows several structural features of the BP3030 that can be observed from the cross-sectional view. These structural features are shown as being on the same plane, but this does not mean that these technical features must be located in the same xy cross-section. Furthermore, the term "lateral" refers to any vector on the yz plane in Figures 16A and 16B. For example, a lateral liquid flow may be a liquid flow moving only in the z direction on the yz plane, and a lateral channel may be a channel located on the yz plane and extending only in the z direction.

[0154] In some embodiments, BP3030 may communicate with a circulating heat exchange system 3080 to form a closed-loop liquid circulation system. The closed-loop liquid circulation system is filled with liquid, and when pressure is applied by a pump to operate the liquid circulation, a liquid flow is generated accordingly.

[0155] Generally, a battery pack is assembled from multiple BMs and lid modules. For example, as shown in Figure 16A, four BMs 3010 (but not limited to, the number of BMs 3010 may vary depending on the actual application of the BP 3030) and two lid modules 3090(a) and 3090(b) are stacked to form a BP 3030, where the lid modules 3090(a) and 3090(b) may be the aforementioned IMs or TMs, or other types of lid modules. In some embodiments, the BMs 3010 and lid modules 3090(a) and 3090(b) may be assembled together with the BP space 3032 to form a liquid-tight BP housing. By introducing a thermal management fluid into the BP space 3032, the relevant BP components within the BP space 3032 can be immersed in the thermal management fluid for heat dissipation. For example, as shown in Figure 16A, each BM 3010 includes a liquid-tight LLC 0080 that provides a lateral fluid barrier (i.e., a peripheral wall 0090). The BM3010s are stacked together to form a BM stack, and the peripheral walls 0090 are also stacked together to form a stacked peripheral wall. The lid modules 3090(a) and 3090(b) are used as vertical lids to form a liquid-tight BP housing together with the stacked peripheral wall. Any two stacked BM3010s can use the aforementioned sealing design to prevent liquid leakage from the interface between the two stacked BM3010s, and the relevant explanation can be inferred from Figures 11A and 11B, so it is omitted here.

[0156] As shown in Figure 16A, BP3030 is in communication with a circulating heat exchange system 3080 via a liquid circulation pipe 3081, and each lid module may include at least one "interface liquid connector" (hereinafter, ILC) 3091 connected to the liquid circulation pipe 3081. The circulating heat exchange system 3080 drives the heat management fluid to flow into BP3030 from one ILC 3091 in the inflow direction F1, and then out of BP3030 from another ILC 3091 in the outflow direction F2, passing through the entire BP space 3032. The circulating heat exchange system 3080 may include other means of regulating the temperature of the heat exchanger or heat management fluid so that the temperature can be adjusted before entering the next circulation for inflow into BP3030.

[0157] More specifically, referring to Figure 16A, the BP3030 may include several structural features that guide the flow of the heat management fluid. As shown in Figure 16A, each lid module includes a lid vertical channel 3092, which is a vertically extending through-hole, thereby allowing the heat management fluid to flow vertically through the through-hole. In some embodiments, the lid vertical channel 3092 communicates directly with the ILC3091 and the BP space 3032, thereby allowing the heat management fluid to flow into or out of the BP space 3032 via the lid vertical channel 3092.

[0158] After the thermal management fluid flows into the BP space 3032 via the lid vertical channel 3092, the area that the thermal management fluid can reach or arrive at may be vertically divided into a lid module zone 3093 and a battery module zone 3011. Specifically, the lid module zone 3093 refers to a zone of the BP space 3032 covered within each lid module. For example, the lid module 3090(a) in Figure 16A may include an inner lid surface 3094. The lid module zone 3093 may be defined by the portion of the BP space 3032 extending from the module interface reference line 3012 between the lid module 3090(a) and BM3010 to the inner lid surface 3094. Specifically, the battery module zone 3011 refers to the portion of the BP space 3032 covered within the peripheral wall 0090 of LLC0080. Because the lid module 3090(a) and BM3010 are tightly sealed to prevent liquid leakage, the thermal management fluid can flow from the lid module zone 3093 to the battery module zone 3011, passing through the module interface reference line 3012. The aforementioned liquid flow from the tubular opening of LLC0080 across the laminated BM3010 is referred to in this disclosure as LLC liquid flow0081.

