Power supply device and its components

Abstract

A battery module comprising: a plurality of battery units held within a corresponding plurality of battery receptacles; a plurality of inter-battery connectors interconnecting the plurality of battery units; a battery tray comprising the plurality of battery receptacles; and a power interface for facilitating power input and power output, wherein the inter-battery connectors are configured as heat dissipation members extending through a first plurality of battery receptacles to interconnect the corresponding plurality of battery units.

Description

Technical Field

[0001] The present disclosure relates to a power supply device, and more particularly, to a mobile power supply device and its components.

Background Art

[0002] Mobile devices are increasingly being powered by electrical energy, which is considered an environmentally friendly or more environmentally friendly energy source. The amount of electrical energy available for powering mobile devices such as electric vehicles is often limited and depends on the energy stored in the device.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The situation can become troublesome if the stored energy is depleted while the mobile device is away from the charging station. A mobile power supply device capable of supplying energy to a mobile device powered by stored electrical energy would be useful and desirable.

Means for Solving the Problems

[0004] A power supply device is disclosed that includes a stored energy source, a power interface, and an electronic circuit configured to control the operation of the device. The stored energy source can be charged to store electrical energy and discharged to release the stored energy. The device may be configured as a power plant, such as a mobile power plant, for supplying power to a load, such as an electric vehicle.

[0005] The device called MOBO-I includes a main housing, wheels that support the main housing to provide mobility, and an assembly of a battery assembly and an electronic circuit housed in the main housing. The battery assembly includes a plurality of battery modules connected in series and / or in parallel. Each battery module includes a module housing, an assembly of battery units connected in series and / or in parallel, and ventilation means for allowing air to enter and exit the battery module.

[0006] This disclosure is described by way of example with reference to the accompanying drawings.

Brief Description of the Drawings

[0007]

Figure 1A

Figure 1B

Figure 1C

[0008]

Figure 1D

Figure 1E

Figure 1F

[0009]

Figure 2A

[0010]

Figure 2B

[0011]

Figure 3A

Figure 3B

[0012]

Figure 3C

[0013]

Figure 3D

[0014]

Figure 3E

Figure 3F

[0015]

Figure 4

[0016]

Figure 5A

[0017]

Figure 5B

[0018]

Figure 6A

Figure 6B

[0019]

Figure 6C

[0020]

Figure 7

[0021]

Figure 8A

Figure 8B

[0022]

Figure 8C

[0023]

Figure 8D

Figure 8E

[0024]

Figure 9

[0025]

Figure 9A

DETAILED DESCRIPTION OF THE INVENTION

[0026] An exemplary power supply device 1000 includes a main housing to which an energy storage source, a power interface, and an electronic circuit for controlling the operation of the device are attached. As shown in FIGS. 1A and 1B, the device 1000 is mobile and includes a main housing 1100 supported on a plurality of wheels. The wheels are attached to a chassis 1120 which is the base of the main housing as shown in FIG. 1C.

[0027] A battery assembly including a plurality of battery modules forms an exemplary energy storage source of device 1000. The battery assembly includes an exemplary plurality of four battery modules 1200A, B, C, D as shown in FIGS. 1D and 1E.

[0028] The electronic circuit includes a power circuit, a communication circuit, and a control circuit. The power circuit includes a power input circuit and a power output circuit. The power input circuit may include a first power converter which may be an AC-DC converter, and the power output circuit may include a second power converter which may be a DC-DC converter. The AC-DC converter may be configured to convert commercial AC power (mains AC power) to DC power for internal operations of the device, such as charging the battery assembly. The DC-DC converter may be configured to convert the battery voltage assembly to another DC voltage for output. The DC output voltage may be higher or lower than the battery assembly voltage. The power circuit may be configured as a power input module including a power input port, a power output port, and an AC-DC converter interconnecting the power input port and the power output port, and as a power output module including a power input port, a power output port, and a DC-DC converter interconnecting the power input port and the power output port.

[0029] The communication circuit can include an internal communication circuit for facilitating data communication within the device and an external communication circuit for facilitating data communication between the device and the outside world, such as with other compatible power supply devices. The communication circuit may include a data communication front end and may be configured as a communication module or a plurality of modules.

[0030] The control circuit is configured to control the operation of the device and includes a battery management system ("BMS") configured to control battery operations including battery charging and discharging. The control circuit may be configured as a control module or a plurality of control modules. The battery management system is configured to monitor parameters of the battery assembly and individual battery modules of the battery assembly. The parameters can include electrical parameters such as charge rate, discharge rate, state of charge (SoC), loop current, and / or state of health (SoH), and / or can include physical parameters such as the temperature, humidity, and / or internal pressure of the battery module.

[0031] The main housing 1100 includes an upper portion having an upper panel 1102, a bottom portion having a bottom panel 1104, and an outer peripheral wall 1106 interconnecting the upper and bottom portions. The upper panel, bottom panel, and outer peripheral wall cooperate to form a cabinet having an internal compartment in which components of the device including the electronic circuit and the battery assembly are housed. An exemplary main housing is organized into a plurality of shelves, compartments, and / or receptacles for housing the battery module 1200, the power module 1300, the control module 1400, and the communication module. The outer peripheral wall may include a plurality of side panels. One or some of the side panels may be removable to allow for repair access to the interior of the main housing in which the modules are housed. The main housing may include a rigid rack frame to which the upper panel and the outer peripheral wall are attached. The rack frame may include vertical columns with slots for attaching the modules, for example, for removably attaching the modules.

[0032] The main housing can include ventilation openings so that heat exchange by air exchange between the device and the surrounding environment, such as forced air exchange, can be performed. By exchanging air between the device and the surrounding environment through the ventilation openings, heat exchange by the air flowing into or out of the main housing can adjust the internal temperature of the device and maintain the optimal or preferred thermal conditions of the device. In an exemplary embodiment such as this example, ventilation openings in the form of ventilation grilles are formed in the outer peripheral wall to enable heat exchange by an air flow across the outer peripheral wall. In an exemplary embodiment, as shown in FIG. 1B, the ventilation openings are formed in the rear panel of the main housing.

[0033] An exemplary device includes an exemplary plurality of four battery modules arranged to form a stack of battery modules, as shown in FIG. 1E. The battery modules are surrounded by an outer peripheral wall and held within a battery compartment above the chassis. The power module, the control module, and the communication module are lightweight (compared to the battery modules) and are held within a compartment located above the battery compartment for easy access by the user and / or operator. The exemplary battery modules have the same specifications including rated voltage, rated power, and outer dimensions (including substantially the same to avoid misunderstanding) and are arranged vertically aligned.

[0034] An exemplary device has a form factor of a tower having a height significantly greater than its base dimension, which can be the width or length of the bottom of the main housing, whereby more energy can be stored per unit base area defining the cross-sectional area of the main housing. The term significantly greater herein means at least 20% greater, including 30%, 40%, 50%, 60%, 80%, 100%, 150%, 200% or more.

[0035] The tower form also facilitates a higher energy storage density so that more energy can be stored per unit volume of the main housing. In an exemplary device, the battery module is configured such that the battery units of the battery module occupy a substantial portion of the cross-sectional area of the battery compartment. As used herein, substantial portion means at least 50%, including 55%, 60%, 65%, 70%, 75%, 80% or more.

[0036] The exemplary device has an exemplary height of about 1 m (988 mm), an exemplary width of about 0.5 m (430 mm), an exemplary length of about 1 m (900 mm), an exemplary volume of 0.382 CBM, and a rated less-than-full energy storage capacity of 8.0 kWh (four modules of 2 kWh each) corresponding to a rated less-than-full energy storage capacity of more than 16 kWh per cubic meter (CBM).

[0037] The main housing of the exemplary device has an internal compartment volume of about 0.27 CBM, i.e., less than 0.3 CBM, a rated less-than-full energy storage capacity of 8 kWh, and a weight of 150 kg corresponding to a rated less-than-full storage energy density of 29.6 kWh per CBM internal compartment volume (= 8 / 0.27). A rated less-than-full storage energy density of more than 20 or 25 kWh per CBM internal compartment volume provides a compact power bank for loads that require a larger energy supply to operate. The rated less-than-full storage energy density can be increased to more than 30 or 35 kWh per CBM internal compartment volume by adding additional battery modules. Here, the rated less-than-full energy means the energy of a battery cell or battery module that is available above the minimum voltage.

[0038] The battery modules may be connected in series and / or in parallel. In an exemplary embodiment, the battery modules are connected in series such that the battery assembly has a nominal voltage rating of 403.2 V, which is equal to four times the nominal voltage rating of the battery module.

[0039] The exemplary apparatus includes a human-machine interface to facilitate the interface between a human operator and a machine. The human-machine interface can include a display such as an LCD display panel or an LCD touch panel, and optionally a manual control device such as a control stick. In an exemplary embodiment, the LCD touch panel may be configured to function as an interface between the user and the machine to achieve operation control of the apparatus, including mechanical control of the drive mechanism.

[0040] The apparatus may be configured as a mobile energy source and provided with wheels to facilitate movement. The wheels may be free-running and / or power-driven. Referring to FIGS. 1D and 1E, the main housing of the exemplary apparatus includes a drive section within which a drive device is held. The drive device includes a drive mechanism 1510 configured to drive a pair of wheels 1520. The drive mechanism can include a motor having a motor shaft and a speed-changing device such as a gearbox configured to interconnect the motor shaft and the driven wheels, and control electronics for controlling the operation of the motor. The control electronics can include a motor drive controller and peripheral circuits. The driven wheels of the exemplary apparatus are intermediate free-running wheels located in front of and behind the drive wheels.

[0041] The drive device optionally includes a power device dedicated to the drive mechanism. As shown in FIG. 1F, the drive device can include a drive battery assembly 1530, a DC-DC converter 1540, and an AC-DC converter 1550. An exemplary drive battery assembly has an exemplary rated voltage of 50V and includes a 14S3P configuration of battery units. The AC-DC converter is designed to convert commercial power to DC power to charge the drive battery assembly and has an exemplary rated power of 160W. The DC-DC converter has an exemplary rated voltage of 12V and an exemplary rated power of 330W for converting the DC power of the drive battery assembly to a 12V DC output for the electronic devices associated with the drive device. In an exemplary embodiment, the drive mechanism can utilize power from a main battery assembly including a battery module 1200 without loss of generality. The drive compartment is below the battery compartment and is the lowest compartment intermediate the chassis and the main battery assembly. In embodiments where the power source is not dedicated to the drive mechanism, the lowest compartment can be used as the battery compartment without loss of generality.

[0042] The device may be driven to move under manual control and / or automatic control. The automatic control may be local control or remote control. To facilitate manual control, as shown in FIG. 1E, a drive control device 1560 is provided on the main housing, for example, on the upper panel.

[0043] The drive control device 1560 may be configured as a drive stick that functions as a user interface for the user to control the movement of the device. An exemplary drive stick protrudes upward from the upper panel of the main housing and is electrically connected to the electronic control circuit of the drive mechanism. The drive stick can have a plurality of predetermined individual operating positions to correspond to a plurality of modes. The modes can include, for example, a recharge / parking mode in which the wheels are locked, a movement mode in which the wheels are released and not locked, a charging mode in which the device outputs the stored power to an external load, and an off mode in which the device is stopped. In an exemplary embodiment, the touch panel may be configured as a drive control device. The drive control device is devised outside the main housing to facilitate manual control of the device by the user from outside the device. The drive control device may be configured at a height such that an average-height user can drive the device to move by operating the drive control device while standing or walking next to the mobile device. For example, the drive control device may be disposed at a height of 1 m to 1.6 m from the supporting ground.

[0044] The control circuit of the exemplary device is housed in the upper receptacle and further includes an EMS (“Energy Management System”) module, a charging standard module, a data front-end module, and a general control module. The upper receptacle in this specification is the receptacle closest to the upper panel of the main housing. The charging standard module can include a CHAdeMo Manager module, a CCS Combo Manager module, and a GB module. The charging standard module may be a separate module or an integrated management module configured to operate with a system compliant with a plurality of common charging standards at that time without loss of generality. In an exemplary embodiment, the receptacles are parallel and the modules are substantially horizontal when the device is placed on a flat surface.

