Battery module and battery module stack

Abstract

A battery module is described that includes a cell enclosure that houses a plurality of battery cells and a cooling assembly. The cooling assembly includes a cooling channel that extends from an aperture in a first side of the battery module to an aperture in a second side of the battery module. The cooling channel is positioned to transfer heat generated within the cell enclosure to a cooling fluid that flows through the cooling channel from the first side of the battery module to the second side of the battery module. Also described is a battery module stack that includes a number of such battery modules. The battery modules are arranged in a stacked configuration such that the cooling channel of at least one battery module is aligned with the cooling channel of at least one adjacent battery module.

Description

[Technical field]

[0001] The present disclosure relates to a battery module and a battery module stack including multiple battery modules. [Background technology]

[0002] One type of rechargeable battery is the lithium-ion battery, which has a multi-layer structure with a positive electrode activated by various mixed oxides or olivine, a negative electrode activated by special carbon, and a separator all immersed in an organic electrolyte. This battery is typically housed in an enclosure to form a battery module. During normal operating conditions, electrical energy is converted into chemical energy, during charging it is stored as chemical energy, and during discharging the stored chemical energy is converted back into electrical energy. Specifically, during charging, the lithium in the positive electrode is ionized and moves layer by layer to the negative electrode, and during discharging the ions move back to their original compound to the positive electrode. A number of lithium-ion battery modules, together with a control module for controlling the battery modules, are mounted in a rack assembly to form a battery pack.

[0003] Many different types of racks may be used to store and transport the interconnected battery modules. In its simplest form, the rack may have a frame structure with a number of bays into which the battery modules are inserted. Power and cooling lines may then be connected to the battery modules. In another form, the rack may have a backplane that houses the power connections. The battery modules, with their power connectors at the rear of the modules, are inserted into the bays and plugged directly into the backplane. Summary of the Invention [Problem to be solved by the invention]

[0004] However, the use of racks generally complicates the battery pack. For example, using racks to house battery modules increases the number of components that make up the battery pack, which in turn increases the cost of manufacturing the pack. Additionally, racks that employ backplanes may be prone to alignment issues between the power connectors of the battery modules and the power lines of the backplane.

[0005] Therefore, there is a need in the prior art to provide a battery module that allows for simple and efficient storage and transportation of multiple interconnected battery modules. [Means for solving the problem]

[0006] In a first aspect of the present invention, there is provided a battery module comprising at least one cell enclosure housing a plurality of battery cells, and a cooling assembly, the cooling assembly including a cooling channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module, the cooling channel positioned to transfer heat generated within the cell enclosure to a cooling fluid flowing through the cooling channel from the first side of the battery module to the second side of the battery module. Thus, the first exterior side of the module may be fluidly coupled to the second exterior side of the module.

[0007] The battery module may further include an exhaust assembly including an exhaust channel extending from an aperture on one side of the battery module to an aperture on another side of the battery module, and an exhaust port extending from the cell enclosure to the exhaust channel. The exhaust channel may extend from an aperture on a first side of the battery module to an aperture on a second side of the battery module.

[0008] The battery module may further include a seal for sealing the exhaust port, the seal configured to open in response to pressure reaching a critical pressure within the cell enclosure, thereby allowing exhaust gas to flow from the cell enclosure to the exhaust channel. The seal may be configured to open in response to thermal runaway occurring within the cell enclosure.

[0009] Exhaust ports may extend through the cooling channels. The cooling assembly may be disposed between the cell enclosure and the exhaust assembly.

[0010] The at least one cell enclosure can include first and second cell enclosures on respective sides of the battery module, and the cooling channel can extend between the first and second cell enclosures. The cooling channel can extend along a length of each of the first and second cell enclosures.

[0011] The battery module may further include a heat sink disposed on one or more sides of the battery module. The heat sink may include one or more cooling fins. The heat sink may comprise a spreader plate or heat pipes that direct heat to a cooling assembly.

[0012] The battery module may further include at least one first locking member extending from a top edge or a bottom edge of the battery module.The battery module may further include at least one first locking member extending from a top corner or a bottom corner of the battery module.

[0013] The battery module may further include at least one second locking member disposed within an edge or corner of the battery module located opposite the edge or corner of the battery module that serves as the starting point from which the at least one first locking member extends.

[0014] The battery module may further include a power and communications assembly including one or more of an electrical circuitry and a processor configured to monitor one or more battery cells contained within the battery module. The power and communications assembly may be located at a first end of the battery module and the cooling assembly may be located at an opposite second end of the battery module. The power and communications assembly may be located at a front end of the battery module and the cooling assembly may be located at a rear end of the battery module. Thus, most of the potentially serviceable components may be located at the front of the battery module such that they are easily accessible.

[0015] The power and communication assembly may include a power pin that is movable between a first position and a second position. In some embodiments, in a first "retracted" position, the power pin may be retracted into the battery module, and in a second "extended" position, the power pin may extend from the battery module. In some embodiments, the power pin may be disposed within the battery module in both its retracted and its extended positions. The battery module may further include a switch configured to move the power pin between the first and second positions when activated. Thus, retracting the power pin may make the battery module safe for handling / transportation. Additionally, retracting the power pin breaks the power loop within the assembled stack of modules for servicing components of the modules.

[0016] The power and communications assembly can further include a power socket disposed on an exterior surface of the battery module. The power socket can be disposed on a lower side of the battery module and the power pin can extend from an upper side of the battery module when in the second position. The power pin and the power socket can be disposed directly opposite one another.

[0017] The battery module may further include a removable panel disposed on a front surface of the battery module for providing access to one or more components of the power and communications assembly.

[0018] The power and communications assembly may further include a first optical communications port on one side of the battery module and a second optical communications port on another side of the battery module.

[0019] The power and communications assembly may further include a wireless communications module for communicating with one or more other battery modules.

[0020] The battery module may further include a heat sink located adjacent to the cell enclosure. The heat sink may fluidly couple the cooling channels of the battery module to an exterior of the battery module such that heat generated within the cell enclosure may be transferred away from the battery module via the heat sink to a cooling fluid flowing from the cooling channels of the battery module to the exterior. The heat sink may include a fluid flow path extending from the cooling channels into the heat sink via one or more inlets and returning from the heat sink to the cooling channels via one or more outlets such that heat generated within the cell enclosure may be transferred away from the battery module by entering the cooling channels from a first side of the battery module, flowing into the fluid flow path, returning to the cooling channels, and exiting the cooling channels to a second side of the battery module.

[0021] One or more of the cooling channels, exhaust channels, and power sockets may extend through the heat sink.

[0022] The cooling fluid may include one or more of forced air, liquid coolant, or air moved by convection.