[0159] Refer to Figure 16B, a conceptual perspective view of the cross-section of BP3030. Some reference numerals shown in Figure 16A but not in Figure 16B can also be used in Figure 16B.

[0160] Referring to Figure 16B, in some situations, components or structures within the BP space 3032 may generate flow resistance. For example, BCA0010 may include at least (but not limited to) cell holders 0050, BC0020, and BCCM0026 (not shown in Figure 16B). LLC0080 may also include cell holder retaining structure 0140 or other structures assembled to cell holder 0050. These structures or components may generate vertical flow resistance or localized vortices, affect the uniformity of the flow field distribution, and create overheating points within the BP space 3032, thus leading to heat dissipation problems.

[0161] Furthermore, since the heat management fluid enters the BP space 3032 and flows through each BM3010 sequentially, the heat dissipation conditions of the first BM3010 and the last BM3010 are different. For example, in each circulation, the temperature of the heat management fluid after leaving the heat exchanger is at its initial state. The longer the distance the heat management fluid travels, the greater the temperature deviation from the initial state. In the entire flow loop, the BM3010 closest to the pump outlet 3082 is called the closest BM3010 (i.e., the first BM3010), and the BM3010 furthest from the pump outlet 3082 is called the furthest BM3010 (i.e., the last BM3010). The temperature of the closest BM3010 is closest to a predetermined target temperature, or has the smallest variation from the predetermined target temperature. On the other hand, the temperature of the furthest BM3010 is the largest difference from the predetermined target temperature, or has the largest variation from the predetermined target temperature.

[0162] As shown in Figure 16B, in this disclosure, the portion of the BP space 3032 extending vertically between the two cell holders 0050 within the BM3010 may be defined as the cell zone 0051, and the portion of the BP space 3032 extending from the two cell holders 0050 to the tubular openings at the top and bottom ends of the LLC0080 may be defined as the edge zone 0052. As described above, the flow resistance from the edge zone 0052 to the cell zone 0051, or from the cell zone 0051 to the edge zone 0052, is relatively large because the cell holders 0050 and other components such as the BCCM0026 connected to the cell holders 0050 may generate flow resistance.

[0163] Figure 17 is a conceptual diagram showing the physical configuration of a battery pack 3030 according to an embodiment of the present invention. This figure shows how the circuit components, functional blocks, and connection interfaces described in Figure 1B are physically arranged and integrated within the mechanical structure of the battery pack 3030.

[0164] In the embodiment shown in Figure 17, the battery pack 3030 includes a plurality of vertically stacked battery modules 3010. The battery pack 3030 further includes a first electrical energy interface module (EEIM) 3060a located at a first vertical end (e.g., the top end) of the stacked battery modules 3010, and a second electrical energy interface module (EEIM) 3060b located at a second vertical end (e.g., the bottom end) opposite the first vertical end.

[0165] As shown in Figure 17, the high-voltage switching circuit in Figure 1B is physically divided into a first circuit module 3001 and a second circuit module 3002 based on their functions and connection relationships.

[0166] The first circuit module 3001 is housed within the first EEIM 3060a. The first circuit module 3001 includes components associated with the positive terminal of the battery pack 3030. Specifically, the first circuit module 3001 includes a contactor (POS) 307, a contactor (PRE) 309, a resistor (PRE) 310, and an HVIL 306. A positive high voltage interface connector (HVIC(+)) is also arranged in the first EEIM 3060a to electrically connect the first circuit module 3001 to an external load.

[0167] The second circuit module 3002 is housed within the second EEIM 3060b. The second circuit module 3002 includes components associated with the negative terminal of the battery pack 3030. Specifically, the second circuit module 3002 includes a contactor (NEG) 312 and a current shunt 311. A negative high voltage interface connector (HVIC(-)) is also arranged in the second EEIM 3060b to electrically connect the second circuit module 3002 to an external load.