[0045] Referring to FIG. 2A, the input of the AC-DC converter is connected to a power source, the output of the AC-DC converter is connected to the input of the DC-DC converter by a first switchable link, the output of the battery assembly is connected to the input of the DC-DC converter by a second switchable link, and the output of the DC-DC converter is connected to the battery assembly by a third switchable link. The first switchable link includes a first power switch SW1 operable to open and close the first switchable link. The second switchable link includes a second power switch SW2 operable to open and close the second switchable link. The third switchable link includes a third power switch SW3 operable to open and close the third switchable link. Each of the first, second, and third power switches is operable to be in an on state or an off state by an electronic control circuit.

[0046] The device can operate in a plurality of modes including a standby mode and a power output mode.

[0047] When in the standby mode, depending on the stored energy level of the battery assembly, the battery assembly may or may not be charged. When the BMS determines that the battery assembly has a good energy level, the BMS controller operates in a non-charging mode and does not charge the battery assembly. When the BMS determines that the battery assembly does not have a good energy level, the BMS controller operates in a charging mode to charge the battery assembly. The good stored energy level may be determined with reference to the stored energy level or voltage of the battery assembly, or may be set according to the requirements of the application. When in the power output mode, power is supplied from the device to an external load.

[0048] During the charging mode, the device is connected to an external power source so that the battery assembly can be charged by the external power source. When the device is connected to an external power source, such as an AC commercial power source, the AC-DC converter operates to output DC power having a DC voltage. The DC power is a rectified version of the AC commercial power source and may not have a voltage high enough to charge the battery assembly. To have charging power with a sufficiently high charging voltage, the output of the AC-DC converter is connected to the input of the DC-DC converter to supply the DC power input to the DC-DC converter. The DC-DC converter up-converts the DC power input and outputs a DC power output having a sufficiently high voltage suitable for charging the battery assembly. The BMS is configured to monitor the charging of the battery assembly by the DC power output and stop charging when the battery assembly reaches the maximum voltage or a percentage below the maximum voltage for a longer operating life.

[0049] When in the charging mode, switches SW1 and SW3 are closed, whereby input power flows from the power source to the AC-DC converter, then to the DC-DC converter, and finally to the battery assembly. The BMS is configured to occasionally monitor the state of the battery assembly and repeatedly acquire and store battery parameter readings. Before the charging of the battery assembly is started, the BMS retrieves data, for example, from a data storage device mounted on the device. The retrieved data can include voltage information of the battery module and the battery assembly, including the maximum voltage, the minimum voltage, the battery charging method, and some or all of the stored battery parameters, to determine the actual charging method to facilitate safe charging and a longer battery life. The BMS controller is configured to follow a predetermined charging pattern depending on the type of battery.

[0050] In the non-charging mode, the BMS controller may stop the operation of the AC-DC converter or may open SW1 to disconnect the first switchable link.

[0051] When in the power output mode, as shown in Figure 2B, the BMS controller operates to close SW2 and open SW3, whereby battery energy flows from the battery assembly to the DC-DC converter and then to the load connected to the output of the device. When in the power output mode, SW1 may be opened or closed. When SW1 is closed and the device is still connected to an external power source, the output power includes the power from the external power source.

[0052] In the case of the output mode, an exemplary battery assembly can output a maximum current of 100 A, but the actual current can be controlled, for example, by agreement between the EMS controller and the counterpart controller.

[0053] Also, when in the charging mode and the power supply device is connected to an external power source, by closing both switches SW1 and SW2, the power from the external power source may be supplied to the DC-DC converter as auxiliary charging power. The first switchable link can include a diode or other unidirectional device that limits the flow of current in one direction, i.e., from the AC-DC converter to the DC-DC converter and not in the reverse direction.

[0054] Modern mobile devices operate using different power systems and voltage ratings, and the device typically has an intelligent central controller with a communication front end configured to communicate data with a counterpart controller such as an EMS controller installed in the power supply device and exchange data.

[0055] The controller of the power supply device is configured to communicate data with a counterpart controller such as the central controller of an electric vehicle and exchange data.

[0056] When a load is connected to the charging coupler, the EMS controller establishes a data connection with the controller installed in the mobile device and identifies the correct protocol for communication. When the data exchange is successful, the EMS controller learns from its counterpart controller other useful data such as charging methods including charging specifications, charging current and voltage, SoC (state of charge), and the installed energy storage device which is usually a battery assembly. When charging data and criteria are input, the EMS controller operates to charge the installed energy storage device of the mobile device.

[0057] In an exemplary embodiment, the external power source is a single-phase, 13A, 50Hz, 220V AC power source as shown in FIG. 6A. The battery assembly has a maximum voltage of 403.2V and a minimum voltage of 200V. The second power converter includes a 2×14kWh DC-DC converter. The DC-Dc converter is switchable to different output voltages including the charging voltage of the battery assembly and charging voltages compliant with different charging specifications such as CHAdeMo, Combo+, Tesla, etc. The charging coupler may be provided with different charging connectors (or "guns") configured according to different charging specifications. When the required charging specification and charging voltage are detected, the EMS controller starts charging according to the requirements of the connected load's specification.

[0058] The DC-DC converter may be a MIMO (multiple-input multiple-output) DC-DC converter having a plurality of switchable inputs and / or a plurality of switchable outputs. The input and output voltages of the DC-Dc converter may be controllable, for example, digitally controllable by the EMS controller. Although a plurality of power converters are shown in the exemplary embodiment, without loss of generality, the power converters may be integrated into a MIMO (multiple-input multiple-output) power converter.

[0059] For example, in the case of a 100V battery module, the charging voltage is set to 114.8V, and it is charged at a constant current (CC) charging rate of 11.475A (0.5C) up to 80%, and then charged at a constant voltage (CV). The charging can be terminated when the charging current drops to 450mA. Or, the charging voltage is set to 117.6V, and it is charged at a constant current (CC) charging rate of 11.475A (0.5C) up to 90%, and then charged at a constant voltage (CV). The charging can be terminated when the charging current drops to 4.5A.

[0060] For example, in the case of a 50V battery module, the charging voltage is set to 57.4V, and it is charged at a constant current (CC) charging rate of 22.95A (0.5C) up to 80%, and then charged at a constant voltage (CV). The charging can be terminated when the charging current drops to 900mA. Or, the charging voltage is set to 58.8V, and it is charged at a constant current (CC) charging rate of 22.95A (0.5C) up to 90%, and then charged at a constant voltage (CV). The charging can be terminated when the charging current drops to 9A.

[0061] In an exemplary embodiment, the power supply device may include an AC power output or a plurality of AC power outputs. To provide the AC power output, a DC-AC inverter or a plurality of DC-AC inverters are provided. The exemplary power supply device can include a 50Hz output of 100 - 120Vac and a 50Hz output of 200 - 240Vac.

[0062] An exemplary battery module of the device includes an assembly of battery units, a monitoring and control circuit, a ventilation means, and a module housing. The assembly of battery units typically includes a plurality of battery units, and the battery units are connected in series and in parallel to meet the designed voltage and current requirements.

[0063] An exemplary module housing includes a base housing portion, and an upper housing portion that defines, in cooperation with the base portion, a first compartment which is an electronic equipment compartment where an electronic circuit configured to control and monitor a local state of a battery module along a longitudinal direction defined by a longitudinal axis is installed, a second compartment which is a battery compartment where an assembly of battery units is accommodated, and a third compartment which is a ventilation compartment where a ventilation device is installed. An exemplary ventilation device includes a plurality of axial fans. The axial fans are arranged along a direction orthogonal to the longitudinal axis of the module housing, as shown in FIGS. 3E and 3F (where the upper housing portion is removed), and the axes of the fans are parallel to the longitudinal axis.

[0064] The base housing portion and the upper housing portion cooperate to define an air channel having a first end which is an inlet end and a second end which is an outlet end, whereby air flowing in through the inlet end exits through the outlet end after traversing the length of the channel. The electronic equipment compartment is arranged at the inlet end, and the ventilation compartment is arranged at the outlet end.

[0065] The electronic circuit of the battery module can include peripheral circuits such as sensors, detection circuits, switching circuits, switching control circuits, control circuits, and communication front-ends. The sensors and detection circuits include, for example, temperature sensors, temperature detection circuits, voltage sensors, voltage detection circuits, current sensors, current detection circuits, pressure sensors, and pressure detection circuits. The control circuit of the battery module is a local control circuit for the battery module, and is called a module management system or a pack management system (PMS) in order to distinguish it from the BMS which is a management system for the entire device.

[0066] In an exemplary embodiment, the temperature sensor is disposed on or within the battery module, more specifically, within the channel. In an exemplary embodiment, when the temperature of the battery module reaches a threshold temperature, the control circuit of the battery module is configured such that the control circuit receiving the temperature signal from the sensor operates the ventilation device to discharge air from the channel, thereby discharging hot air from the battery module.

[0067] The battery module is attached such that the ventilation compartment is proximal and juxtaposed to the ventilation surface of the main housing.

[0068] An exemplary battery module is assembled from cylindrical battery units, such as cylindrical battery cells having a size code 18650. Currently, lithium-ion rechargeable 18650 cylindrical batteries (e.g., Panasonic (registered trademark) model UR18650ZM2) are widely used.

[0069] In an exemplary embodiment, the battery units of the battery module are arranged in an nSmP configuration, where n is the number of cells connected in series and m is the number of cells connected in parallel.

[0070] An exemplary battery module includes a plurality of 252 18650 lithium rechargeable cells, each having a current rating of 2550 mAh, a nominal voltage V of 3.6 V, cell nominal , 2.5 V (V cell min ) to 4.1 V (V cell max ), a rated storage energy capacity of 2.3 kWh, and a rated storage energy capacity of less than 2.0 kWh. The exemplary battery cells have an operating temperature range of 0 °C to 45 °C for charging and -20 °C to 60 °C for discharging.

[0071] In an exemplary embodiment, the battery module has a nominal voltage nV of 100.8 V for the battery module, cell-nominal , 70 V (nV cell min ) to 114.8 V (nV cell max) is arranged in a 28S9P configuration so as to have a voltage range of, a maximum discharge current of 100 A, and a continuous output rating of 7 kW. The battery unit is arranged in two series-connected groups, each held on a crate having a 14S9P configuration and including 14 columns and 9 cell receptacles per column. In the embodiment of FIG. 3E, the columns of the battery crate are parallel to the longitudinal axis of the module housing, and the two groups are connected in series.

[0072] In an exemplary embodiment, the battery module is arranged in a 14S18P configuration so that the battery module has a nominal voltage of 50.4 V cell-nominal , a voltage range of 35 V to 57.4 V, a maximum discharge current of 100 A, and a continuous output rating of 3.5 kW. The battery unit is arranged in two parallel-connected groups, each held on a crate having a 14S9P configuration and including 14 columns and 9 cell receptacles per column. In the embodiment of FIG. 3F, the columns of the battery crate are parallel to the longitudinal axis of the module housing, and the two groups are connected in parallel.

[0073] An exemplary battery module has a rated energy storage capacity of less than 2.0 kWh and a weight of 18.25 kg, which corresponds to a rated energy storage density higher than 0.1 kWh / kg (2 kWh / 18.25 kg).

[0074] An exemplary battery module has dimensions of 588 mm × 315 mm × 94 mm (length × width × height) and a volume of 0.0174 CBM, corresponding to a rated energy storage density of less than 115 kWh per CBM. The battery module has a rated energy storage density of more than 100 kWh or 110 kWh per CMB, which is advantageous in either roadside rescue or daily charging.

[0075] The exemplary battery module has an area of 0.185 square meters and corresponds to more than 80% or 90% of the internal cross-sectional area (L×W) of the internal compartment of the main housing.

[0076] In an exemplary embodiment, the control circuit of the battery module is configured to activate the operation of the ventilation means to generate a forced air flow through the channel when the temperature reaches the threshold temperature of 40 degrees Celsius, and to stop the operation of the ventilation means when the temperature drops to 40 degrees Celsius.

[0077] The battery modules are interconnected to form a power bank. The power bank herein is a power storage device that can save or store power and can take out or draw out power. The power herein means power unless otherwise required by the context. The battery modules can be connected in series and / or in parallel to form a battery assembly with a predetermined rated voltage and current.

[0078] In an exemplary embodiment, the battery units of the battery module are arranged in a plurality of cell rows. Each cell row comprises a plurality of battery units. The adjacent battery units of the battery module are spaced apart and separated by a gap. For example, a battery module having an nSmP battery cell configuration may be arranged in an exemplary plurality of n cell rows or an exemplary plurality of m cell rows. The adjacent cell rows of the battery module are spaced apart and separated by a gap.