[0023] The battery module may further include one or more male connectors on one of the top and bottom sides of the battery module and one or more female connectors on the other of the top and bottom sides of the battery module, at least one of the connectors may have a tapered portion, for example, the one or more female connectors may have a tapered portion.

[0024] The one or more male connectors may have at least one first locking member and the one or more female connectors may have at least one second locking member.

[0025] The one or more male connectors may include one or more power pins and the one or more male connectors may include one or more power sockets.

[0026] In another aspect of the present invention, there is provided a battery module stack including a number of battery modules, each battery module including at least one cell enclosure housing a plurality of battery cells, and a cooling assembly including a cooling channel, the cooling channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module and positioned to transfer heat generated within the cell enclosure through the cooling channel to a cooling fluid flowing from the first side of the battery module to the second side of the battery module, the battery modules being arranged in a stacked configuration such that the cooling channel of at least one battery module is aligned with the cooling channel of at least one adjacent battery module.

[0027] The battery module stack may further include a base disposed at the bottom of the stacked configuration, and an air conveying or blowing device configured to cause air to flow through the base and through the cooling channels of the stacked battery modules via cooling channels formed in the base and in fluid communication with the cooling channels of the stacked battery modules.

[0028] Each battery module can further include an exhaust assembly including an exhaust channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module, and an exhaust port extending from the cell enclosure to the exhaust channel, the exhaust channel of at least one battery module can be aligned with the exhaust channel of at least one adjacent battery module. The base can have an exhaust outlet in fluid communication with the exhaust channel of the stacked battery modules.

[0029] Advantageously, the integrated nature of the cooling and / or exhaust assemblies and the battery modules allows for the assembly of module stacks without the need for a dedicated backplane, which refers to a simple structure that houses the power connections for the battery modules and to which multiple battery modules are linked or "plugged in."

[0030] The battery module stack may further include a pack controller communicatively coupled to the battery modules and operable to control operation of the battery modules. The pack controller may be stacked with the battery modules.

[0031] The battery module stack may further include a cover positioned on the top of the stacked configuration to seal the cooling channels of the uppermost battery module of the stacked configuration.

[0032] The battery module stack may further include a stabilizing mechanism configured to apply a compressive action to the stacked configuration to stabilize the stacked configuration.

[0033] The stabilizing mechanism may include one or more cables or solid bars (e.g., tie rods) attached to the cover and at least at one or more points as low as the bottommost battery module in the stack configuration.

[0034] Additionally, in the case of liquid-cooled modules, the cover may terminate at the coolant manifold, and the cover may house a "jumper" bus bar to return the current toward the base of the stack, and the cover may use the jumper to direct the current back to the communications section toward the base of the stack.

[0035] Each battery module can further include one or more locking members that correspond and engage with one or more locking members of an immediately adjacent upper battery module and an immediately adjacent lower battery module, and the one or more locking members of a battery module can be configured to correspond and engage with the locking members of an immediately adjacent upper battery module in response to another battery module being stacked on top of the immediately adjacent upper battery module.

[0036] In another aspect of the invention, there is provided a method of assembling a battery module stack by stacking a number of battery modules to form a stacking configuration, each battery module including at least one cell enclosure housing a plurality of battery cells and a cooling assembly including cooling channels, the cooling channels extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module and positioned to transfer heat generated within the cell enclosures through the cooling channels to a cooling fluid flowing from the first side of the battery module to the second side of the battery module, the stacking configuration being such that the cooling channels of at least one battery module are aligned with the cooling channels of at least one adjacent battery module.

[0037] The method may further include positioning a cover on the top of the stacking arrangement to seal the cooling channels of the uppermost battery module of the stacking arrangement. The method may further include applying a compressive action to the stacking arrangement to stabilize the stacking arrangement with a stabilizing mechanism.

[0038] According to yet another aspect of the present invention, there is provided a method of using a battery module stack, the battery module stack including a number of battery modules, each battery module including at least one cell enclosure housing a plurality of battery cells, and a cooling assembly including a cooling channel, the cooling channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module and positioned to transfer heat generated within the cell enclosure through the cooling channel to a cooling fluid flowing from the first side of the battery module to the second side of the battery module, the battery modules being arranged in a stacked configuration such that the cooling channel of at least one battery module is aligned with the cooling channel of at least one adjacent battery module, the method including the steps of identifying a battery module requiring removal from the stacked configuration; engaging a lifting mechanism with the battery module immediately above the identified battery module; and lifting the battery module from the stacked configuration above the identified battery module using the lifting mechanism.

[0039] According to yet another aspect of the present invention, there is provided a method of fabricating a battery module stack, comprising using a lifting mechanism to position a battery module stack according to any of the above-described embodiments at a predetermined location relative to an interface base, wherein at the predetermined location, the cooling channels of the battery module stack are aligned with one another within one or more holes formed in the interface base, such that air channeled through the interface base can flow into the cooling channels of the battery module stack.

[0040] Embodiments of the present invention will now be described with reference to the accompanying drawings. [Brief description of the drawings]

[0041] [Figure 1]FIG. 2 is a diagram showing a battery module stack according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a diagram showing the top of a battery module according to an embodiment of the present invention. [Diagram 3] FIG. 3 is a diagram showing the bottom of the battery module of FIG. 2. [Figure 4] FIG. 3 shows the rear of the battery module of FIG. 2 with the rear cover shown in transparency. [Diagram 5] FIG. 2 is a diagram showing a stack of battery cells. [Figure 6] FIG. 3 is an exploded view of the battery module of FIG. 2. [Figure 7] 1A-1D illustrate interlocking battery modules according to an embodiment of the present invention. [Figure 8] 1A-1D illustrate interlocking battery modules according to an embodiment of the present invention. [Figure 9] FIG. 2 illustrates a module stack base and an interface base according to an embodiment of the present invention. [Figure 10] FIG. 2 illustrates a module stack base and an interface base according to an embodiment of the present invention. [Figure 11] FIG. 2 illustrates a module stack base and an interface base according to an embodiment of the present invention. [Figure 12] FIG. 2 shows air being forced into the module stack of FIG. 1. [Figure 13] FIG. 2 illustrates a multiple module stack and pack controller according to an embodiment of the present invention. [Figure 14] FIG. 2 illustrates a multiple row or column stack of modules and a pack controller according to an embodiment of the present invention. [Figure 15] 1A-1C illustrate a method of assembling a single row of module stacks in accordance with an embodiment of the present invention. [Figure 16] 1 is a diagram showing a battery pack according to an embodiment of the present invention; [Figure 17] FIG. 2 illustrates an interface base according to an embodiment of the present invention. [Figure 18] FIG. 2 illustrates a pack controller module according to an embodiment of the present invention. [Figure 19] FIG. 2 illustrates a pack controller. [Figure 20] 2A-2C show top and bottom views of a battery module according to an embodiment of the present invention. [Figure 21] 2A-2C show top and bottom views of a battery module according to an embodiment of the present invention. [Figure 22] FIG. 22 is a diagram showing a cooling and exhaust manifold of the battery module of FIGS. 20 and 21. [Diagram 23] FIG. 22 is a diagram showing a cooling and exhaust manifold of the battery module of FIGS. 20 and 21. [Figure 24A] FIG. 2 illustrates the power pin in its retracted state in accordance with an embodiment of the present invention. [Figure 24B] FIG. 2 illustrates a power pin in its extended state in accordance with an embodiment of the present invention. [Diagram 25] FIG. 22 is a rear view of the front cover of the battery module of FIGS. 20 and 21. [Figure 26] FIG. 26 is a front view of the front cover of FIG. 25 with the protective service panel removed. [Figure 27] FIG. 17 shows the top of the battery pack of FIG. 16. [Figure 28] FIG. 17 shows the bottom of the battery pack of FIG. 16. [Figure 29] FIG. 17 is a diagram showing the lid of the battery pack of FIG. 16. [Figure 30A] FIG. 2 is a circuit diagram of the battery modules in an interconnected state. [Figure 30B] FIG. 2 is a circuit diagram of the battery modules in an interconnected state. [Figure 30C] FIG. 2 is a circuit diagram of the battery modules in an interconnected state. [Figure 30D] FIG. 2 is a circuit diagram of the battery modules in an interconnected state. [Diagram 31] FIG. 2 is a circuit diagram of the battery modules in an interconnected state. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] The present invention aims to provide an improved battery module and an improved battery pack. Various embodiments of the present invention are described below, but the present invention is not limited to these embodiments, and modifications of these embodiments can be said to be well within the scope of the present invention, which should be limited only by the scope of the claims.