[0168] In this distributed architecture, where the first circuit module 3001 (positive switching side) and the second circuit module 3002 (negative switching side) are physically separated at the opposite vertical end of the battery pack 3030, efficient space utilization and improved thermal management are possible by separating the heat sources.

[0169] In some embodiments, the spaces within the first EEIM3060a and the second EEIM3060b are hydrodynamically isolated from the battery pack space in which the battery cells are immersed, thereby preventing the first circuit module 3001 and the second circuit module 3002 from being immersed in the thermal management fluid. However, in other embodiments, these spaces may be configured to be hydrodynamically continuous with the battery pack space in order to allow immersion cooling of the first circuit module 3001 and the second circuit module 3002.

[0170] The battery pack 3030 further utilizes the vertical wall channel 0230 of the LLC0080 of the battery module 3010 to accommodate signal cables and interfaces. As shown in Figure 17, the vertical wall channel 0230 of the stacked battery module 3010 forms a continuous vertical passage. Signal cables (represented by connecting wires within the channel) are arranged within this vertical passage to establish signal connections between the battery management circuit 300 (which may be externally located or connected via connectors) and components located in different layers of the battery pack 3030.

[0171] For example, a cell monitoring circuit 305 is positioned physically close to each battery cell in each battery module 3010 to perform accurate measurements. The cell monitoring circuit 305 is signal-connected to a signal cable in the vertical wall channel 0230 via a signal interface. Measurement data from each cell monitoring circuit 305 can be transmitted upward to the battery management circuit 300 through this vertical signal backbone. Similarly, control signals from the battery management circuit 300 can be transmitted downward through the vertical wall channel 0230 to control the contactor (NEG) 312 and receive data from the current shunt 311 located in the second circuit module 3002 within the second EEIM 3060b.

[0172] Regarding the high-voltage loop (represented by the thick line), electrical energy flows from the battery module 3010 to HVIC(+) via the contactor (POS) 307 and pre-charge circuit (309, 310) of the first circuit module 3001, and then flows from the battery module 3010 to HVIC(-) via the current shunt 311 and contactor (NEG) 312 of the second circuit module 3002.

[0173] With respect to the low-voltage loop (represented by thin wires), the battery management circuit 300 is powered by an external power source or the battery pack itself and is signal-connected to the pump 302 to control liquid circulation. The battery management circuit 300 is connected via a connector to a signal cable in the vertical wall channel 0230. This configuration allows the battery management circuit 300 to centrally manage the first circuit module 3001, the second circuit module 3002, and the cell monitoring circuit 305, which are distributed throughout the battery pack 3030.

[0174] Figure 18A shows a perspective view of BP3030 according to an exemplary embodiment of the present disclosure. Figure 18B shows the electronic connection structure of the cell monitoring circuits 3110 and 3120 shown in Figure 18A, according to an exemplary embodiment of the present disclosure.

[0175] Parts described in both this embodiment and the previously described embodiment, or parts with the same reference numeral, represent parts having similar structure or function, and related descriptions are omitted here.

[0176] Referring to Figure 18A, in some embodiments, each of the BM3010 may include corresponding cell monitoring circuits 3110 and 3120 (i.e., cell monitoring device 0260 shown in Figure 12A) mounted within the corresponding BM3010. In some embodiments, cell monitoring circuit 3110 may be electrically connected to cell monitoring circuit 3120 to transmit monitoring data or control signals. In some embodiments, the electrical connector of cell monitoring circuit 3110 may be mounted on the BM3010 or exposed to LLC0080. The electrical connector of cell monitoring circuit 3120 may be mounted on the BM3010 or exposed to LLC0080. When the BM3010s are connected to each other, the electrical connector of cell monitoring circuit 3110 may be directly or electrically connected to the electrical connector of cell monitoring circuit 3120. Therefore, when the BMs are connected to each other, the electrical connectors of cell monitoring circuits 3110 and 3120 do not need to be exposed outside the BM3010.