[0079] The battery unit is held in a battery holder to maintain the battery modules of the battery unit in a substantially fixed relative position and a substantially fixed relative spacing. An exemplary holder comprises a grid of cell receptacles, each cell receptacle being configured to receive a single battery cell. The grid of cell receptacles comprises a plurality of receptacle columns. Each receptacle column comprises a plurality of cell receptacles and has a column axis. Each cell receptacle (hereinafter abbreviated as receptacle) defines a cell compartment and has a receptacle axis that is parallel, e.g., coaxial, to the cell axis of the received battery cell. The column axis intersects the receptacle axis and defines a column direction that is orthogonal to the receptacle axis in exemplary embodiments such as this example. Each receptacle has a receptacle width that is measured in the column direction and that includes the receptacle axis which is the central axis of the receptacle. Each receptacle column has a column width that is equal to the receptacle width multiplied by the number of receptacles forming the receptacle column. Each receptacle has a spacer device configured to maintain the battery cell received therein in a relatively fixed and stable position.

[0080] In an exemplary embodiment, the cell receptacle includes an outer peripheral wall with a plurality of axially extending ribs formed thereon as an exemplary spacer configuration. The ribs of the receptacle extend axially and project radially towards the receptacle axis. Here, the ribs may be continuous ribs or broken ribs. The radial extent of the ribs is configured to maintain a gap surrounding the battery cell housed inside the receptacle. The ribs, and thus the gap, can have a radial extent of 0.5 mm to 1.5 mm or 2.5% to 8.5% of the diameter of the battery cell. In an exemplary embodiment, the outer peripheral wall of the receptacle has a hexagonal cross-sectional shape, and the ribs project from the corners of the hexagon that define the hexagonal cross-sectional shape. In an exemplary embodiment, the outer peripheral wall of the receptacle has a wall thickness of about 1 mm, such as 0.8 to 1.5 mm, or 4% to 8.5% of the diameter of the battery cell. Passages parallel to the column direction are formed in the outer peripheral wall so that a part of the inter-cell connector can pass through the receptacle, for example, at a level between the top and bottom of the receptacle. The passages are offset from the column axis and the receptacle axis, parallel to the column axis and the receptacle axis, and cross or penetrate two directly adjacent receptacle columns. In other words, each passage is shared between two directly adjacent receptacle columns. An exemplary receptacle includes a first slot and a second slot that cooperate to define the passage. Each of the first slot and the second slot is a slot formed in the outer peripheral wall that is shared by adjacent columns and parallel to the receptacle axis. The first slot is also a slot on the first receptacle on its adjacent column, and the second slot is also a slot on the second receptacle on the adjacent column, and the second receptacle is in contact with the first receptacle.

[0081] In an exemplary embodiment, the outer peripheral wall of the receptacle is shared by 3 to 7 receptacles. More specifically, the outer peripheral wall of the receptacles in the last row is shared by 3 or 4 receptacles, the outer peripheral wall of the first or last receptacle in the middle row is shared by 4 or 5 receptacles, and the outer peripheral wall of the middle receptacles is shared by 6 receptacles. Middle receptacles are those that are not in the last row or the first or last receptacle in a row. The middle row is a row that is neither the first nor the last row. In other words, the outer peripheral wall of the middle receptacles is shared by two receptacle rows that are directly adjacent to the middle row containing the middle receptacles. In an exemplary embodiment, the directly adjacent receptacle rows are offset in the row direction such that the receptacle portion of one row is also the receptacle portion of another row. In other words, a portion of the receptacle is shared by or between two directly adjacent receptacle rows.

[0082] An exemplary hexagonal receptacle comprises an outer peripheral wall having six side walls, and two opposing parallel side walls cooperate to define a receptacle width. The receptacle axis is in the middle of the two parallel side walls, and the parallel side surfaces defining the two parallel side walls are orthogonal to the row axis. Two adjacent side walls of the exemplary hexagonal receptacle interconnecting the parallel side walls are shared by two directly adjacent receptacles of two directly adjacent receptacle rows. The two adjacent side walls are joined at the vertex of the hexagonal receptacle to form a V-shaped outer peripheral wall portion, and the vertex of the hexagonal receptacle is also the vertex of the hexagonal receptacles in the adjacent row. More specifically, the vertex is also the end of the parallel walls of the hexagonal receptacles in the adjacent row.

[0083] Exemplary receptacles include a first slot and a second slot that cooperate to define a passageway. Each of the first slot and the second slot is shared by adjacent columns and is a slot formed in an outer peripheral wall parallel to the receptacle axis. The first slot is also a slot on the first receptacle on its adjacent column, the second slot is also a slot on the second receptacle on the adjacent column, and the second receptacle is in contact with the first receptacle.

[0084] In an exemplary embodiment such as this example, directly adjacent receptacle columns are offset or displaced by half the receptacle width in the column direction. The offset or displacement in the row direction helps to increase the compactness of the battery module in order to increase the battery cell density. The voids surrounding each battery cell defined by a plurality of insulating ribs mitigate the heating of the battery cells in a high cell density environment.

[0085] The receptacles of the battery module may be formed on a battery crate or a plurality of battery crates. The battery crate may be integrally molded of a rigid plastic such as ABS or PC (polycarbonate). Each battery crate can have an i, j configuration comprising a plurality of i receptacle columns, each of which comprises a plurality of j integrally molded receptacles, where i and j are natural numbers. An exemplary battery module comprising an exemplary plurality of i×j×k cells requires k crates for assembly. The plurality of crates may be connected in series or in parallel, side by side, and / or end to end to form a battery module.

[0086] An exemplary battery crate has an exemplary plurality of i = 14 columns, and each column has an exemplary plurality of j = 9 receptacles. An exemplary battery module of 252 battery units can be assembled from two battery crates.

[0087] When the crate has an i=n, j=m configuration, the cells within a column are connected in parallel, and adjacent rows can be connected in series to form an nSmP configuration. In such an arrangement, the cell terminals of the battery units of the first polarity are connected to the first inter-column connector, and the cell terminals of the battery units of the second polarity, which is opposite to the first polarity, are connected to the second inter-column connector.

[0088] The battery units of the module are interconnected by a plurality of integrally formed connectors to form an nSmP configuration, where n and m are natural numbers.

[0089] An exemplary connector is an inter-column connector configured to connect two cell columns in series. The inter-column connector is an integrated connector having a plurality of integrally formed terminal contacts configured to connect a first group of cell terminals of the first polarity of the battery units in one column to the cell terminals of the second polarity of the battery units in another column. The terminal contacts include a first group of contacts configured to connect the cell terminals of the first polarity of the battery units in one column in parallel, and a second group of contacts configured to connect the cell terminals of the second polarity of the battery units in another column in parallel. An exemplary plurality of n-1 inter-column connectors are required to form an assembly of n cell columns.

[0090] An exemplary inter-column connector includes a main portion and a plurality of branch portions joined to the main portion. The plurality of branch portions include a first group of branch portions configured to connect the cell terminals of the first polarity (the "first cell terminal group") of the battery units in one column, and a second group of branch portions configured to connect the cell terminals of the second polarity (the "second cell terminal group") of the battery units in another column.

[0091] The main part extends along the column direction to interconnect the branch part of the first group and the branch part of the second group. The branch part of the first group is on one axial side of the main part, and the branch part of the second group is on the other axial side of the main part such that the main part is in the middle between the branch part of the first group and the branch part of the second group. The number of branch parts in each group of branch parts (i.e., the first group or the second group) is equal to the number of cells in one column or a "different" column. If there are m cells in a column, the group of branch parts for connecting to that column usually has m branch parts.

[0092] Each branch part includes a cell contact terminal and a finger part. The finger part includes a first end that is the proximal end joined to the main part and a second end that is the distal end joined to the cell contact terminal. The cell contact terminal is configured to physically and electrically contact the cell terminal, and the contact is usually a permanent contact and has a contact surface area comparable to the exposed area of the cell terminal. The cell contact terminal projects away from the finger part and extends at an angle with respect to the finger part to reach the cell terminal to be contacted. In an exemplary embodiment such as this example, the cell contact terminal is 90 degrees with respect to its finger part. The cell contact terminal can be welded to the cell terminal by spot welding or other joining techniques without loss of generality.

[0093] The main part of an exemplary inter-column connector comprises an elongated column conductor that extends in the column direction and through the passage of the cell column. A first plurality of finger portions forming a first group of branch portions project away from the main part and extend toward a first axial end of the first receptacle to reach cell terminals of the first group. A second plurality of finger portions forming a second group of branch portions project away from the main part and extend toward a second axial end of the first receptacle to reach cell terminals of the second group. The first plurality and the second plurality are usually equal pluralities, but they may not be equal. The finger portions of the branch portion of the first group may project at a first angle with respect to the column conductor such that the plurality of finger portions forming the branch portion of the first group cooperate to form a grid of finger portions extending toward the cell terminals of the first group. The finger portions of the branch portion of the second group may project at a second angle with respect to the column conductor such that the plurality of finger portions forming the branch portion of the second group cooperate to form a grid of finger portions extending toward the cell terminals of the second group. In an exemplary embodiment such as this example, both the first angle and the second angle are equal to 90 degrees, and as a result, the finger portions are orthogonal to the column direction.

[0094] The finger portions of the branch portion of the first group may project at the same angle with respect to the column conductor such that the finger portions are parallel or substantially parallel.

[0095] The finger portions of the branch portion of the second group may project at the same angle with respect to the column conductor such that the finger portions are parallel or substantially parallel.

[0096] The finger portions have a main surface that is parallel to the column direction and parallel to the receptacle axis.

[0097] In an exemplary embodiment, finger portions belonging to the same group of the branch portions are at the same angle with respect to the column conductors, and as a result, an air gap exists between two directly adjacent finger portions of the same group. The cell contact terminals of the branch portions of the first group project in a first direction, and the cell contact terminals of the branch portions of the second group project in a second direction opposite to the first direction.

[0098] The cell contact terminals of the branch portions of the first group are at a first axial level, the cell contact terminals of the branch portions of the second group are at a second axial level, and the cell contact terminals of the branch portions of the first group and the cell contact terminals of the branch portions of the second group are separated by an axial distance equal to the axial length of the battery cell.

[0099] The cell contact terminals of the branch portions of the first group and the cell contact terminals of the branch portions of the second group are for contacting cell terminals of opposite polarities in adjacent cell columns. Contact in this specification means both electrical and physical contact unless otherwise required by the context.

[0100] The inter-column connector is attached such that the column conductors are accommodated within a passage defined by a first cell column and a second cell column abutting the first column, whereby the finger portions of the branch portions of the first group are within a first receptacle, which is one or any receptacle of the first column, and the finger portions of the branch portions of the second group are within a second receptacle, which is one or any receptacle of the second column abutting the first receptacle.

[0101] The finger portions of the first group of the branching portion of the inter-column connector are inside the receptacles of the first cell column and extend in a first axial direction so as to reach a first axial end of the receptacle where the first cell terminal of the first battery cell having a first polarity is located. The finger portions of the second group of the branching portion of the inter-column connector are inside the receptacles of the second cell column and extend in a second axial direction so as to reach a second axial end of the receptacle where the second cell terminal of the second battery cell having a second polarity is located.

[0102] In an exemplary embodiment, the plurality of finger portions include a first group of finger portions configured to connect to the cell terminals of the first polarity of the battery units in one column, and a second group of finger portions configured to connect to the cell terminals of the second polarity of the battery units in another column. The first group of finger portions protrude in a first axial direction, and the second group protrudes in a second axial direction opposite to the first axial direction.

[0103] In an exemplary embodiment, the column conductor is a metal strip having a main surface parallel to the axial direction, and the finger portions are substantially in the same plane as the metal strip. As a result, the column conductor and the finger portions cooperate to define a planar portion. In an exemplary embodiment, the main surface of the finger portions is parallel to or in the same plane as the main surface of the column conductor. The column connector is housed inside the passage and has a thickness equal to or smaller than the width of the passage, and the width of the passage is measured in a direction orthogonal to the column direction and the receptacle axis. In an exemplary embodiment such as this example, the passage has a width of about 1 mm and may be in the range of 0.8 mm to 1.2 mm.

[0104] The column conductor has a width slightly smaller than the length of the slot that defines the passageway. An exemplary column conductor has a thickness of 0.1 mm to 0.2 mm and can have a thickness range of 0.1 mm to 0.6 mm. An exemplary column conductor has a width of about 0.8 mm and can have a width range of 0.5 cm to 1.5 cm. An exemplary finger portion has a width of about 0.7 mm and can have a width range of 0.5 cm to 1 cm. The finger portions are dispersed along the column direction and are arranged in the form of a grating or grid of finger portions.