[0043] The words "a" or "an" used in connection with "comprising" or "including" in the claims and / or specification mean "one," which is consistent with the meanings of "one or more," "at least one," and "one or more," unless the context clearly indicates otherwise. Similarly, the term "another" or "another" may mean at least a second or more, unless the context clearly indicates otherwise.

[0044] The terms "coupled," "couples," or "connected" as used herein may have several different meanings depending on the context in which the terms are used. For example, "coupled," "connects," or "coupled" may have mechanical or electrical connotations. For example, "coupled," "connects," or "connected" as used herein may indicate that two elements or devices are directly connected to each other, or are connected to each other via one or more intermediate elements or devices, via electrical elements, electrical signals, or mechanical elements, depending on the particular context. The term "and / or" as used herein when used in the context of a series of items means any one or more of the items in that list.

[0045] As used herein, a reference to "about" or "approximately" a numerical value, or a reference to being "substantially" equal to a numerical value, means within ±10% of that number.

[0046] In the following, a battery module generally refers to an enclosure that houses a number of interconnected battery cells. The battery cells form one or more battery cell stacks (which may also be called battery cell strings). A number of battery modules stacked on top of each other generally form a battery module stack (or simply a module stack). When one or more battery modules are coupled to a module controller (also called a pack controller), the combination of the battery modules and the module controller as a whole forms a battery pack. The pack controller may be stacked with the battery pack stack or may be located outside the module stack.

[0047] Referring to FIG. 1, a battery module stack 100 according to an embodiment of the present invention is shown. The module stack 100 is formed of a stacking arrangement of different components. In particular, the module stack 100 includes a module stack base 10 located at its bottom, a stack of interconnected battery modules 50 stacked on top of the module stack base 10, and a module stack cover 80 positioned at the top of the module stack 100 adjacent to the topmost battery module 50. The module stack 100 is stacked on top of an interface base 95, and the module stack base 10 is adapted to engage with the top surface of the interface base 95. As will be appreciated by those skilled in the art, the present invention extends to battery packs including any number of stacked battery modules and any number of columns or columns of stacked battery modules. Furthermore, in some embodiments, the module stack can be formed without the module stack cover 80 and / or without the module stack base 10. Thus, in some embodiments, the module stack may be formed with only one or more columns of stacked battery modules.

[0048] The footprint of the modular stack 100 is roughly the same as the footprint of a standard size pallet. In particular, the footprint of the modular stack 100 is identical to a standard EUR2 European size pallet (e.g., 1,200 x 1,000 x 144 mm) as defined by the European Pallet Association, although as will be recognized by those skilled in the art, the present invention extends to modular stacks with any other suitable footprint size.

[0049] 2 and 3, top and bottom views of the battery module 50 are shown. The battery module 50 includes a pair of cell enclosures 52a, 52b, each housing a battery cell stack 72a, 72b (not shown in FIGS. 2 and 3). The left, right and bottom sides of the cell enclosures 52a, 52b facing away from the battery module 50 include cooling fins 53 to facilitate heat transfer from the interior of the cell enclosures 52a, 52b to the exterior of the battery module 50.

[0050] At the rear of the battery module 50, an exhaust assembly is provided that includes a pair of exhaust channels 57a, 57b. The exhaust channels 57a, 57b extend from exhaust holes formed in the lower and upper sides of the battery module 50. Thus, the exhaust channels 57a, 57b extend from the lower side of the battery module 50 to the upper side of the battery module 50. The exhaust channels 57a, 57b are used to convey exhaust gases from the battery module 50 that may be generated within the cell enclosures 52a, 52b (e.g., in response to one or more of the battery cell stacks 72a, 72b experiencing thermal runaway). In particular, each exhaust channel 57a, 57b is fluidly coupled to the interior of one of the cell enclosures 52a, 52b such that exhaust gases exiting one of the battery cell stacks 72a, 72b within the cell enclosures can be directed away from the battery module 50.

[0051] A cooling assembly including a cooling channel 56 extends between the cell enclosures 52a, 52b. The cooling channel 56 extends from cooling holes formed in each of the lower and upper sides of the battery module 50. Thus, the cooling channel 56 extends from the lower side of the battery module 50 to the upper side of the battery module 50. The cooling channel 56 is used to convey a cooling fluid between the cell enclosures 52a, 52b. The cooling channel 56 extends along substantially the entire length of the cell enclosures 52a, 52b, and is separated from the exhaust channels 57a, 57b by a physical interface, so that the cooling fluid flowing through the cooling channel 56 does not mix with the exhaust gas flowing through the exhaust channels 57a, 57b. Cooling fluids include, for example, liquid coolant, forced airflow (e.g., cool air forced upward or downward through the battery modules 50 via the cooling channels 56), or passive airflow (e.g., air flowing through the battery modules 50 via the cooling channels 56 by free convection).

[0052] When two or more such battery modules 50 are stacked on top of each other, the cooling channels 56 of one battery module 50 align with the cooling channels 56 of an adjacent battery module 50. In addition, the exhaust channels 57a, 57b of one battery module 50 align with the exhaust channels 57a, 57b of an adjacent battery module 50.