[0177] In some embodiments, as shown in Figures 18A and 18B, BM3010 may further include at least one PCB for a particular function. Such a functional PCB may be arranged within the BP space 3032 and may be located in the vertical wall channel 0230 as previously disclosed (see Figure 12A and its description), or in both of the aforementioned spaces.

[0178] In some embodiments, as shown in Figure 18B, BM3010 may further include at least one FPC component for a particular function. Such a functional FPC component may be arranged within the BP space 3032 and may be located in the vertical wall channel 0230 as previously disclosed (see Figure 12A and its description) or in both of the aforementioned spaces.

[0179] In some embodiments, as shown in Figure 18B, the BM3010 may further include at least one PCB-FPC interface 3163 configured to electrically or signally connect the PCB and the FPC. In some embodiments, the PCB-FPC interface 3163 may be a pair of interconnectable connectors arranged on the PCB and the FPC, respectively.

[0180] For example, as shown in Figure 18B, each of the BM3010 of BP3030 includes a PCB arranged in a vertical wall channel 0230 (not shown in this figure) and two FPC components arranged in both another vertical wall channel (or the same vertical wall channel in which the PCB is arranged) and BP space 3032. The PCB-FPC interface 3163 is arranged in the vertical wall channel and the PCB.

[0181] As shown in Figure 18B, each of the two FPC components includes a first portion in a vertical wall channel and a second portion in BP space 3032. In the vertical wall channel, the first portions of the two FPC components are signal- or electrically connected to the PCB-FPC interface 3130 and the PCB. In the vertical wall channel, each body of the first portion of the FPC component extends vertically to the vertical position of the vertical wall channel, so that in such a vertical position, each body of the FPC extends continuously along the z-direction and enters BP space 3032 (which is considered the second portion of the FPC).

[0182] In some embodiments, the second portion of the FPC may extend laterally within the BP space 3032 and be directly mounted in any later direction of the BCA0010 to form electrical and / or signal connections to the BCA0010.

[0183] For example, as shown in Figure 18B, the second portion of the FPC extends along the positive y-edge (along the z-direction) of BCA0010 and directly connects to and contacts each BCCM0026.

[0184] For example, as shown in Figure 18B, the second portion of the FPC may further include a branch that extends from the positive y-edge of BCA0010 along the negative y-direction of BCA0010, reaching a specific lateral position of BCA0010, and directly connecting and contacting BCCM0026 at such a specific lateral position.

[0185] In some embodiments, the functional purpose of the PCB and FPC circuit configuration may be cell monitoring. For example, the PCB may be a cell monitoring device including a processor, controller, and driver used to control sensors that detect the status of BC0020 or BCA0010. Such sensors and connections for detection may be arranged on the FPC components, forming a loop to the PCB where the cell monitoring device is arranged.

[0186] In some embodiments, the functional purpose of the PCB and FPC circuit configuration may be BP heating. For example, the PCB may be a cell heating device including a processor, controller, and driver used to control heaters that generate heat to warm the BP space 3032. Such heaters and connections for heating may be arranged in the FPC components and form a loop to the PCB where cell monitoring devices are arranged.

[0187] In some embodiments, each BM3010 may include a plurality of BC0020s. In some embodiments, the first BM3010 may further include a plurality of BCCM0026(a) and a plurality of BCCM0026(b), and each of the BC0020s of the first BM3010 may be electrically connected to one of the BCCM0026(a) and one of the BCCM0026(b). In some embodiments, the last BM3010 may further include a plurality of BCCM0026(c) and a plurality of BCCM0026(d), and each of the BC0020s of the last BM3010 may be electrically connected to one of the BCCM0026(c) and one of the BCCM0026(d). In some embodiments, multiple BCCM0026(a), BCCM0026(b), BCCM0026(c), and BCCM0026(d) may be used to electrically connect the BC0020 to one another. Furthermore, the BC0020 may be electrically connected to one another in series or in parallel by multiple BCCM0026(a), BCCM0026(b), BCCM0026(c), and BCCM0026(d). Referring to Figure 18A, in some embodiments, one of the multiple BCCM0026(a) may be electrically connected to the HVIC3063 of the lid module 3090(a), and one of the multiple BCCM0026(d) may be electrically connected to the HVIC3063 of the lid module 3090(b). Furthermore, one of the multiple BCCM0026(b) may be electrically connected to one of the multiple BCCM0026(c). Therefore, power may be released from or stored in BC0020 via the HVIC3063 of lid module 3090(a) and the HVIC3063 of lid module 3090(b).