[0105] An exemplary inter-column connector, or at least the column conductor and the finger portion, is integrally formed from a single metal sheet, such as a copper sheet, a copper alloy sheet, or a steel plate.

[0106] The column conductor and the finger portion cooperate to define an intermediate portion of the inter-column connector. An exemplary intermediate portion of the inter-column connector has a configuration similar to the shape of a fishbone and defines a grid of spaced-apart finger portions. The intermediate portion has a sheet form factor and has a thin thickness configured to fit into the narrow inter-column space between adjacent cell columns.

[0107] An exemplary intermediate portion defines a network of connectors comprising laterally extending column conductors and axially extending finger portions, and directly adjacent finger portions are separated by voids to define a comb-like spacing. The network of connectors defines a grid of connector portions that define the intermediate portion of the inter-column connector. The intermediate portion extends axially and has an axial range comparable to the axial direction of the battery cells of the battery module. In an exemplary embodiment where the cell battery is a cylindrical battery having a battery axis that is a cylindrical axis and having battery terminals of opposite polarities at opposite axial ends on the battery body, the intermediate portion has an axial range equal to or greater than the axial length of the battery body or the battery cell, and the axial length is parallel to the battery axis and / or the receptacle axis.

[0108] Even when the intermediate portion has an axial range approximately equal to the axial length of the battery cell, the networked configuration of the intermediate portion including the integrated network of finger portions spaced apart from the column connectors defines column connectors having a very low inter-column resistance due to the parallel connection of the finger portions.

[0109] It is very advantageous that the inter-column electrical resistance, which is the series resistance between adjacent abutting cell columns, is very low. For example, the cell terminals of battery units of the same polarity belonging to directly adjacent or abutting cell columns can be at the same axial level, and there is no need to arrange some battery units upside down with respect to other cells in order to shorten the length of the column connectors, which not only improves the reliability and durability of the battery units but also provides other advantages.

[0110] The very low inter-column electrical resistance of the intermediate portion also means a very low thermal resistance. A very low thermal resistance means that heat from the battery unit can be efficiently transported from the battery unit to the intermediate portion for heat dissipation. The intermediate portion configured in the form of a grating functions as a heat sink and an effective radiator for the rapid dissipation of heat to reduce the overheating risk. In other words, the exemplary intermediate portion forms the partition walls of the heat sink within the narrow inter-column space. Such a configuration of the intermediate portion can achieve miniaturization of the battery module and enhance the reliability and durability of the battery module.

[0111] Referring to FIGS. 3A to 9A, the battery module 1220 includes a battery assembly 100, a management circuit, and a main module housing 200 in which the battery assembly 100 and the management circuit 300 are accommodated. The battery assembly 100 includes a plurality of batteries 102, which are usually rechargeable batteries organized into a plurality of battery groups.

[0112] As shown in FIG. 3, the housing 200 includes a plurality of compartments, for example, a main compartment and a fan compartment. The main compartment is partitioned into a battery compartment 106 in which the battery assembly 100 is housed, a circuit compartment 104 in which the management circuit is housed, an air compartment 400, and a functional compartment that may be useful or beneficial. The fan compartment 500 is formed at a longitudinal end of the housing 200, and a ventilation device is installed in the fan compartment.

[0113] The housing 200 may be formed from metal parts, strong plastic parts, or a combination of both metal and strong plastic parts. The housing may comprise a plurality of housing parts. For example, the housing may comprise a main compartment housing part and a fan compartment housing part. The main compartment housing may be partitioned into a plurality of functional compartments.

[0114] The housing comprises a first housing part (abbreviated as "the first part"), a second housing part (abbreviated as "the second part"), and a peripheral housing part (abbreviated as "the peripheral part") that interconnects the first part and the second part. The first part is at a first axial end and has an inward-facing major surface ("the first major surface"). The second part is at a second axial end and has an inward-facing major surface ("the second major surface") that faces in a direction opposite to the direction of the first major surface. An exemplary housing 200 comprises an upper part 202 as an exemplary first part, a bottom part 204 as an exemplary second part, and a peripheral part 206 that interconnects the upper part and the bottom part, and these cooperate to define the main compartment housing. The peripheral part extends axially in the Z direction between the bottom part and the upper part and surrounds and defines the main compartment. The peripheral part has a first end which is the first longitudinal end 210 in this example and a second end which is the second longitudinal end 220 in this example. The first longitudinal end 210 and the second longitudinal end 220 respectively define the first longitudinal end and the second longitudinal end of the main compartment.

[0115] The first longitudinal end 210 and the second longitudinal end 220 are opposite longitudinal ends of the housing 200 and are on the main longitudinal axis L-L’ of the housing, which is also the longitudinal axis of the main compartment and defines the main longitudinal direction Y of the device. The axial direction Z of the peripheral part defines the main axis direction of the device that is orthogonal to the main longitudinal direction L.

[0116] The fan compartment housing part is a longitudinal housing part that protrudes away from the main compartment and extends in the main longitudinal direction of the main longitudinal axis L-L’ so as to define the fan compartment.

[0117] The circuit compartment is at the first longitudinal end 210 of the housing, the fan compartment is at the second longitudinal end 220 of the housing, and the battery compartment is in the middle between the circuit compartment and the fan compartment.

[0118] A plurality of peripheral devices are arranged on the front panel of the first longitudinal end 210 of the housing. The peripheral devices can be provided with input, output, and control interfaces including power input, power output, data interface, and user interface.

[0119] The device is configured as a power module, and the power module can operate as a stand-alone power source or as a module component of a plurality of power modules that form a larger-scale power source.

[0120] The management circuit includes a battery management circuit and a peripheral circuit. The battery management circuit can include a battery charge control circuit, a battery discharge control circuit, a battery state monitoring circuit, a battery safety control circuit, and / or other useful circuits. The peripheral circuit can include a measurement circuit, an electrical communication circuit including a data communication front end, a switching control circuit, a remote sensing circuit, and other useful circuits.

[0121] The exemplary housing 200 includes a first housing portion and a second housing portion that cooperate to form the housing. The exemplary first housing portion is an upper housing portion 230 that includes an upper portion and a peripheral portion, and the exemplary second housing portion is a lower housing portion 240 that includes a bottom portion.

[0122] In exemplary embodiments such as this example, the upper housing portion 230 is shaped and configured to define a battery compartment and is formed from a heat insulating material such as a rigid engineering plastic. The exemplary upper housing portion is integrally formed from a strong engineering plastic material such as ABS, and the battery compartment is a closed compartment except at locations where ventilation openings 232 are provided. In some embodiments, the upper housing portion may be a thermally conductive material, such as steel, aluminum, or other metal. The upper housing includes a peripheral flange that is complementary to the peripheral flange of the lower housing portion to facilitate rapid assembly.

[0123] The exemplary lower housing portion 240 is formed as a metal casing portion. The metal casing portion includes a metal plate portion 242, a fan panel 244 at a longitudinal end, and a peripheral flange 246 that extends along its side surface. The metal plate portion defines the bottom of the housing as well as the floor 208 of the housing. The fan panel extends orthogonally to the metal plate portion and is aligned with a fan mounted to a fan mounting frame formed in the upper housing portion to define a plurality of fan openings that allow air movement through the fan mounted in the fan compartment.

[0124] The portion of the metal casing portion 242 that forms the bottom of the housing is a stainless steel plate that cooperates with the upper housing portion 230 to form a main compartment and a fan compartment that is adjacent to the air compartment and in fluid communication with the air compartment.

[0125] The battery assembly 100 is attached to the housing and is held between the upper portion of the housing and the air compartment.

[0126] The battery assembly 100 includes a plurality of electrically interconnected batteries. The batteries of the battery assembly may be interconnected to form a plurality of parallel-connected batteries and / or a plurality of series-connected batteries. The battery assembly may be disposed in one battery assembly or a plurality of battery assemblies, and each battery assembly is called a battery group. The battery assembly can include a plurality of parallel-connected batteries and / or a plurality of series-connected batteries. The batteries of the battery assembly are electrically interconnected by a plurality of inter-battery connectors. A plurality of inter-battery connectors can be connected in series to form an inter-assembly connector for connecting adjacent pairs of battery assemblies.

[0127] The battery assembly may be configured as one battery module or a plurality of battery modules. Each battery module includes a plurality of parallel-connected battery groups and / or a plurality of series-connected battery groups.

[0128] An exemplary battery module includes a first module portion having a first module surface defining a first module end, and a second module portion having a second module surface defining a second module end. The exemplary battery module has an upper portion as an exemplary first module portion, and an upper surface as an exemplary first module surface defining an upper end as an exemplary first end of the battery module. The exemplary battery module has a bottom portion as an exemplary second module surface, a bottom surface as an exemplary second module surface defining a bottom end of the battery module, and a peripheral portion extending axially between the upper end and the bottom end. The upper portion and the bottom portion are axially opposite ends of the battery module. The axial direction of the exemplary battery module is parallel to the battery axis of the battery of the battery module. The axial direction of the exemplary battery module is parallel to the main axis direction of the exemplary housing, although in some embodiments it may be at an angle to or orthogonal to the main axis direction of the housing.

[0129] The battery module includes a plurality of first battery terminal contact tabs 112 distributed on a first portion of the battery module to form an exposed first module surface, and corresponding a plurality of second battery terminal contact tabs 114 distributed on a second portion of the battery module to form an exposed second module surface. The first battery terminal contact tabs are physically connected to the first battery terminals of the battery, for example, by spot welding or laser welding. The first battery terminals of the battery have a first electrical polarity and a safety vent formed at or near the first battery terminals. The first battery terminal contact tabs 112 have slits or openings and are exposed in a discharge compartment intermediate the battery module and a first portion of the housing. The battery is held such that its safety vent is proximal to the first module surface and is not blocked by the first module surface, whereby hot gaseous discharge emitted from the battery can freely move from the first battery terminals to the first module surface and then to the ventilation opening 232 of the housing. The safety vents of conventional batteries are typically formed proximal to the positive terminals of the batteries. In this case, the first battery terminals are the positive terminals of the battery and the second battery terminals are the negative terminals of the battery. When the safety vent is proximal to the negative battery terminal, without loss of generality, the first battery terminal becomes the negative terminal and the second battery terminal becomes the positive terminal.

[0130] The second battery terminal contact tabs 114 are physically connected to the second battery terminals of the battery, for example, by spot welding or laser welding. The second battery terminals have a second electrical polarity opposite to the first electrical polarity. When the first battery terminals are positive terminals and the second battery terminals are negative terminals, and vice versa, the second module surface is an exposed module surface for facilitating physical and thermal connection with a heat exchange device.

[0131] The peripheral portion of the battery module includes an outer peripheral wall surrounding the battery of the battery module. The outer peripheral wall includes a peripheral surface extending in the axial direction and defining a first portion and a second portion of the battery module.

[0132] The battery module is attached to the housing such that its first surface is proximal to the first portion of the housing and distal from the second portion, and its second surface is proximal to the second portion of the housing and distal from the first portion. An exemplary battery module is attached to an exemplary housing such that its upper surface is proximal to and distal from the upper part of the bottom of the housing, and its bottom surface is proximal to and distal from the bottom of the housing.

[0133] The battery module is maintained at an axial level with respect to the first surface of the housing such that an axial separation between the first surface of the battery module and the first surface of the housing is maintained. This axial separation defines a discharge chamber, whereby gaseous discharges emitted from the battery of the battery module can exit the module through the ventilation opening 232 of the first surface of the housing after moving through the discharge chamber. This axial separation is selected to be relatively small to facilitate effective monitoring of extreme battery conditions. The axial separation distance may be about 0.2 cm to 2 cm in an exemplary battery arrangement, which is 3% to 30% of the axial range of a battery module of 18650 batteries. Generally, the axial range is selected to be, as a rule of thumb, 3%, 5%, 7%, 9%, 11% or more and less than 20%, 25%, 30% of the axial range of the battery module.