[0053] In some embodiments, the exhaust channels 57a, 57b and the cooling channels 56 can be located anywhere on the battery module 50. For example, a cooling channel can be provided along each side of the battery module 50 facing away from the battery module 50. As another example, the battery module 50 can include a single exhaust channel that serves both cell enclosures 52a, 52b. As will be appreciated by those skilled in the art, any number of cooling and exhaust channels can be included in the battery module 50, and these numbers can vary according to the desires of one skilled in the art, provided that the cooling and exhaust channels extend through the battery module 50 from one side of the battery module 50 to another side of the battery module 50.

[0054] At each corner of the battery module 50, there is a male auto-locking member 59. The male auto-locking members 59 protrude upward from the battery module 50 and are configured to engage or mate with a corresponding female auto-locking member 51 on the underside of another battery module 50. Each female auto-locking member 51 has a tapered portion to facilitate engagement with the male auto-locking member of the adjacent battery module 50. The tapered portion allows for some tolerance for misalignment between the battery modules 50, so that the battery modules 50 can easily "self-center" when engaged with each other.

[0055] Power connectors 83 are provided at the front of the battery modules 50, one on each of the top and bottom sides of the battery modules 50. The power connectors 83 have a pair of conductive pins and a ground connection. The conductive pins may be retractable as described in connection with the power pins 67 of Figures 24A and 24B. Each power connector 83 has a tapered portion to facilitate engagement with the power connector 83 of an adjacent battery module 50. Thus, the male power connector 83 on the top of a battery module 50 has a tapered portion to facilitate engagement with the tapered female power connector 83 on the bottom side of the adjacent battery module 50 above. The tapered portion allows for some tolerance of misalignment between the battery modules 50, so that the battery modules 50 can easily "self-center" when engaged with each other.

[0056] In conjunction with a tapered portion provided on one or both of the male and female power connectors 83, the power connectors 83 may be adapted to "float" relative to the cell enclosures 52a, 52b to provide additional tolerance when the power connector 83 of a battery module 50 is mated with the power connector 83 of an adjacent battery module.

[0057] 4 shows the rear of the battery module 50 with the rear cover removed to reveal the burst disk 64. The burst disk 64 is configured to open in response to a sufficiently high pressure being applied to the burst disk 64, such as would occur in the event of a thermal runaway within the cell enclosures 52a, 52b. When the burst disk 64 is opened, exhaust gases can flow from the interior of the cell enclosures 52a, 52b and away from the battery module 50 via the exhaust channels 57a, 57b.

[0058] 5 shows battery cell stacks 72 housed within one of the cell enclosures 52a, 52b. Each battery cell stack 72 includes multiple battery cells, groups of which are interconnected by bus bars 73.

[0059] Referring to FIG. 6, a module control board service panel 68 is provided at the front end of the battery module 50. The service panel 68 is removable to expose a module control board 69. The module control board 69 contains the control, communication, and power delivery hardware for the battery module 50 and is responsible for monitoring the battery module 50 and ensuring that the battery cells of the battery cell stacks 72a, 72b remain in balance. A connector 73 (which in some embodiments may be a bus bar) interconnects a power connector 83 to the battery cell stacks 72a, 72b housed within the cell enclosures 52a, 52b. The cover 55 of the cell enclosure 52a has been removed to reveal the battery cell stack 72a housed within the cell enclosure. The connector 73 is configured to connect the battery cell stacks 72a, 72b in series or parallel to define the voltage and current ratings of the battery module 50.

[0060] The module control board 69 further includes a pack controller and / or a wireless communication module that allows the battery module 50 to communicate with one or more other battery modules. In some embodiments, other types of wireless or wired communication may be implemented, such as optical communication achieved using optical ports on the top and bottom sides of the battery module 50.

[0061] 7 and 8 show multiple stacked battery modules 50a, 50b, 50c. Battery module 50c is stacked on top of battery module 50b, and battery module 50b is stacked on top of battery module 50a. In FIG. 8, the male auto-locking members 59a, 59b of battery modules 50a, 50b are shown housed in receiving outer sleeves 61a, 61b and received in the corresponding female auto-locking members 50b, 50c of battery modules 50b, 50c. Due to the weight of the upper battery module 50 pressing down the lower battery module 50 located directly below the upper battery module 50, the outer sleeve 61 of the lower battery module 50 translates downward and activates the gripper 62 disposed in the female auto-locking member 51. Upon activation, the gripper 62 engages with the male auto-locking member 59 of the next lowest battery module 50. 8, the weight of the battery module 50c causes the outer sleeve 61b of the battery module 50b to translate downward to engage the gripper 62b of the battery module 50b. The gripper 62b thus engages the male auto-locking member 59a of the battery module 50a, thereby locking the battery module 50b to the battery module 50a. Until weight is applied to the battery module 50c (e.g., by another battery module 50 or the module stack cover 80), the battery module 50c remains unlocked relative to the battery module 50b because the gripper 62c has not yet been activated by the outer sleeve 61c.

[0062] 9 and 10 are top and bottom views, respectively, of the modular stack base 10 engaged with the interface base 95. Cooling channels 156 are formed within the modular stack base 10 and positioned to align with the cooling channels 56 of the battery modules 50 stacked on top of the modular stack base 10. Additionally, the modular stack base 10 has exhaust channels 157 at its rear end that are positioned to align with the exhaust channels 57a, 57b of the battery modules 50 stacked on top of the modular stack base 10. The modular stack base 10 also has holes 111 that are used to interface with a forklift truck or similar lifting device for transporting the battery module stack 100 as a whole. The modular stack base 10 also has male auto-locking members 159 to allow the stack of battery modules 50 to be locked to the modular stack base 10 as described above. In some embodiments, the modular stack base 10 has one or more fans to force air through the battery module stack 100. In some embodiments, air may be delivered to the battery module stack 100 through a duct system that runs underneath the battery module stack 100, as described in more detail below. Furthermore, in some embodiments, air may flow through the battery module stack 100 by free convection if the thermal duty cycle is low enough.

[0063] The interface base 95, which may be part of the vessel in which the modular stack 100 is installed, has an exhaust port 150 at its underside for allowing exhaust gases to flow away from the modular stack 100. As shown in FIG 11, the interface base 95 further has a power connector 173 for electrically coupling the modular stack 100 to a pack controller (not shown).