[0188] In some embodiments, the cell monitoring circuit 3110 may be electrically connected to BCCM0026(a), BCCM0026(b) and a plurality of cell detection circuits 3111. The cell detection circuit 3111 may be electrically connected to at least one of BCCM0026(a) and at least one of BCCM0026(b). In some embodiments, BCCM0026(a), BCCM0026(b) and the cell detection circuit 3111 may be housed in the BP space 3032 of the BM3010, thereby immersing BCCM0026(a), BCCM0026(b) and the cell detection circuit 3111 in a heat management fluid contained in the BM3010 for heat dissipation of BCCM0026(a), BCCM0026(b) and the cell detection circuit 3111. In some embodiments, the cell monitoring circuit 3120 may be electrically connected to BCCM0026(c) and BCCM0026(d) via a plurality of cell detection circuits 3121. The plurality of cell detection circuits 3121 may be electrically connected to BCCM0026(c) and BCCM0026(d). In some embodiments, BCCM0026(c), BCCM0026(d) and the cell detection circuit 3121 may be immersed in a heat management fluid contained in BM3010 for heat dissipation of BCCM0026(c), BCCM0026(d) and the cell detection circuit 3121. In some embodiments, the cell detection circuits 3111 and 3121 may be flexible printed circuits (FPCs).

[0189] In some embodiments, cell detection circuits 3111 and 3121 may be used to measure the voltage and temperature of BCCM0026(a), BCCM0026(b), BCCM0026(c), and BCCM0026(d) and provide the measurement results to cell monitoring circuits 3110 and 3120. In some embodiments, cell monitoring circuits 3110 and 3120 may control the temperature of the thermal management fluid by controlling the temperature and voltage of BC0020 and the cell detection circuits 3111 and 3121 based on the measurement results. For example, cell monitoring circuit 3110 may control / use cell detection circuit 3111 to convert the power of BC0020, which is electrically connected to BCCM0026(a) and BCCM0026(b), into heat, thereby controlling the voltage and temperature of BC0020. In some embodiments, the cell monitoring circuits 3110 and 3120 control the temperature and voltage of the BC0020, and the operation of the cell detection circuits 3111 and 3121 is further controlled through programmable drive signals. For example, the management circuit 3110 may generate switching control signals, current limiting commands, or pulse-width-modulation (PWM) signals to pass a control current through the heating components in the BC0020 or the cell detection circuit 3111. Due to the internal resistance of the BC0020 or the heating components in the cell detection circuit 3111, this control current is converted into heat, thereby increasing or stabilizing the temperature of the BC0020 or the thermal management fluid. Similarly, voltage regulation is achieved by adjusting the magnitude, duration, or duty cycle of the current supplied through the cell detection circuit 3111, thereby controlling the voltage level of the BC0020.

[0190] In some embodiments, the cell monitoring circuit 3120 may control / use the cell detection circuit 3121 to convert the power of BC0020 into heat and control the voltage and temperature of BC0020. Therefore, if the cell monitoring circuits 3110 and 3120 control the temperature of the cell detection circuits 3111 and 3121, the power of BC0020 may be used directly to heat the heat management fluid and BC0020 to improve the temperature of the heat management fluid. Thus, the voltage control and temperature control functions of the cell monitoring circuits 3110 and 3120 eliminate the need to install additional heating devices in the BM3010. Furthermore, since the cell monitoring circuits 3110, 3120 and the cell detection circuits 3111, 3121 are mounted inside the BM3010 without being exposed outside the BM3010, the possibility of component damage is reduced and the durability of the components can be improved. In some embodiments, the cell detection circuits 3111 and 3121 may include heating traces that generate heat when current flows through the cell detection circuits 3111 and 3121 under the control of the cell monitoring circuits 3110 and 3120. Thus, the resistance loss generated by the cell detection circuits 3111 and 3121 is dissipated as thermal energy, which is then transferred from the cell monitoring circuits 3110 and 3120 to the heat management fluid. In this way, the temperature of the heat management fluid can be increased without requiring additional heating components.