[0134] The ventilation openings are in fluid communication with the discharge chamber, and the number of ventilation openings is significantly less than the number of batteries in the battery assembly. An exemplary battery assembly has more than 250 batteries but only has four ventilation openings. Each ventilation opening is equipped with a thermal sensor, and the thermal sensor is connected to a temperature monitoring circuit of a battery management circuit for monitoring the temperature of the gaseous discharge of the battery assembly. The upper part of the discharge chamber, more specifically the housing, is thermally insulated from the surroundings to facilitate accurate temperature monitoring so that the temperature of the high-temperature gaseous discharge emitted from the batteries of the battery assembly does not drop significantly before reaching the thermal sensor. In this example, the first module surface is proximal and directly faces the ceiling of the man housing, the plurality of ventilation openings are distributed in the upper part of the housing, and the battery module is maintained at an axial level below the ceiling of the housing so that an axial separation is maintained between the upper surface of the battery module and the ceiling of the housing. In some embodiments, the first module surface is proximal and directly faces the floor of the man housing, the plurality of ventilation openings are distributed in the bottom of the housing, and the battery module is maintained at an axial level above the floor of the housing so that an axial separation is maintained between the bottom surface of the battery module and the floor of the housing. Terms such as upper and lower, top and bottom, up and down are used to facilitate reference by reference to how the module is configured during use and are not meant to be limiting. For example, the module may be configured such that the battery axis defining the module axis is horizontal or at an angle to the vertical, and the terms upper and lower, top and bottom, up and down are interpreted accordingly and with the necessary modifications without loss of generality.

[0135] An exemplary battery assembly includes an exemplary plurality of two battery modules 101A, 101B, which are mounted adjacent to each other side by side for maximum compactness. The battery modules may be mounted spaced apart if compactness is not required. The exemplary battery modules are mounted such that the upper surfaces of the component battery modules are aligned at the same axial level and face the ceiling of the housing, the bottom surfaces of the battery modules are aligned at the same axial level and face the bottom of the housing, and the peripheral portions are mounted such that they are laterally aligned so that the battery assembly has a generally rectangular profile.

[0136] The battery assembly 100 includes a base plate 120 that is attached to the bottom end portion of the battery module(s) (or, if the battery assembly has a single battery module, to the bottom end portion of the battery module) so as to form the bottom end portion of the battery module. The base plate 120 partitions a portion of the housing into an upper portion that defines a battery compartment and a lower portion that defines an air compartment. The base plate is fastened onto the peripheral flange of the housing to form a substantially airtight battery compartment except for the ventilation openings. The peripheral flange extends along the inner circumference of the housing and projects inwardly to form a ceiling flange, such that when cooperating with the base plate and the fasteners distributed along the peripheral flange, a substantially airtight battery compartment is formed. The base plate is in physical and thermal contact with the battery terminal tabs at the bottom end portion of the battery module, but is electrically insulated from the battery terminal tabs.

[0137] The battery assembly is attached to the housing and is maintained at an axial level above the floor of the housing. The floor of the housing is the inward-facing surface at the bottom of the housing.

[0138] The axial height of the battery assembly above the floor of the housing defines the axial extent of the air compartment. The axial extent of the air compartment is, for example, 25%, 30%, 35%, 40% or more greater than the axial extent of the discharge compartment.

[0139] The base plate 120 forms the bottom end of the battery module, has a main surface facing away from the battery module, and forms the bottom surface of the battery assembly. An air compartment is defined between the bottom surface of the base plate and the floor of the housing.

[0140] The battery assembly 100 includes a heat exchange device for facilitating heat exchange between the battery assembly and the air in the air compartment or the ambient air. The heat exchange device includes a heat exchange device having a heat exchange surface that is thermally connected to the battery module and is thermally exposed to the air compartment or, in embodiments where the housing does not have an air compartment, to the ambient air so that heat exchange occurs with the ambient air.

[0141] An exemplary heat exchange device in this example includes a thermally conductive plate having a heat contact surface 122 that is thermally connected to the battery terminals of the battery assembly by a heat transfer network, and the thermally conductive plate has a heat exchange surface 124 that is exposed to air, such as the air in the air compartment or the ambient air if there is no air compartment. The heat contact surface and the heat exchange surface are opposite main surfaces of the thermally conductive plate.

[0142] The base plate 120 of the exemplary battery assembly is a thermally conductive plate that functions as a heat exchange device in this example. To establish an efficient thermal connection between the battery terminals and the base plate, the battery contact tabs exposed at the bottom of the battery module are joined to the upper surface of the base plate by an electrically insulating thermally conductive medium such as a thermally conductive adhesive or preferably an elastomeric thermally conductive sheet or thermally conductive strip 130, whereby the base plate and the battery contact tabs are maintained in thermal connection but electrically insulated from each other. Regarding the operation when the heat exchange device is for preventing overheating of the batteries of the battery assembly, the upper surface of the base plate is for collecting heat from the batteries of the battery assembly and is thus a heat collecting surface, and the lower surface of the base plate is an exhaust heat surface for dissipating heat into the air compartment. Regarding the operation when the heat exchange device is for warming the batteries of the battery assembly to their operating temperature range, the operation is reversed, the lower surface of the base plate becomes a heat collecting surface for collecting heat from the air compartment, and the upper surface of the base plate becomes an exhaust heat surface for dissipating heat to the batteries.

[0143] The air compartment is an air compartment that is in fluid communication with the fan compartment at one longitudinal end and in fluid communication with the ambient air at the other longitudinal end distal to the fan compartment. The circuit compartment has a lower surface 250 that is substantially coplanar with the base plate so as to form a through air passage between the first longitudinal end of the housing and the inlet to the air compartment so that the ambient air can be freely drawn into the air compartment for heat exchange.

[0144] In exemplary embodiments such as this example, the base plate 120 is physically and thermally connected to the battery contact tabs on the bottom surface of the battery module to ensure good thermal contact and good thermal connection between the battery module and the base plate. The exemplary base plate 120 is a metal plate having a plurality of contact tracks 126. The contact tracks are an integral part of the metal plate, and adjacent contact tracks are separated and insulated. Each track is thermally connected to a row of batteries by a corresponding formed thermal connector strip 130. The exemplary base plate has a composite structure similar to that of a composite substrate for forming a printed circuit board, except that the base substrate has an insulating layer formed on a metal substrate rather than a metal layer formed on an insulator substrate. The exemplary base plate has an aluminum plate substrate and an electrical insulating coating on the plate substrate. The contact tracks may be formed by masked imprinting and etching such that after mask removal of the upper insulating layer, the contact tracks appear as metal tracks printed remaining on the metal substrate. The thermal contact tracks are tracks separated from each other and insulated from each other. Adjacent contact tracks are separated by insulating tracks forming an insulating gap and / or surrounded by insulating tracks. Each track is elongated and has a zigzag outer shape at each of its long edges, following the zigzag contour of the battery compartments forming the battery receptacle row. The exemplary zigzag outer shape on the long side of the exemplary contact track is symmetric with respect to the longitudinal axis of the contact track, which is also the central axis of the contact track. The base plate functions as a heat sink that absorbs heat accumulated or generated in the battery assembly and functions as a radiator that dissipates the heat into the air compartment. To increase the heat dissipation rate, heat dissipation protrusions such as fins or dispersion protrusions can be formed on the lower surface of the base plate. The lower surface of the base plate is the heat exchange surface of the base plate, and the base plate is exposed to the air compartment and is in thermal contact with the air in the air compartment or the ambient air. The heat exchange surface functions as a heat dissipation surface when arranged to dissipate heat from the battery compartment.

[0145] The metal plate forming the bottom of the housing further serves to increase the heat dissipation rate.

[0146] An exemplary thermal connector strip may be an elastomeric thermal connector, such as an elastomeric thermal connector made of a non-silicone thermal interface material. Products of the F-CO TM series available from Furukawa are an example of a thermal conductive medium suitable for this purpose.

[0147] In this embodiment, the battery contact tab forming the upper surface of the battery assembly is a contact tab physically joined to the positive battery terminal of the battery of the battery assembly, and the battery contact tab forming the lower surface of the battery assembly is a contact tab physically joined to the negative battery terminal of the battery of the battery assembly. The battery contact tabs may be physically joined by spot welding, laser welding, or other metal joining techniques.

[0148] The base plate is thermally attached to the negative battery terminal via the battery contact tab at the bottom of the battery module in order to utilize the larger end face area of the negative battery terminal of the cylindrical battery (compared to the end face area of the positive battery terminal) to improve better heat dissipation from the battery to the base plate, which functions as a heat sink or heat dissipation surface in the exemplary embodiment.

[0149] In an exemplary module, the upper and peripheral portions of the housing cooperate with the base plate to define a battery compartment, and the bottom of the housing cooperates with the base plate to define an air compartment. The battery compartment is a closed compartment having a ventilation opening as the only air outlet, so that gaseous discharges from the battery assembly can only exit through the ventilation opening at the top of the housing. The air compartment is preferably a closed chamber having an air inlet at one longitudinal end and an air outlet at the other longitudinal end, whereby the ambient air drawn into the air compartment must move along the entire span of the air compartment for good heat exchange.

[0150] To form an exemplary air movement configuration, an array of electric fans is attached to the fan compartment housing. The fan array extends transversely with respect to the longitudinal axis and includes an exemplary plurality of three-axis fans, and the fan axes are parallel to the longitudinal axis of the housing. The fans are configured to discharge air from the air compartment via the axial flow fans and draw ambient air into the air compartment. In an exemplary embodiment, the ambient air inlet is formed at the longitudinal end of the housing distal to the fan compartment, such that the incoming ambient traverses the entire length of the base plate before reaching and exiting the fan compartment. In some embodiments, the ambient air inlet may be formed on the side of the housing that defines the air compartment.

[0151] During operation of the ventilation device, the air in the fan compartment is drawn out of the fan compartment and exits the module through the fans. As a result, a low-pressure region is formed within the fan compartment, and the air in the air compartment is drawn into the fan compartment by the pressure difference. As a result of the movement of air from the air compartment to the fan compartment, a low-pressure region is formed inside the air compartment, and ambient air is drawn into the air compartment from outside the module to compensate for the loss of air from the air compartment.

[0152] The contact between the base plate and the air in the air compartment results in heat exchange between the base plate and the air in the air compartment, and the movement of air around the air compartment results in the transfer of heat present in the air of the air compartment to the outside of the module.

[0153] When the heat-carrying air is moved across the air compartment and subsequently exits the module, the air compartment is replenished with newly drawn-in air at a lower temperature, for example, the ambient air temperature. It is desirable for the continuous operation of the heat exchange and removal process by the operation of the ventilation device to rapidly cool the battery assembly, prevent the accumulation of harmful and contact heat inside the battery assembly, and prevent catastrophic battery melting.

[0154] The heat exchange device is configured to collect heat from the battery of the battery assembly, more specifically from inside the battery. To facilitate the collection of heat from inside the battery, a heat collection and transfer network (abbreviated as heat transfer network) that thermally interconnects the electrodes of the battery and the heat exchange device is provided. An exemplary heat transfer network includes a heat collection terminal integrally connected to the first battery terminal of the battery. Since the first battery terminal of the battery is always a good conductor of both heat and electricity that is directly or integrally joined to the battery electrode to minimize resistance, a heat transfer network having a heat collection terminal in good thermal contact with the battery terminal facilitates the efficient and rapid extraction of heat from inside the battery for dissipation to the surroundings when the heat transfer network is thermally connected to the surroundings, for example, by a heat exchange device.

[0155] An exemplary heat transfer network includes a plurality of inter-battery connectors of the battery assembly. An exemplary inter-battery connector includes a first battery terminal contact tab 112 (abbreviated as "first contact tab"), a second battery terminal contact tab 114 (abbreviated as "second contact tab"), and an inter-terminal tab 116 that interconnects the first contact tab and the second contact tab. The first contact tab is for connecting to the first terminal of the battery, the second contact tab is for connecting to the second terminal of another adjacent battery, and the inter-terminal tab is an inter-battery link that interconnects a pair of adjacent batteries.

[0156] An exemplary inter-battery link includes a first link portion 116a, a second link portion 116b, and an intermediate link portion 116c that interconnects the first link portion and the second link portion. Each link portion is a tab portion having a tab shape. The tab has a main surface 116d that is a flap surface, and the main surface of the tab has an area that is significantly larger (e.g., advantageously 5 times, 10 times, 15 times, 20 times or more) than the area of the facet 116e of its main surface. The terms tab and flap have the same technical meaning in this specification and are used interchangeably.