[0064] FIG. 12 shows that the forced air is directed upward through the center of the module stack 100. In particular, the forced air is directed through the interface base 95, through the cooling channel 156 of the module stack base 10, and through each cooling channel 56 of the battery module 50. The stack cover 80 at the top of the module stack 100 allows the topmost battery module to be locked to the next bottommost battery module. In addition, the stack cover 80 seals the exhaust channels 57a, 57b and the cooling channel 56 of the topmost battery module. Thus, by capping the top of the module stack 100, the air forced into the module stack 100 is directed through the gaps 81 between the adjacent stacked battery modules 50 from the sides of the module stack 100. In some embodiments, instead of the stack cover 80, the topmost battery module may have the cooling channel 56 and the exhaust channels 57a, 57b that are sealed together with the battery module. In yet other embodiments, air flowing through the module stack 100 may exit at one or more other locations disposed within the module stack 100 .

[0065] In some embodiments (not shown), the battery modules 50 can be cooled using liquid coolant as opposed to or in addition to airflow. In such embodiments, each battery module 50 can have one or more cold plates positioned below the cell enclosures 52a, 52b. The coolant entering the cold plate can be distributed throughout the cold plate (thereby absorbing heat from the cell stacks 72a, 72b) and then directed upward from the cold plate through tubing or similar conduits positioned within the cooling channels 56. After flowing through the cooling channels 56, the coolant can be directed to a cold plate in the next battery module 50 in the battery module 50 sequence. In some embodiments, the liquid coolant can flow directly through the cooling channels 56 without the need for tubing. In some embodiments, instead of or in addition to a cold plate located on the underside of the battery module 50, the battery module 50 can have one or more cold plates provided on one or more other sides of the battery module 50.

[0066] FIG. 13 illustrates an example of a multi-stack battery pack 1000 including multiple module stacks 100a-h. Each module stack 100a-h is positioned adjacent to one or more other module stacks 100a-h. A pack controller 160 is located at an end of the multiple module stacks 100a-h. In some embodiments, the pack controller 160 may be located elsewhere relative to the multiple module stacks 100a-h. Additionally, while only a single row of module stacks is shown, one skilled in the art will recognize that the present invention extends to a multi-stack battery pack having any suitable number of rows of battery stacks.

[0067] Each module stack 100a-100h is communicatively and operably coupled to a pack controller 160. Thus, a single pack controller is used to interface with all of the module stacks, thereby reducing the number of pack controllers required to control the module stacks 100a-100h. Cool air may be delivered to each module stack 100a-100h via a plenum 170 that extends below each interface base 95 engaged with the module stack 100a-100h. Air may flow along the plenum 170 and may be directed upwardly through a central cooling channel of each module stack 100a-100h, the central cooling channel being formed by the cooling channel 156 of the stack base 10 and the cooling channels 56 adjacent the battery modules 50 that form the module stack.

[0068] FIG. 14 illustrates an exemplary embodiment of a high density battery store with multiple rows of battery module stacks 100 arranged side-by-side. Each row of the module stacks 100 is terminated with a pack controller 160 configured to control the module stacks 100 in the associated column of the module stacks 100. The module stacks 100 may be oriented such that the module service panel 68 faces a service aisle interposed between every second pair of adjacent rows of the module stacks 100. In some embodiments, to reduce the footprint of multiple battery stacks 100, the rows of the module stacks 100 may be positioned immediately adjacent to each other without any service aisle. To service the module stacks 100, a lifting mechanism may be used to remove individual modules 10 from the module stacks 100. Another lifting mechanism 98, for example an I-beam hoist, may be used to position the stacks 100 and engage them with the interface base 95.

[0069] 15 illustrates an exemplary method of assembling a battery pack. A lifting mechanism 96, such as an overhead crane, is used to position a stack 100 of battery modules on a movable pallet 180. For example, the module stack 100 can be suspended from the lifting mechanism 96 by use of lifting straps wrapped around the module stack 100. Another lifting mechanism 98, such as an I-beam hoist, is used to position the stack 100 and engage it with an interface base 95. The interface base 95 provides power, communication, and cooling connections for each module stack 100. Once properly positioned, the module stack 100 can be mechanically restrained to the interface base 95 prior to use.

[0070] In the following, modified embodiments of the module stack, the battery pack, and the battery module are described.

[0071] Referring to FIG. 16, a battery pack 100' according to an embodiment of the present invention is shown. The battery pack 100' is formed of a stacked arrangement of different components. In particular, the battery pack 100' has an interface base 10' located at its bottom, a pack control module 30' stacked on top of the interface base 10', and two adjacent columns of interconnected battery modules 50' stacked on top of the pack control module 30'. A battery pack cover 80' is positioned at the top of the battery pack 100' immediately adjacent the two uppermost battery modules 50'. Each column is formed of an equal number of stacked battery modules 50', with the battery modules 50' in one column having an inverted orientation relative to the battery modules 50' in the other column. Thus, the battery modules 50' in the left column (when facing the front of the battery pack 100') are oriented face up, i.e., with their cooling plates (described in more detail below) facing the interface base 10', whereas the battery modules 50' in the right column are oriented upside down, so that their cooling plates face the battery pack cover 80'. This particular stacking of battery modules 50' is the only possible way to arrange the battery modules 50' in the battery pack 100', and alternative examples are described in more detail below. Moreover, as will be appreciated by those skilled in the art, the present invention extends to battery packs with any number of stacked battery modules and any number of columns of stacked battery modules. Additionally, in some embodiments, the columns of battery modules may have different numbers of battery modules, in which case the battery pack cover may be split and jumper cables or bus bars may be used to route power back.

[0072] Referring to FIG. 17, the interface base 10' is shown in detail. The interface base 10' has a pair of cooling channels 12a', 12b' that extend from the front 16' of the interface base 10' to the upper side at the rear end 18' of the interface base 10'. Cool air can be drawn through vents 11' at the front 16' of the interface base 10' to the rear end 18', and then the cool air can be forced upward through the cooling holes 13a', 13b' (in some embodiments, air can be drawn into the interface base 10' through one or more other locations). Adjacent to the cooling holes 13a', 13b' are holes 15a', 15b' for thermal runaway or exhaust. The exhaust holes 15a', 15b' are part of exhaust channels 17a', 17b' that communicate with respective thermal runaway and exhaust ports 19' on each side of the interface base 10' (in some embodiments, the exhaust channels 17a', 17b' may communicate with ducting at the bottom of the interface base 10'). The exhaust channels 17a', 17b' and the cooling channels 12a', 12b' are separated by a physical interface 14' such that the cooling fluid flowing through the cooling channels 12a', 12b' does not mix with the exhaust gases flowing through the exhaust channels 17a', 17b'. The interface base 10' further includes a recessed portion 21' that provides space for a power bus.