[0191] Figure 19 shows a schematic diagram of BC0020, the cell monitoring circuit 3110, and the cell detection circuit 3111 shown in Figures 18A and 18B, according to an exemplary embodiment of the present disclosure.

[0192] Parts described in both this embodiment and the previously described embodiment, or parts with the same reference numeral, represent parts having similar structure or function, and related descriptions are omitted here.

[0193] Referring to Figures 18B and 19, in some embodiments, BM3010 may further include one or more switches 3130 and a heating module 3140. In some embodiments, one or more switches 3130 may be electrically connected to BC0020, a cell monitoring circuit 3110, and a heating module 3140. In some embodiments, the cell monitoring circuit 3110 may transmit switch signals to control one or more switches 3130 to be turned on or off. In some embodiments, if one or more switches 3130 are turned off by the cell monitoring circuit 3110, the current in BC0020 may not flow through the heating module 3140. Therefore, the heating module 3140 does not convert the power of BC0020 into heat. In some embodiments, if one or more switches 3130 are turned on by the cell monitoring circuit 3110, the current in BC0020 may flow through the heating module 3140. Therefore, the heating module 3140 converts the power of BC0020 into heat to heat the heat management liquid contained in BC0020 and BM3010. In some embodiments, the heating module 3140 may be a heating copper trace. In some embodiments, the cell monitoring circuit 3110 may control one or more switches 3130 by generating drive signals such as gate control voltage, base current, or pulse width modulated signals, depending on the type of switch 3130 (e.g., MOSFET, BJT, or other semiconductor switching device). These drive signals may selectively drive one or more switches 3130 to an off or on state. In actual applications, BM3010 may include at least two of the cell monitoring circuit, cell detection circuit, and heating module.

[0194] In some embodiments, the BM3010 may further include an electrical safety device 3150 electrically connected to one or more switches 3130 and a heating module 3140. In some embodiments, the electrical safety device 3150 may include a wire or soluble metal strip that melts or interrupts the circuit when the current exceeds a threshold current. Thus, if the current in the heating module 3140 exceeds the threshold current, the electrical safety device 3150 can interrupt the current and stop heating the heat management fluid and BC0020. In some embodiments, if the electrical safety device 3150 melts due to excessive current, the conductive path between one or more switches 3130 and the heating module 3140 may be physically disconnected. As a result, the electrical connection supplying current to the heating module 3140 is interrupted, stopping the heating module 3140 from receiving power. Thus, the heating module 3140 can stop heating the heat management fluid and BC0020 by immediately stopping heat generation.

[0195] In some embodiments, the heating module 3140 may further include a temperature sensor 3141 electrically connected to the cell monitoring circuit 3110. The cell monitoring circuit 3110 may control the temperature sensor 3141 to monitor the temperatures of the heat management fluid and BC0020. In some embodiments, the cell monitoring circuit 3110 may control the temperature sensor 3141 by providing a detection control signal that activates the temperature measurement function of the temperature sensor 3141. For example, the cell monitoring circuit 3110 may periodically transmit a reference voltage or current to the cell monitoring circuit 3110 so that the temperature sensor 3141 can generate a temperature detection signal. The cell monitoring circuit 3110 can then receive the temperature detection signal and determine the temperatures of the heat management fluid and BC0020. The functional purpose of the cell detection circuit described above still includes temperature detection, and the cell detection circuit and temperature sensor 3141 detect the temperatures of different components within the BP3030.

[0196] Therefore, the power of BC0020 may be used directly to heat the heat management fluid and BC0020. The voltage control and temperature control functions of the cell monitoring circuit 3110 eliminate the need to install additional heating equipment on BM3010. Furthermore, since the cell monitoring circuit 3110, one or more switches 3130 and heating module 3140 are all mounted inside BM3010 without being exposed outside of BM3010, the possibility of damage to the cell monitoring circuit 3110 and cell detection circuit 3111 is reduced, and the durability of the cell monitoring circuit 3110 and cell detection circuit 3111 can be improved.