[0157] The first link portion (or the first battery unit connector) includes a first metal flap portion that integrally interconnects a first contact tab and an intermediate metal flap portion, and the first contact tab protrudes away from the first metal flap portion in a first protruding direction. The second link portion (or the second battery unit connector) includes a second metal flap portion that integrally interconnects a second contact tab and an intermediate metal flap portion, and the second contact tab protrudes away from the second metal flap portion in a second protruding direction opposite to the first protruding direction. The first contact tab and the second contact tab are parallel and are separated by an axial separation distance equal to the axial height of one of the connected batteries. The first metal flap portion and the intermediate metal flap portion are integrally joined and have a main flap surface on the same plane. The second metal flap portion and the intermediate metal flap portion are integrally joined and have a main flap surface on the same plane. Advantageously, these portions are integrally joined or integrally connected when joined to each other by fusion welding or when formed from a single piece of material.

[0158] In exemplary embodiments such as this example, the batteries of a battery module or a battery assembly are organized into a plurality of battery groups, and pairs of adjacent battery groups are interconnected in series by inter-battery-group connectors.

[0159] In exemplary embodiments such as this example, the battery module includes a plurality of battery groups arranged in a plurality of battery rows. Each battery row includes a plurality of batteries connected in parallel, and the battery rows are connected in series.

[0160] The battery rows and the adjacent battery rows that constitute a pair of battery rows of the battery module are connected by an inter-battery-row connector 110 (abbreviated as an "inter-row connector" or an "inter-group connector"). The inter-row connector includes an array of inter-battery connectors, and the inter-battery connectors forming the array are distributed in the row direction to form a series of inter-battery connectors.

[0161] The inter-column connector includes a first connector portion, a second connector portion, and a third connector portion. The first connector includes an array of first contact tabs, the second connector portion includes an array of second contact tabs, and the third connector portion includes an array of between-terminal tabs. The first contact tabs forming the array of first contact tabs are dispersed along the row direction, and adjacent first contact tabs are separated by a gap. The second contact tabs forming the array of second contact tabs are dispersed along the row direction, and adjacent second contact tabs are separated by a gap. The between-terminal tabs forming the array of between-terminal tabs are interconnected at their intermediate link portions to form a between-terminal link that interconnects the array of first contact tabs, the array of second contact tabs, and the array of between-terminal tabs. The first tab and the second tab project in opposite projecting directions and have contact surfaces orthogonal to the row direction.

[0162] The inter-column connector includes a plurality of first metal flap portions that are dispersed along the column direction to form a column of first metal flap portions, a plurality of second metal flap portions that are dispersed along the column direction to form a column of second metal flap portions, and a plurality of intermediate metal flap portions that are dispersed along the column direction to form a column of intermediate metal flap portions. The first metal flap portion and the second metal flap portion are, in this example, a first link portion and a second link portion, respectively.

[0163] The first metal flap portions of the exemplary inter-column connector are dispersed along the column direction and form a plurality of metal flaps that extend orthogonally to the column direction between the intermediate metal flap portions and the first contact tabs.

[0164] The second metal flap portions of the exemplary inter-column connector are dispersed along the column direction and form a plurality of metal flaps that extend orthogonally to the column direction between the intermediate metal flap portions and the second contact tabs.

[0165] The first metal flap portion and the second metal flaps are alternately arranged in the row direction such that the first metal flap portion is intermediate a pair of adjacent second metal flap portions and the second metal flap portions are intermediate a pair of adjacent first metal flap portions.

[0166] Adjacent first metal flap portions of the inter-column connectors are separated by a comb-shaped separation distance, the comb-shaped separation distance between directly adjacent first metal flap portions of the inter-column connectors is uniform, and the width of the first metal flap portions is uniform. The comb-shaped separation distance of the first metal flap portions of the inter-column connectors may depend on the width of the second metal flap portions and may be equal to or greater than the dimension of the battery in the column direction.

[0167] Adjacent second metal flap portions of the inter-column connectors are separated by a comb-shaped separation distance, the comb-shaped separation distance between directly adjacent second metal flap portions of the inter-column connectors depends on the separation distance of the adjacent batteries, is uniform, and the width of the second metal flap portions is uniform. The comb-shaped separation distance of the second metal flap portions of the inter-column connectors may depend on the width of the second metal flap portions and may be equal to or greater than the dimension of the battery in the column direction.

[0168] The first metal flap portion and the intermediate metal flap portion cooperate to form a first metal grating. The second metal flap portion and the intermediate metal flap portion cooperate to form a second metal grating. The first metal flap portion, the second metal flap portion, and the intermediate metal flap portion cooperate to form a main metal grating. Each of the metal gratings may be flexible and may be exposed such that its major surface is non-thermally insulated and non-electrically insulated. The intermediate metal flap portion of the inter-column connector is integrally connected so as to extend along the column direction and defines the dimension of the inter-column connector in the column direction.

[0169] An exemplary inter-column connector includes an elongated column tab 118 that is a column link extending in the column direction to interconnect a first metal flap portion and a second metal flap portion of an inter-battery connector forming the inter-column connector.

[0170] The metal flap portion has a main flap surface parallel to the row direction.

[0171] An exemplary inter-column connector is formed from a single flexible metal sheet and includes a plurality of flexible tab portions.

[0172] Another exemplary inter-column connector is shown in FIG. 7. Adjacent pairs of columns of batteries, each consisting of two columns of batteries, are connected in series by the inter-column connectors. Each inter-column connector includes a plurality of N inter-battery connectors, and each inter-battery connector includes a first battery terminal contact tab 1112, a second battery terminal contact tab 1114, and a between-terminal tab 1116 that interconnects the first battery terminal contact tab 1112 and the second battery terminal contact tab 1114. A window or opening is formed in the between-terminal tab 1116 that extends over a substantial portion of the axial length of the inter-battery connector.

[0173] To assemble the battery columns of the batteries in parallel, inter-column battery connectors are attached to the plurality of batteries forming the battery columns, and the module members are fitted together to form a sub-assembly. When the battery columns are assembled, the first battery terminal contact tab 1112 is at the first axial end of the battery receptacle and makes physical and electrical contact with the first battery terminal, the second battery terminal contact tab 1114 projects from the second end of the battery receptacle and extends into another column to make physical and electrical contact with the second battery terminal of a battery in another column, and the between-terminal tab 1116 extends axially inside the battery receptacle between the first axial end and the second axial end of the battery receptacle of the battery to which the first terminal is connected to the first battery terminal contact tab 1112.

[0174] An exemplary battery module includes a battery tray 140 (or simply tray), a plurality of batteries 160 held on the battery tray, and a plurality of inter-column connectors that interconnect the batteries. The inter-column connectors are for connecting the battery terminals of the batteries in one receptacle column to the battery terminals of the batteries in the adjacent receptacle column in contact therewith. In an exemplary embodiment, when the battery module has a plurality of M receptacle columns, there are a corresponding plurality of M inter-column connectors.

[0175] When adjacent pairs of the receptacle rows of the battery module have a plurality of N battery receptacles, the inter-row connector comprises a plurality of N inter-battery connectors interconnected by row links. Each inter-battery connector comprises a first contact tab, a second contact tab, and an intermediate link interconnecting the first contact tab and the second contact tab. Since the first contact tab and the second contact tab are terminal contact tabs for connecting to different batteries, the intermediate link is also an inter-battery link. The contact tabs in this specification are battery terminal contact tabs unless otherwise required by context. An exemplary first contact tab is for connecting to the first terminal of the battery in the receptacle row, and an exemplary second contact tab is for connecting to the second terminal of the corresponding battery on the adjacent receptacle row. The exemplary first contact tab projects away from the intermediate link and extends away from the adjacent receptacle row, for example orthogonally. The exemplary second terminal projects away at a right angle from the intermediate link and extends away from the first contact tab. The first contact tab and the second contact tab are parallel and have an axial separation equal to or equivalent to the length, axial range, or height of the cylindrical battery (65 mm in the case of a 18650-sized battery). The exemplary intermediate link is an elongated metal flap having a main surface parallel to the row direction of the receptacle row and parallel to the battery axis of the corresponding battery to which the inter-battery connector connects. The metal flap forming the intermediate link extends into the gap between the first and second terminals of the corresponding battery. Since the contact tabs are physically and electrically connected to the battery terminals of the corresponding battery, the heat accumulated in the battery is transmitted to the inter-row connector and then to the base plate. The inter-row connector is configured to have a high surface area to volume ratio and is made of a good heat and conductor to improve heat transfer to the base plate and good heat dissipation. The base plate and the inter-row connector are configured to form a heat transfer network through which the heat generated by the batteries of the battery module is transmitted to the base plate via the inter-row connector. The heat transfer network comprises a heat transfer matrix comprising a row of heat conducting flaps thermally joined to the base plate.The heat conduction flap extends axially along the length of the battery.

[0176] The second contact tab, which is permanently joined to the base plate by a heat transfer interface medium to facilitate efficient transfer of heat from the interior of the battery of the battery assembly to the base plate and then to dissipate into the air compartment, has a dimension equal to, equal to, or slightly larger than that of the second terminal of the battery in contact.

[0177] Exemplary inter-column connectors of the present disclosure are configured to have a high surface area to volume ratio to function as good heat sinks.

[0178] The battery tray 140 of the present disclosure includes a plurality of battery receptacles 142 for holding a corresponding plurality of batteries such that each battery has its own battery receptacle. The battery receptacles of the battery tray are arranged in a plurality of M receptacle rows. Each receptacle row (or simply row) includes a plurality of N battery receptacles and extends along a receptacle row axis defining a receptacle row direction X. Each battery receptacle has a receptacle axis that is the central axis of the battery receptacle defining the axial direction of the receptacle. The receptacle row axis of a receptacle row is formed by joining the receptacle axes of the battery receptacles of that receptacle row. The battery receptacles forming a receptacle row are distributed along the receptacle row axis of the receptacle row between a first row end and a second row end. The first row end is the first side end where the first end receptacle (or the first receptacle) is located, and the second row end is the second side end of the receptacle row where the second end receptacle (or the last receptacle) is located.

[0179] The battery tray comprises a plurality of directly abutting receptor columns, and the directly abutting receptor columns are parallel to each other. The receptor columns constituting the battery tray are dispersed in the dispersion direction Y. The dispersion direction may be orthogonal to the receptor column direction X, or may form an angle with the receptor column direction. The receptor columns may be dispersed such that the intervals between directly adjacent receptor columns that abut adjacent receptor columns are the same or uniform. The receptor columns forming the battery tray may have the same number or different numbers of battery receptors.

[0180] The exemplary battery trays of FIGS. 8A and 8B comprise an exemplary plurality of 14 receptor columns (M = 14). The exemplary plurality of receptor columns forming the exemplary battery tray comprises a first receptor column 142_01, a last receptor column 142_14, and an exemplary plurality of 12 intermediate receptor columns 142_02, ..., 142_13, which are uniformly dispersed between the first receptor column and the last receptor column. The first receptor column is the first end column of the battery tray, and the last receptor column is the second end column. The first end column and the second end column cooperate to define the longitudinal ends of the battery tray in the dispersion direction Y. Each receptor column of the battery tray comprises an exemplary plurality of 9 battery receptors (N = 9). The battery receptors within the receptor column are identified by a numbering system for ease of reference. In this numbering system, the position number of the battery receptor is relative to the first end (or the first column end), and thus the first receptor is at the first end, the second receptor is next to the first receptor, the third receptor is next to the second receptor, ..., and the last receptor (or the ninth receptor in this example) is at the second end (or the second column end).

[0181] The receptacle rows are arranged such that directly adjacent receptacle rows are parallel but offset laterally, and alternating receptacle rows are aligned laterally. Due to this lateral offset configuration, each of the lateral boundaries of the battery tray has a zigzag or serrated outer shape. The serrated outer shape of the first side 146a is formed by the end wall of the first end receptacle, and the serrated outer shape of the second side 146b is formed by the end wall of the second end receptacle. The range of the lateral offset between adjacent receptacle rows is the same in this exemplary battery tray, and as a result, each lateral boundary comprises a plurality of depressions and protrusions of a uniform lateral extent. An exemplary range of the lateral offset is approximately half the width of the lateral extent (or width) of the battery receptacle such that three consecutive adjacent receptacle rows cooperate to define a half-battery receptacle 148a on the first side. If the receptacle rows have the same number of battery receptacles, three consecutive adjacent receptacle rows cooperate to define another half-battery receptacle 148b on the second side. Despite the zigzag boundaries, the exemplary battery tray has a generally rectangular shape defined by the first and last receptacle rows and the lateral protrusions on the lateral boundaries.