[0073] Referring to FIG. 18, the pack control module (PCM) 30' is shown in detail. The PCM 30' has exhaust channels 34a', 34b' that extend from holes in the underside of the PCM 30' to exhaust holes 38a', 38b' in the upper part of the rear end 34' of the PCM 30'. Adjacent to the exhaust holes 38a', 38b' are cooling holes 36a', 36b' that are part of cooling channels 32a', 32b' that extend from the upper part of the PCM 30' to holes in the lower part of the PCM 30'. The exhaust channels 34a', 34b' and the cooling channels 32a', 32b' are separated by a physical interface 31' such that the cooling fluid flowing through the cooling channels 32a', 32b' does not mix with the exhaust gases flowing through the exhaust channels 34a', 34b'. Located at the front of the PCM 30' are an optical communication port 33', a power pin 35', and a power socket 37'. The PCM 30' has a compartment accessible by removal of a pull-out tray 39'. Housed within the PCM 30' is a master control module 40' (FIG. 19). The master control module 40' is operatively and communicatively coupled to the optical communication port 33', the power pin 35', and the power socket 37'. In some embodiments, rather than using an optical communication port, communication between the battery modules 50' may be accomplished using a wireless communication module or a wired connection.

[0074] 20 and 21, the battery module 50' is shown in detail. The battery module 50' includes a cell enclosure 52' that houses a number of battery cells. Each battery cell is enclosed within a cell carrier, such as those described in WO 2017 / 181284. Other cell structures without cell carriers may be used. Electrical energy from the battery cells may be delivered via bus bars to battery terminal connection studs 71' (see below).

[0075] The battery module 50' further includes a cooling assembly 54' with a cooling and exhaust manifold 55', with cooling channels 56' extending from cooling holes 51' on the underside of the battery module 50' to cooling holes 53' on the top side of the battery module 50'. In this embodiment, the cooling assembly 54' further includes a heat sink in the form of a cooling plate 58' on the underside of the battery module 50'. Thus, the cooling holes 51' are formed directly in the cooling plate 58', so that the cooling channels 56' extend from the underside of the cooling plate 58' to the top side of the battery module 50'. In some embodiments, the battery module 50' may not include a cooling plate 58', in which case the cooling channels 56' extend from the underside of the cooling and exhaust manifold 55' to the very side of the cooling and exhaust manifold 55'. The cooling plate 58' includes a heat sink (e.g., a finned structure of heat transfer elements) to aid in the removal of heat by conduction from the cell enclosures 52'. The cooling channels 56' are in fluid communication with the cooling plate 58' such that cool air can flow through the cooling channels 56' and the cooling plate 58'. The air can then exit the battery module 50' at a front 61' of the cooling plate 58'.

[0076] Adjacent to the cooling channel 56' is an exhaust channel 57' that extends from an exhaust hole 59' in the bottom side of the battery module 50' to an opening 60' in the top side of the battery module 50'. In this embodiment, since the battery module 50' includes a cooling plate 58', the exhaust hole 59' is formed in the cooling plate 58'. The cooling channel 56' and the exhaust channel 57' are separated by a physical interface 62' such that the cooling fluid flowing through the cooling channel 56' does not mix with the exhaust gas flowing through the exhaust channel 57'. When two or more such battery modules 50' are stacked on top of each other, the cooling channel 56' of one battery module 50' aligns with the cooling channel 56' of an adjacent battery module. In addition, the exhaust channel 57' of one battery module 50' aligns with the exhaust channel 57' of an adjacent battery module.

[0077] In an alternative embodiment (not shown), the battery module 50' may be cooled using liquid coolant as opposed to or in addition to airflow. In such an embodiment, the cooling channels 56' are in fluid communication with the cooling plate 58'. However, the cooling plate 58' includes a fluid flow path extending from a fluid inlet between the cooling channels 56' and the cooling plate 58' to a fluid outlet between the cooling plate 58' and the cooling channels 56'. Thus, the liquid coolant enters the cooling channels 56' through the cooling holes 51', enters the cooling plate 58' through the liquid inlet, returns from the cooling plate 58' through the liquid outlet, and then exits the cooling channels 56' through the cooling holes 53'. The exhausted coolant is then returned to the base of the stack where it may be recirculated to a cooling system, for example, a cooling system of a container in which the battery pack 100' is deployed.

[0078] Thus, the cooling assembly 54' is positioned to transfer heat generated within the cell enclosure 52' to a cooling fluid (e.g., a liquid coolant or a gas coolant, e.g., cold air) flowing from the lower side of the battery module 50' to the upper side of the battery module 50' via the cooling channels 56'.

[0079] 22 and 23 show the cooling and exhaust manifold 55' in greater detail. In particular, the cooling and exhaust manifold 55' has a thermal runaway and exhaust port 63' that extends from the cell enclosure 52' through the cooling channel 56' to the exhaust channel 57'. A rupture disk 64' is provided at the interface between the exhaust port 63' and the exhaust channel 57'. The rupture disk 64' is configured to open in response to a sufficiently high pressure being applied to the rupture disk 64' to occur in the event of a thermal runaway within the cell enclosure 52'.

[0080] 20 and 21, an optical communication port 65' is provided on the top side of the battery module 50' at the front end of the battery module 50'. In addition, a manual power switch 66' is provided on the front face of the battery module 50', which is configured to control the retraction and extension of a power pin 67', as will be described in more detail below. A master control board service panel 68' can be removed from the front face of the battery module 50' to expose a master control board 69', as can be seen in FIG. 26. Thus, servicing of the battery module 50' can be facilitated by providing, for example, a master control board 69' provided at the front end of the battery module 50', which includes control, communication, and power delivery hardware.

[0081] As mentioned above, instead of using optical communication ports, communication between the battery modules 50' may be accomplished using wireless communication modules or wired connections. Additionally, to service the master control board 69', it may be necessary to first retract the power pins 67' by activating the manual power switch 66'.

[0082] Figures 24A and 24B show the power pin 67' in a retracted and extended position, respectively. As can be seen in Figure 24B, rotation of the manual power switch 66' produces corresponding linear movement of the power pin 67', for example by use of a suitable linear rotation converter. As shown in Figure 25, a power socket 70' is provided directly opposite the power pin 67'. A battery terminal connection stud 71' connects the power pin 67' and power socket 70' to the terminals of a battery cell 72' contained within the cell enclosure 52'.

[0083] 27 and 28, the top of the battery pack 100' is shown in detail. A cover 80' seals the exhaust channels 57' and cooling channels 56' of the topmost battery modules 50a', 50b'. Thus, air drawn into the battery pack 100' is directed out the front of the battery pack 100' through the front portion of the cooling plate 58'. In an alternative embodiment, instead of a cover, the topmost battery module 50a', 50b' may have the cooling channels 56' and exhaust channels 57' sealed integrally with the battery module.