[0197] In some embodiments, the cell detection circuit 3111 increases the temperature of the heat management fluid because the heating module 3140 (e.g., a heated copper trace or a resistive element) generates heat when current flows through it. When the cell monitoring circuit 3110 turns on one or more switches 3130, current passes through the heating module 3140, and the resistive losses generated by the heating module 3140 are converted into thermal energy. Thus, the thermal energy is transferred to the heat management fluid, thereby increasing the temperature of the heat management fluid.

[0198] In some embodiments, the PCB (e.g., cell monitoring circuit 3110) may further include a vertical stack connector 3160 located at the vertical end of at least one battery module.

[0199] The vertical stack connector 3160 may be configured to be a signal interface between the PCB of the lower BM3010 (e.g., cell monitoring circuit 3110) and another PCB of the adjacent BM3010 (e.g., cell monitoring circuit 3110). The vertical stack connector 3160 may also electrically couple two adjacent BMs (i.e., BM3010 directly stacked with each other).

[0200] In some embodiments, two vertically stacked connectors 3160 configured to connect to each other may be configured to achieve blind mating (or auto-mating). This blind mating feature means that the connectors automatically align mechanically when the BM3010 is vertically stacked, ensuring a fast and reliable electrical connection. This feature significantly improves the efficiency and automation level of the battery pack manufacturing process.

[0201] In some embodiments, a PCB (e.g., a cell monitoring circuit 3110) located within a vertical wall channel 0230 may further include a vertical interface connector 3162 located at its vertical end.

[0202] The vertical interface connector 3162 is configured to electrically connect the circuit board to a corresponding connector located on one of the two lid modules 3090 when the BM3010 and lid module 3090 are assembled vertically. The primary purpose of this connection is to transmit state information (e.g., voltage, temperature, or current) collected by the circuit board to the main electronic control unit located in the lid module 3090.

[0203] Specifically, the EEIM3060, located in one of the two cover modules 3090, is configured to house or be electrically coupled to a battery management circuit for further processing or control.

[0204] In some embodiments, the vertical stack connector 3160 and the vertical interface connector 3162 may be implemented as a single physical connector located on the circuit board, the single connector consisting of separate pins or contact points that perform both the functions of inter-module stacking and module-to-EEIM signaling interfaces.

[0205] Therefore, the vertical interface connector 3162 is configured to electrically connect the circuit board 3110 to the battery management circuit located within the EEIM 3060. This arrangement facilitates direct, modular transmission of accurate cell data to the battery management circuit for control and protection purposes, thereby substantially improving the modularity and maintainability of the battery pack.

[0206] The embodiments shown and described above are merely examples. Many details are commonly seen in the art. Therefore, many such details are not shown or described. Many features and advantages of the disclosure, along with structural and functional details, are described above, but the disclosure is illustrative only and modifications to the details are possible. Therefore, it should be understood that the embodiments described above may be modified in the claims.

[0207] Those skilled in the art will readily realize 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. A charge / discharge circuit including at least one battery cell assembly containing multiple mechanically and electrically integrated battery cells, A battery pack housing that houses the charging and discharging circuit, The battery pack housing is provided with at least one high-voltage interface connector configured to transmit high-voltage power between the battery pack and an external electrical device, A high-voltage switching circuit is disposed within the battery pack and configured to selectively open and close the high-voltage electrical connection between the charge / discharge circuit and the external electrical equipment, The battery pack includes a battery management circuit configured to control and drive the high-voltage switching circuit, The battery pack housing is formed by at least one tubular casing stacked vertically as a tube stack, and two lid modules covering opposite ends of the tube stack, thereby providing an insulating barrier that isolates the at least one battery cell assembly from the outside of the battery pack. The two cover modules mentioned above are a battery pack including a first cover module and a second cover module.