[0182] The exemplary battery tray is arranged such that odd-numbered rows are aligned laterally with odd-numbered rows, even-numbered rows are aligned laterally with even-numbered rows, and odd-numbered rows and even-numbered rows are offset laterally from each other. When the receptacle rows are aligned or aligned laterally, the corresponding battery receptacles on the aligned rows have battery receptacle axes aligned in a direction parallel to the dispersion direction Y. Corresponding battery receptacles herein mean battery receptacles having the same receptacle position number relative to the row ends.

[0183] The exemplary battery tray has an even number of columns of three or more, such that the first and last receptacle columns are laterally offset and the first and second - last receptacle columns are laterally aligned. When the receptacle columns are aligned, the first end receptacles of the aligned receptacle columns have their receptacle axes on a line parallel to the dispersion direction Y. When the receptacle columns have the same number of battery receptacles, the second end receptacles of the receptacle columns have their receptacle axes on a line parallel to the dispersion direction Y. When the battery tray has an odd number of columns greater than three, the first and last receptacle columns are laterally aligned without loss of generality.

[0184] Each of the intermediate receptacle columns comprises a plurality of column passages. Each column passage passes through two adjacent receptacle columns and defines a column channel spanning all of the battery receptacles of the two adjacent receptacle columns. The column channels are elongated and extend in a direction parallel to the column axis. The intermediate columns of the battery tray comprise a first column channel on a first side of the column axis and a second column channel on a second side of the column axis such that the column axis is parallel to and midway between the first and second column channels. Exemplary first and second column channels are symmetrically disposed with respect to the column axis and are equidistant from the column axis of the intermediate column. The end receptacle columns (the first receptacle column, the last receptacle column) have a single column passage that extends through both the end receptacle column and the intermediate column that abuts the end receptacle column (or, briefly, the end column).

[0185] Each passage has an end opening at a first column end and / or an end opening at a second column end to facilitate external electrical contact between connectors passing through the passage.

[0186] The exemplary battery tray is designed to hold prismatic batteries, such as cylindrical rechargeable batteries. The exemplary battery receptacle is customized to hold 18650 lithium-ion rechargeable batteries, which are cylindrical rechargeable batteries widely used in the operation of electric vehicles and have a rated voltage of about 3.6 volts. The 18650 batteries are single-cell batteries with a nominal diameter of 18 mm and a nominal length of 65 mm. When the battery tray is adapted to hold a single type of battery, the battery receptacle is designed such that the battery compartments for holding the batteries have the same (including substantially the same) compartment dimensions. For a regular design, the battery receptacles forming the receptacle rows are uniformly dispersed along the row direction such that the separation distance between adjacent receptacle axes is uniform throughout the row and they have the same dimensions. Since the receptacle rows formed by the battery receptacles have the same dimensions and a uniform separation distance, the receptacle rows having the same number of battery receptacles have the same length. When the batteries of the battery assembly are single-cell batteries, the inter-battery connector is called an inter-cell connector without loss of generality.

[0187] The battery receptacle 142 (or simply "receptacle") comprises a first axial end, a second axial end axially aligned with the first axial end, and an intermediate portion interconnecting the first axial end and the second axial end. The first axial end is an open end having an end opening large enough for the battery terminal to be exposed for external contact but not large enough for the battery to depart. The second axial end is an open end having an entry opening large enough for the axial entry of the battery. The first axial end of the battery receptacle defines the upper surface of the tray, and the second end of the battery receptacle defines the bottom surface of the tray. The intermediate portion comprises an outer peripheral wall having an inner surface surrounding the battery cell compartment. A plurality of spacer fins are formed on the inner surface of the outer peripheral wall. Each spacer fin projects from the outer peripheral wall and extends inwardly, and the spacer fins cooperate to define the outer periphery of the battery cell compartment. The battery cell compartment, or the outer periphery of the battery cell compartment, is calculated to conform to the contour of the outer periphery of the battery such that the battery fits snugly inside the battery cell receptacle or the gap between the battery and the outer periphery of the battery cell compartment is very small. The spacer fins are dispersed around the inner surface of the outer peripheral wall to define a cylindrical compartment and to define a void between the battery and the outer peripheral wall to facilitate heat dissipation during the operation of the module when the battery generates heat. The battery cell compartment has a cross-sectional dimension with a diameter slightly larger than 18 mm, for example 18.2 to 18.5 mm. Generally, a void of about 0.5% or less on both sides is sufficient. The void dimension is adapted to depend on the size and / or capacity of the battery. For 18650 batteries, the void fins are selected to be about 1 mm, but a range of 0.5 to 1.5 mm may be used.

[0188] The battery tray has a first surface (or first tray surface), a second surface (or second tray surface), and an outer peripheral wall (or tray outer peripheral wall) that interconnects the first surface and the second surface. Each battery receptacle defines a battery cell compartment having a compartment axis parallel or coaxial with the receptacle axis. The plurality of corresponding battery cell compartments defined by the plurality of battery receptacles of the battery tray are dispersed within the outer peripheral wall of the battery tray. The outer peripheral wall has a generally rectangular contour, notwithstanding having a serrated side wall. The first tray surface is defined by the first axial end of the battery receptacle, and more specifically, is formed by the aggregate of the first axial ends of the battery receptacles, and is orthogonal to the receptacle axis of the battery receptacle. The second tray surface is defined by the second axial end of the battery receptacle, and more specifically, is formed by the aggregate of the second axial ends of the battery receptacles, and is orthogonal to the receptacle axis of the battery receptacle. The tray outer peripheral wall is parallel to the receptacle axis of the battery receptacle. In an exemplary embodiment, the battery tray is formed of a strong engineering plastic such as polycarbonate or ABS to withstand expected harsh operating conditions.

[0189] The battery receptacle 142 includes a first side wall portion 142a, a second side wall portion 142b, a third side wall portion, and a fourth side wall portion that together form an outer peripheral wall of an intermediate portion surrounding the battery compartment.

[0190] The first side wall portion and the second side wall portion are opposing side wall portions on both sides of and on the column axis of a column of receptacles that houses the battery receptacle and the receptacle axis. The first side wall portion defines the first lateral boundary of the battery receptacle, the second side wall portion defines the second lateral boundary of the battery receptacle, and the first side wall portion and the second side wall portion together define the lateral extent (or width) of the battery receptacle. Here, the lateral extent is the extent in the column axis direction.

[0191] When the battery receptacle is an intermediate battery receptacle that abuts two adjacent battery receptacles in the same receptacle row, each of the first sidewall portion and the second sidewall portion is a receptacle wall portion of the intermediate battery receptacle that is shared with one of the adjacent battery receptacles in the same receptacle row as the intermediate battery receptacle. In other words, the first sidewall portion and the second sidewall portion of the intermediate battery receptacle are opposing receptacle sidewall portions shared by three consecutive battery receptacles on the receptacle row. The first sidewall portion and the second sidewall portion are also partition wall portions that provide a partition between three consecutive battery receptacle compartments on the receptacle row. When the battery receptacle is an end receptacle, i.e., at the end of the row, one of the first sidewall portion and the second sidewall portion is shared with the adjacent battery receptacle that abuts it.

[0192] The third sidewall portion and the fourth sidewall portion are sidewall portions on both sides of the row axis and on both sides of the receptacle axis such that the receptacle axis of the battery receptacle and the row axis of the receptacle row that houses the battery receptacle are in the middle between the third sidewall portion and the fourth sidewall portion. Each of the third sidewall portion and the fourth sidewall portion is a sidewall portion that interconnects the first sidewall portion and the second sidewall portion.

[0193] The exemplary battery tray includes a first tray end 144a which is the first end of the tray, a second tray end 144b which is the second end of the tray, a first tray side 146a which is the first side of the tray, and a second tray side 146b which is the second side of the tray. The first side wall portion 142a of the battery receptacle 142 is a side wall portion proximal to (and distal to the second side) the first side of the tray. The second side wall portion 142b of the battery receptacle is a side wall portion proximal to (and distal to the first side) the second side 146b of the tray. The third side wall portion of the battery receptacle is a side wall portion proximal to the first tray end 144a (and distal to the second tray end). The fourth side wall portion of the battery receptacle is a side wall portion proximal to the second tray end 144b (and distal to the first tray end).

[0194] The receptacle rows are distributed in parallel and in contact between the first tray end and the second tray end, and include a first end row, a last end row, and a plurality of intermediate rows between the first end row and the last end row. The first end row is the receptacle row at the first tray end, and the last end row is the receptacle row at the second tray end.

[0195] The battery tray has a first end wall which is the outer peripheral wall of the first tray end, and a second end wall which is the outer peripheral wall of the second tray end. The first end wall is defined by the side wall portion (or more specifically, the third side wall portion) of the receptacle on the first end row. The second end wall is defined by the side wall portion (or more specifically, the fourth side wall portion) of the receptacle on the last end row. The first tray end includes a flange portion that protrudes away from the first end wall. Since no flange portion is formed on the second tray end, the first end and the second end can be more easily distinguished. In some embodiments, a flange portion that protrudes away from the second end wall can be formed. The flange portion will seat on a corresponding flange formed on the housing during assembly.

[0196] The battery tray has a first side wall which is the outer peripheral wall on the first tray side and a second side wall which is the outer peripheral wall on the second tray side. The first side wall is formed by the side wall portion (more specifically, the first side wall portion) of the first receptacle in the receptacle row. The second side wall is formed by the side wall portion (or more specifically, the second side wall portion) of the last receptacle in the receptacle row.

[0197] A plurality of conductor outlets are formed in the outer peripheral wall on the first tray side and / or the second tray side. The conductor outlet is formed as a slit portion extending axially in the side wall portion of the receptacle that defines a part of the side wall of the tray. The slit portion is a continuation of the conductor path on the receptacle row to allow a part of the inter-column connector, for example, the tab portion, to protrude or pass through. The number of required slit portions is equal to the number of inter-column connectors, which is equal to the number of rows - 1.

[0198] A plurality of windows and corresponding protruding portions are formed at selected positions on the outer peripheral wall on the first tray side and / or the second tray side. The window is formed as a slot extending axially in the side wall portion of the receptacle that defines a part of the side wall of the tray. The protruding portion is formed as an axially extending bar protruding away from the side wall portion of the receptacle that defines a part of the side wall of the tray. The windows and corresponding protruding portions of adjacent trays are complementary to facilitate complementary engagement and latching of adjacent battery trays to form a combined battery tray as shown in FIG. 9. The windows and protruding portions are arranged such that when combined, the first end and the second end of the component tray are at both ends of the tray. This provides flexibility in the combination of trays so that the trays can be joined to form a battery assembly having the same number of rows as a single tray but having a greater number of battery receptacles per receptacle row or a smaller number of battery receptacles per receptacle row.

[0199] Each receptacle row has the same number of battery receptacles, but is a combined battery tray having a greater number of battery rows, e.g., a multiple of the number of receptacle rows, and the component trays are still arranged side by side and engaged or latched.

[0200] To avoid misunderstanding, the use of ordinal numbers such as first, second, third, fourth, etc. is for reference and convenience of explanation only, and does not mean to indicate a degree of importance or significance, or a required order or sequence, unless otherwise required by the context.

[0201] When the battery receptacle is an intermediate battery receptacle on an intermediate row, each of the third side wall portion and the fourth side wall portion is a shared side wall portion shared with two adjacent battery receptacles of the adjacent receptacle rows in contact. More specifically, the third side wall portion on one intermediate row is also part of the fourth side wall portion of the first adjacent battery receptacle in contact, and part of the fourth side wall portion of the second adjacent battery receptacle in contact of the first adjacent receptacle row in contact, and the fourth side wall portion on that intermediate row is also part of the third side wall portion of the first adjacent battery receptacle in contact, and part of the third side wall portion of the second adjacent battery receptacle in contact of the second adjacent battery receptacle row in contact.

[0202] The outer peripheral wall of the intermediate portion of the exemplary battery receptacle has a prismatic hexagonal shape having the receptacle axis as the central axis or the prismatic axis. Each of the first side wall portion and the second side wall portion forms a prismatic hexagonal wall orthogonal to the column axis, and the first side wall portion and the second side wall portion are directly opposed to each other. Each of the third side wall portion and the fourth side wall portion includes two abutting side walls of the prismatic hexagonal shape. The exemplary battery receptacle has a regular hexagonal shape such that the hexagonal side walls have the same length. The battery receptacle is dispersed in a manner similar to the dispersion of the cells of a honeycomb such that a typical battery receptacle is abutted and surrounded by six surrounding battery receptacles and the side walls of the typical battery receptacle are shared with the six surrounding battery receptacles.