[0084] The battery pack 100' further includes a stabilizing mechanism designed, for example, to provide stability to the pack 100' to prevent the battery modules 50' from accidentally falling out of their stacked arrangement when no rack is provided. In this embodiment, the stabilizing mechanism includes a compression cable 90' ​​attached to the PCM 30' at the front of the pack 100', extending over the cover 80' in a groove 82' formed in the cover 80', and attached to the PCM 30' at the rear side (not shown) of the pack 100'. A bridge bus bar 95' (which in some embodiments may be a cable) interconnects the power pins of the left-hand top-most battery module 50a' to the power sockets of the right-hand top-most battery module 50b'. FIG. 28 shows the compression cable 90' ​​attached to the PCM 30' at the front of the pack 100'.

[0085] To remove a battery module 50' from a battery pack 100', the power pins 60' of the battery module to be removed are retracted and the stabilizing mechanism is released by removing the compression cables 90'. A lifting mechanism is then used to remove the battery module positioned directly above the battery module to be removed. The battery module to be removed can then simply be removed from the stack, for example for servicing. This same method can be used to disassemble a stack of battery modules.

[0086] 30A-30D, various exemplary manners in which battery modules (e.g., battery modules 50 or battery modules 50') of a battery module stack (e.g., battery module stack 100 or module stack of pack 100') may be interconnected are shown.

[0087] Figure 30A shows a battery pack 200 in which the pack controller 202 is integrated with the module stack 204, similar to the embodiment of Figure 16. In particular, Figure 30A shows a first left column 206 of battery modules positioned adjacent to a right column 208 of battery modules. The orientation of the battery modules in the right column 208 is inverted relative to the orientation of the battery modules in the left column 206, such that the power connections of one column are adjacent to the power connections of the other column, thereby minimizing the electrical path length of the string of battery modules.

[0088] FIG. 30B shows an alternative exemplary setup with a single column of interconnected battery modules. A return conductive path 210 is provided from the cover 212 back to the pack controller 202. FIG. 30C shows another similar setup with a single column of interconnected battery modules. However, each battery module includes two side-by-side stacks of battery cells (similar to the embodiment of FIG. 2). FIG. 30D shows the same setup as FIG. 30C, except that instead of optical communication ports, a wireless communication transceiver or module 214 is used to enable communication between the battery modules. As mentioned above, hardwired connections can be used for communication instead.

[0089] FIG. 31 shows an alternative configuration including multiple module stacks 300 and a single pack controller 310 configured to control the module stacks 300 (similar to the embodiment of FIG. 13). Each battery module includes two battery cell stacks. A return conductive path 312 connects the top of each module stack 300 to an interface base 320, where an electrical path is then directed to the pack controller 310. A wireless communication receiver or module 330 is used to enable communication between the battery modules. In some embodiments, two or more module stacks 300 can be connected in series and then connected to the pack controller 310, thereby providing improved configurability regarding the height and footprint of the battery pack.

[0090] In the above embodiment, the cooling fluid can also be used to heat the battery modules. An example case is when the battery modules are not in use and the surrounding environment is cold. The "cold" battery modules benefit from being warmed up so that they can be used efficiently. "Cold start" is a challenge with most battery technologies.

[0091] Additionally, in the above embodiments, the battery modules may include one or more self-centering features to aid in the alignment of multiple battery modules in engagement with one another. In particular, the self-centering features allow the battery modules to be lowered onto one another with some tolerance for misalignment. For example, the female auto-locking members may include tapered portions, as discussed above.

[0092] Although the present invention has been described in connection with particular embodiments, it should be understood that the present invention is not limited to these embodiments, and that modifications, adaptations, and variations of these embodiments can be made by those skilled in the art without departing from the scope of the present invention. Moreover, it is contemplated that any aspect or any portion of the embodiment described herein can be implemented or combined with any other aspect or any portion of the embodiment described herein.

Claims

1. A battery module, at least one cell enclosure housing a plurality of battery cells; and a cooling assembly, the cooling assembly comprising: a cooling channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module, the cooling channel comprising: a cooling channel positioned to transfer heat generated within the cell enclosure to a cooling fluid flowing from the first side of the battery module to the second side of the battery module; the battery module further comprising: an exhaust assembly including an exhaust channel extending from an aperture on one side of the battery module to an aperture on another side of the battery module; and an exhaust port extending from the cell enclosure to the exhaust channel.

2. The battery module of claim 1 , wherein the exhaust channel extends from an opening in the first side of the battery module to an opening in the second side of the battery module.

3. 3. The battery module of claim 1, further comprising a seal that seals the exhaust port, the seal being configured to open in response to pressure reaching a critical pressure within the cell enclosure, thereby allowing exhaust gas to flow from the cell enclosure to the exhaust channel.

4. The battery module of claim 3 , wherein the seal is configured to open in response to a thermal runaway occurring within the cell enclosure.

5. The battery module according to claim 1 , wherein the exhaust port extends through the cooling channel.

6. The battery module according to any one of claims 1 to 5, wherein the cooling assembly is disposed between the cell enclosure and the exhaust assembly.

7. 7. The battery module of claim 1, wherein the at least one cell enclosure includes first and second cell enclosures provided on respective sides of the battery module, and the cooling channel extends between the first cell enclosure and the second cell enclosure.

8. The battery module of claim 7 , wherein said cooling channel extends along a length of each of said first and second cell enclosures.

9. The battery module of claim 1 , further comprising a heat sink provided on one or more sides of the battery module.

10. The battery module of claim 9 , wherein the heat sink comprises one or more cooling fins.

11. The battery module according to any one of claims 1 to 10, further comprising at least one first locking member extending from a top edge or a bottom edge of the battery module.

12. The battery module of claim 11 , further comprising at least one first locking member extending from a top or bottom corner of the battery module.

13. 13. The battery module according to claim 11 or 12, further comprising at least one second locking member arranged within an edge or corner of the battery module located on the opposite side to the edge or corner of the battery module as a starting point from which the at least one first locking member extends.

14. The battery module of any one of claims 1 to 13, further comprising a power and communications assembly including one or more of electrical circuitry and a processor configured to monitor one or more battery cells contained within the battery module.

15. 15. The battery module of claim 14, wherein the power and communications assembly is disposed at a first end of the battery module and the cooling assembly is disposed at an opposing second end of the battery module.

16. 16. The battery module of claim 15, wherein said power and communications assembly is disposed at a front end of said battery module and said cooling assembly is disposed at a rear end of said battery module.

17. The battery module of any one of claims 14 to 16, wherein the power and communications assembly includes a power pin movable between a retracted position and an extended position.

18. 20. The battery module of claim 17, further comprising a switch configured, when activated, to move the power pin between a first position and a second position.

19. 20. The battery module of claim 18, wherein the power and communications assembly further comprises a power socket disposed on an exterior surface of the battery module.

20. 20. The battery module of claim 19, wherein the power socket is disposed on a lower side of the battery module, and the power pin extends from a top side of the battery module when in the second position.