2. The battery pack according to claim 1, wherein the at least one tubular casing is a liquid-restricting casing, the battery pack housing is configured to be liquid-tight so as to define a battery pack space for containing a thermal management fluid, and when the thermal management fluid is introduced into the battery pack space, the charge / discharge circuit is immersed in the thermal management fluid.

3. At least one of the preceding first cover module and the preceding second cover module is an interface module. The battery pack further includes at least one electrical energy interface module located in the at least one interface module, The battery pack according to claim 1, wherein the high-voltage switching circuit includes a positive contactor and a negative contactor housed in the at least one electrical energy interface module.

4. The first lid module is positioned at the first vertical end of the tube stack, and the second lid module is positioned at the second vertical end of the tube stack. Both the earlier 1st cover module and the earlier 2nd cover module are interface modules. The battery pack according to claim 3, wherein a first electrical energy interface module is located in the first cover module, and a second electrical energy interface module is located in the second cover module.

5. The high-voltage switching circuit and the battery management circuit are functionally divided into a first circuit module and a second circuit module. The first circuit module is housed within the first electrical energy interface module and includes the positive contactor, precharge contactor, precharge resistor, and high-voltage interlocking loop. The battery pack according to claim 4, wherein the second circuit module is housed within the second electrical energy interface module and includes the negative electrode contactor and the current shunt.

6. The battery pack according to claim 5, wherein each of the at least one tubular casings includes a vertical wall channel, and the battery pack further includes signal lines arranged within the vertical wall channel, the signal lines electrically connecting the low-voltage loop of the first circuit module and the low-voltage loop of the second circuit module for the transmission of control signals.

7. The battery pack according to claim 5, wherein the charge / discharge circuit is electrically connected to the positive electrode contactor and the precharge contactor of the first circuit module and is electrically connected to the current shunt and the negative electrode contactor of the second circuit module.

8. The first lid module is located at the first vertical end of the tube stack and is an interface module. The battery pack according to claim 3, wherein the second lid module is located at the second vertical end of the tube stack and is a terminal module.

9. The battery pack according to claim 8, wherein the high-voltage switching circuit includes the positive contactor, pre-charge contactor, pre-charge resistor, high-voltage interlocking loop, negative contactor, and current shunt, all of which are housed within the electrical energy interface module.

10. The battery pack according to claim 9, wherein each of the at least one tubular casings includes a vertical wall channel, and the battery pack further includes signal lines arranged within the vertical wall channel, the signal lines electrically connecting the low-voltage loop of the high-voltage switching circuit.

11. The battery pack according to claim 10, wherein the charge / discharge circuit is electrically connected to the positive electrode contactor, the precharge contactor, and the current shunt, which are housed in the electrical energy interface module.

12. The battery pack according to claim 10, wherein the vertical wall channels of at least one tubular casing are aligned to form a continuous vertical through-hole that penetrates the tube stack, and the battery pack further includes a conductor rod housed in the continuous vertical through-hole, the conductor rod being configured to electrically connect the electrodes of the charge / discharge circuit located at the second vertical end to the electrical energy interface module located at the first vertical end.

13. The battery pack according to claim 3, wherein each of the at least one battery cell assemblies includes a cell monitoring circuit located within the tubular casing, the cell monitoring circuit includes a vertical interface connector located at the vertical end of the tubular casing, and the vertical interface connector is configured to electrically connect the cell monitoring circuit to the battery management circuit housed within the electrical energy interface module in order to transmit the status of the plurality of battery cells.

14. The battery pack according to claim 2, further comprising sealing members arranged at the interface between two adjacent stacked tubular casings, or at the interface between the tubular casing and one of the two lid modules, wherein the tubular casing or at least one of the two lid modules includes a sealing member housing structure configured to house and position the sealing member for sealing the battery pack space.

15. The battery pack according to claim 5, wherein the battery management circuit is housed within the first electrical energy interface module, the at least one tubular casing includes a vertical wall channel in which signal lines are arranged, the signal lines electrically connect the first electrical energy interface module and the second electrical energy interface module, and the battery management circuit is configured to transmit control signals to the second electrical energy interface module via the signal lines to control the open or closed state of the negative electrode contactor.

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