21. 21. The battery module according to claim 19 or 20, wherein the power pin and the power socket are disposed directly opposite each other.

22. 22. The battery module of claim 14, further comprising a removable panel on a front surface of the battery module for providing access to one or more components of the power and communications assembly.

23. The battery module of any one of claims 14 to 22, wherein the power and communication assembly further includes a first optical communication port provided on one side of the battery module and a second optical communication port provided on another side of the battery module.

24. The battery module of any one of claims 14 to 22, wherein the power and communication assembly further comprises a wireless communication module for communicating with one or more other battery modules.

25. 21. The battery module of claim 20, further comprising a heat sink located adjacent to said cell enclosures.

26. 26. The battery module of claim 25, wherein the heat sink fluidly couples the cooling channels of the battery module to the outside of the battery module, and heat generated within the cell enclosures can be dissipated from the battery module by being transferred via the heat sink to cooling fluid flowing from the cooling channels of the battery module to the outside.

27. the heat sink includes a fluid flow path extending from the cooling channel into the heat sink via one or more inlets and returning from the heat sink into the cooling channel via one or more outlets; 27. The battery module of claim 26, wherein heat generated within the cell enclosures can be transferred from the battery module to a cooling fluid that enters the cooling channel from the first side of the battery module, flows into the fluid flow path, returns to the cooling channel, and exits the cooling channel to the second side of the battery module.

28. 26. The battery module of claim 25, wherein one or more of the cooling channels, the exhaust channels, and the power socket extend through the heat sink.

29. The battery module of any one of claims 1 to 28, wherein the cooling fluid comprises one or more of forced air, liquid coolant, or convection air.

30. 30. The battery module of claim 1, further comprising one or more male connectors provided on one of the top and bottom sides of the battery module, and one or more female connectors provided on the other of the top and bottom sides of the battery module, at least one of the connectors having a tapered portion.

31. The battery module of claim 13 , wherein the one or more male connectors have the at least one first locking member and the one or more female connectors have the at least one second locking member.

32. 32. The battery module of claim 30 or 31, wherein the one or more male connectors include one or more power pins, and the one or more male connectors include one or more power sockets.

33. 30. The battery module of claim 1, further comprising one or more male power connectors and one or more female power connectors, at least one of the power connectors configured to float relative to the electrical cell enclosures.

34. A battery module stack, A battery pack includes a plurality of battery modules, each of which includes: at least one cell enclosure housing a plurality of battery cells; and a cooling assembly including a cooling channel, the cooling channel comprising: extending from an opening in a first side of the battery module to an opening in a second side of the battery module; a cooling channel positioned to transfer heat generated within the cell enclosure to a cooling fluid flowing from the first side of the battery module to the second side of the battery module; the battery modules are arranged in a stacked configuration such that the cooling channels of at least one battery module are aligned with the cooling channels of at least one adjacent battery module; Each battery module is an exhaust assembly including an exhaust channel extending from an opening on one side of the battery module to an opening on another side of the battery module; an exhaust port extending from the cell enclosure to the exhaust channel; The battery module stack, wherein the exhaust channel of at least one battery module is aligned with the exhaust channel of at least one adjacent battery module.

35. 35. The battery module stack of claim 34, further comprising a base disposed at a bottom of the stacked configuration, and an air conveyor configured to cause air to flow through the base and through the cooling channels of the stacked battery modules via cooling channels formed in the base and in fluid communication with the cooling channels of the stacked battery modules.

36. 36. The battery module stack of claim 35, wherein said base has an exhaust outlet in fluid communication with said exhaust channel of said stacked battery module.

37. The battery module stack of any one of claims 34 to 36, further comprising a pack controller communicatively coupled to the battery modules and operable to control operation of the battery modules.

38. 38. The battery module stack of claim 37, wherein the pack controller is stacked with the battery module.

39. The battery module stack of any one of claims 34 to 38, further comprising a cover positioned on the top of the stacking configuration so as to seal the cooling channel of the uppermost battery module of the stacking configuration.

40. The battery module stack of any one of claims 34 to 39, further comprising a stabilizing mechanism configured to apply a compressive action to the stacked configuration to stabilize the stacked configuration.

41. 40. The battery module stack of claim 39, wherein the stabilizing mechanism includes one or more cables or bars attached to the cover and attached at one or more points at least as low as the bottommost battery module in the stacked configuration.

42. The battery module stack of any one of claims 34 to 41, wherein each battery module further includes one or more locking members that correspond and engage with one or more locking members of an immediately adjacent upper battery module and an immediately adjacent lower battery module.

43. 43. The battery module stack of claim 42, wherein the one or more locking members of a battery module are configured to correspondingly engage with locking members of an immediately adjacent upper battery module in response to another battery module being stacked on top of the immediately adjacent upper battery module.

44. A method of assembling a battery module stack by stacking the battery modules of any one of claims 1 to 33 to form a stacked structure, comprising: Each battery module is at least one cell enclosure housing a plurality of battery cells; and a cooling assembly including a cooling channel, the cooling channel comprising: extending from an opening in a first side of the battery module to an opening in a second side of the battery module; a cooling channel positioned to transfer heat generated within the cell enclosure to a cooling fluid flowing from the first side of the battery module to the second side of the battery module; The method, wherein the stacking configuration is such that the cooling channels of at least one battery module are aligned with the cooling channels of at least one adjacent battery module.

45. 45. The method of claim 44, further comprising positioning a cover on the top of the stacked configuration to seal the cooling channels of the uppermost battery module of the stacked configuration.

46. 46. ​​The method of claim 45, further comprising the step of applying a compressive action to the stacked configuration to stabilize the stacked configuration with a stabilizing mechanism.

47. 1. A method of using a battery module stack, the battery module stack including a number of battery modules, each battery module comprising: at least one cell enclosure housing a plurality of battery cells; and a cooling assembly including a cooling channel, the cooling channel comprising: extending from an opening in a first side of the battery module to an opening in a second side of the battery module; a cooling channel positioned to transfer heat generated within the cell enclosure to a cooling fluid flowing from the first side of the battery module to the second side of the battery module; The battery modules are arranged in a stacked configuration such that the cooling channels of at least one battery module are aligned with the cooling channels of at least one adjacent battery module, and the method includes: identifying a battery module requiring removal from the stack; engaging a lifting mechanism with the battery module immediately above the identified battery module; and lifting the battery module from the stacking configuration above the identified battery module using the lifting mechanism.

48. 1. A method of fabricating a battery module stack, comprising: A method comprising the steps of: using a lifting mechanism to position a battery module stack according to any one of claims 34 to 43 at a predetermined location relative to an interface base, wherein at the predetermined location, the cooling channels of the battery module stack are aligned with one another within one or more holes formed in the interface base, such that air directed through the interface base can flow into the cooling channels of the battery module stack.

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