[0203] A typical battery receptacle in the intermediate column includes a first passage portion formed in the third side wall portion and a second passage portion formed in the fourth side wall portion. Each passage portion is parallel to the column axis and is defined by a first slit portion and a second slit portion. The slit portion 143 is formed in the side wall of the hexagonal battery receptacle for a part of the third side wall portion or a part of the fourth side wall portion. Each slit portion extends along a slit axis parallel to the receptacle axis and orthogonal to the column axis. The intermediate battery receptacle on the intermediate column is a typical battery receptacle in this context.

[0204] The slit portions on the third side wall portion of the battery receptacle on the intermediate receptacle column form an aggregate of slit portions. The aggregate of slit portions extends across all the battery receptacles on the receptacle column and defines a first passage that provides a through-passage for the inter-battery row conductor.

[0205] The slit portions on the fourth side wall portion of the battery receptacle on the intermediate receptacle column form an aggregate of slit portions. The aggregate of slit portions extends across all the battery receptacles on the receptacle column and defines a second passage that provides a through-passage for the inter-battery row conductor.

[0206] The battery receptacles on the end columns have either the side wall portion of the third slit or the side wall of the fourth slit, which forms a passage portion through the passage. The flange is formed on one of the end columns and protrudes away from the battery receptacle in a direction parallel to the dispersion axis.

[0207] The slit portion of each passage portion starts from the second axial end of the tray and extends axially toward the first axial end over the axial depth. Each passage portion has an inlet opening defined by the slit portion to allow a part of the column link to enter the passage portion.

[0208] The plurality of windows and the corresponding plurality of protrusions cooperate to form a plurality of tray alignment devices. The alignment devices are formed on some of the end battery receptacles. The alignment devices include an axially protruding portion and an axially extending slot formed on an end side wall portion that is not shared with another battery receptacle. The end side wall portion can be the first side wall portion or the second side wall portion. The axially protruding portion protrudes away from the end side wall portion along the column axis direction and extends axially on the column axis and parallel to the receptacle axis. The axially extending slot has a slot axis that intersects the column axis and extends axially parallel to the receptacle axis. The axially protruding portion and the axially extending slot extend over less than half of the height of the side wall portion. The height of the side wall portion is its dimension measured in a direction parallel to the receptacle axis. An axially through hole is formed in the axially protruding portion to allow a pin to pass through and enter a perforated protruding portion of another battery tray when the battery assembly includes two or more battery trays.

[0209] To assemble the battery module, the first contact tab of the inter-column connector is inserted into the receptacle column from the second axial end and moved toward the first axial end until the first contact tab reaches the first axial end of the battery receptacle.

[0210] When the first contact tab reaches its designated position, the column tab 118 of the inter-column connector is in a predetermined position, seated within the passageway, with its major surfaces interconnected and facing the battery, being parallel to the battery axis. The column tab penetrates the columns of the battery receptacle along a path defined by the passageway and has an end tab portion 118a protruding from the battery tray. When the column tab is in the predetermined position, the first contact tab is within the receptacle of one receptacle column and the second contact tab is within the receptacle of another receptacle column that shares the column tab passageway with the receptacle column.

[0211] When the first contact tab reaches the first axial end, the second contact tab is on the second axial end of the battery receptacle.

[0212] After all the inter-column connectors are positioned in the predetermined positions, the battery is inserted into the battery receptacle and the battery terminals are electrically connected to the corresponding contact tabs, for example, by welding such as laser welding or spot welding, to integrally connect the battery terminals and the corresponding contact tabs.

[0213] When the battery comprises a plurality of battery modules, the plurality of battery trays of the corresponding plurality of battery modules are arranged side by side, and the inter-column connectors having column tabs of a length sufficient to pass through the battery modules are arranged inside the battery trays, and similar steps are executed.

[0214] In some embodiments, the individual battery modules may be assembled separately, attached to the housing, and then the inter-column connectors may be electrically joined to each other.

[0215] After one or more battery modules are assembled, the base plate is attached to the bottom surface of the battery module by an electrically insulating thermal contact medium to facilitate effective heat exchange between the heat transfer network and the base plate, completing the construction of the module's heat exchange assembly. The heat transfer assembly includes an inter-cell connector of the battery assembly and the base plate as an example of a heat exchange device. When the batteries are not connected by the inter-cell connector, the heat transfer assembly is formed by an aggregate of individual inter-battery connectors and heat exchange devices without loss of generality. In this example, the second battery terminal is the negative terminal of the battery, and the negative terminal of the battery in the battery assembly is welded to a second contact tab that is thermally joined to the base plate. When the battery module is assembled, the battery is housed inside the battery receptacle with its battery axis aligned with the receptacle axis, for example, the first contact tab is exposed proximal to the first module surface and physically and electrically joined to the first battery terminal, the second contact tab is exposed proximal to the second module surface and physically and electrically joined to the second battery terminal, the inter-battery link of the inter-battery connector is inside the battery receptacle and extends between the first contact tab and the second contact tab. The inter-battery link extends between two adjacent receptacle rows and between adjacent receptacles on adjacent receptacle rows. The first link portion of the inter-battery connector is inside the receptacle of one battery, and the second link portion of the inter-battery connector is inside the receptacle of the other battery. The intermediate link portion or row link is inside both receptacles. The row link portion is held in place by a passage formed in the battery receptacle and is held at an axial level above the axial end by a slit portion of the battery receptacle. The axial range of an exemplary slit portion defining the passage portion on the battery receptacle has an exemplary length of 22 mm, which is about 1 / 3 of the axial range of a typical battery receptacle of an exemplary tray. Generally, a slit portion having an axial range exceeding 20%, 25%, 30% and less than 35%, 40% of the axial length of the battery provides a good balance.The link portion of the battery - to - battery connector is configured to extend inside the gap portion of the battery receptacle defined by the spacer fin and the battery. The first link portion and the second link portion are displaced laterally by the lateral displacement of the abutting receptacles on the abutting receptacle rows.

[0216] In exemplary embodiments such as this example, the first link portion extends axially inside the battery receptacle, and the second link portion extends axially inside the adjacent battery receptacle on the adjacent receptacle row. The exemplary first link portion extends, the column links are orthogonal to each other, and define a T - shaped cross - section inside the battery receptacle. The exemplary second link portion extends, the column links are orthogonal to each other, and define another T - shaped cross - section inside the battery receptacle. The T - shaped cross - section formed by two tab portions orthogonal to each other forms a more stable connector structure inside the battery receptacle. Each battery receptacle has either the first link portion or the second link portion, but not both.

[0217] To minimize the space between adjacent columns while reducing the risk that adjacent battery terminal contact tabs electrically contact adjacent receptacle rows, the adjacent columns of contact tabs can be electrically and partially insulated. For example, an electrical insulating medium can be applied to the portion of the second tab that abuts the intermediate link portion of the battery - to - battery connector. In an exemplary embodiment, an electrically insulating (preferably non - thermally insulating) tape is applied across the column of the second contact tab to cover the portion of the second contact tab proximal to the intermediate link portion and reduce the potential risk of electrical contact between the second contact tabs of the abutting receptacle rows. Since the first contact tab typically has a smaller surface dimension than the second contact tab, electrical insulation may not be required for the adjacent columns of the first contact tab.

[0218] Referring to FIG. 9, an exemplary battery tray includes an exemplary plurality of M = 14 receptacle rows and an exemplary plurality of N = 9 battery receptacles for each row. Two battery modules forming an exemplary battery assembly are mounted side by side in aligned rows such that each row of the battery assembly includes N = 18 batteries. The inter-column connectors have N first terminal tabs and N second terminal tabs. The inter-battery connectors are distributed in the row direction such that adjacent inter-battery connectors have a substantially uniform separation distance, but the separation distance between two directly adjacent inter-battery connectors on two adjacent battery trays is greater than the separation distance between two directly adjacent inter-battery connectors on the same battery tray. With the batteries of the M rows connected in series, the battery assembly has an output voltage equal to MV b and V b is the voltage of each battery row. For 18650 batteries, V b is considered to be 3.6V, and the battery assembly has a voltage of approximately 50.4V.

[0219] When the inter-column connectors and the batteries are placed in predetermined positions within the tray and the assembled battery, the batteries of the receptacle rows are in parallel electrical connection, and the battery rows or adjacent battery rows are connected in series. Assembled in this way, the first battery terminals of a row of batteries are connected to the first contact tabs of one inter-column connector, and the second battery terminals of all the batteries in a row are connected to the second contact tabs of another inter-column connector. The first battery terminals of a row of batteries are at the same potential due to the electrical interconnection of the first battery terminals by the row tabs of one inter-column connector. The second battery terminals of a row of batteries are at the same potential due to the electrical interconnection of the second battery terminals by the row tabs of another inter-column connector.

[0220] After assembling the battery module, the base plate 120 is attached to the battery module to form the battery assembly 100. The battery assembly is attached to the housing and electrically connected to the battery management circuit. When the battery assembly is attached, its upper surface is proximal and faces the ceiling of the discharge chamber. An exemplary battery of the exemplary battery module has a safety vent adjacent to the positive terminal, which is the first battery terminal. When the battery assembly is properly attached, the first battery terminal of the battery is aligned with the upper surface of the battery tray, exposed to the air chamber, and faces the ceiling of the air chamber.

[0221] Before the battery assembly is attached to the upper housing portion, a thermal sensor is attached to the discharge chamber to facilitate detection of the temperature within the battery compartment. In this example, the vent openings are formed in the upper wall of the housing and are symmetrically distributed on both sides of the longitudinal central axis of the housing. The vent openings 232 are distributed near the middle portion of the upper wall of the upper housing portion. The inner surface of the upper wall defines the ceiling of the discharge chamber, and since the discharge chamber is part of the battery compartment in this example, it is also the ceiling of the battery compartment. The thermal sensor is attached to the vent opening, thereby enabling monitoring of the temperature within the battery compartment and detection of the temperature of the gaseous discharge exiting the battery compartment through the vent opening. In some embodiments, the thermal sensor may alternatively or additionally be attached at other locations within the battery compartment 106 or the discharge compartment 108. The battery compartment is configured such that gaseous discharge emitted from the battery of the battery module can only exit through the vent openings. In an exemplary embodiment, the upper housing portion of the housing is integrally formed from a non-venting material (rigid plastic), and the vent openings are integrally molded. When the upper housing portion and the battery assembly are properly assembled, the base plate and the upper housing portion cooperate to form an airtight battery compartment, excluding the vent openings.

[0222] To facilitate more accurate detection of the temperature inside the discharge compartment, which is a battery compartment, more specifically, the part of the battery compartment intermediate between the battery assembly and the housing, the upper housing portion is made of a heat-insulating material such as rigid plastic so that the discharge chamber is thermally separated from the ambient air, reducing the likelihood of detecting an abnormal high temperature due to heat exchange between the air inside the discharge chamber and the ambient air passing through the upper housing portion. Such heat exchange can cause a decrease in the temperature inside the battery compartment and may adversely affect the accurate detection of harmful battery conditions and the timing of activation of countermeasures.

[0223] When the battery assembly is in a predetermined position, the battery's safety vent is proximal and exposed to the upper surface of the battery assembly and the discharge chamber. If the safety vent of a failed battery operates to release high-temperature gas from the battery, the high-temperature gas inside the defective battery exits from the upper or upper part of the battery as a high-temperature gas discharge and moves directly into the discharge chamber.

[0224] Batteries can deteriorate, for example, due to aging and weathering, and gradually become defective batteries. When a battery becomes a defective battery, it begins to have a higher temperature and there is a possibility that high-temperature gas is released from the battery. The initial rate of gas release is usually relatively low, and the initial high-temperature gas temperature is also relatively low, for example, 100 to 120 degrees Celsius (°C). When the temperature of the battery further rises to a critical temperature, such as the melting temperature of the battery's electrode separator, the melting of the separator promotes and exacerbates battery damage, and the temperature of the high-temperature gas released by the defective battery can rapidly reach 500 degrees Celsius or 650 degrees Celsius, and even 800 degrees Celsius or 1000 degrees Celsius. The high temperature of a defective battery can spread to adjacent batteries in the battery module, causing thermal runaway and potentially an explosion. The electrode separator is typically made of polyethylene with a melting temperature of 133°C or polypropylene with a melting temperature of 159°C. The melting temperature of the separator can be used as a critical temperature for battery condition monitoring.

[0225] In some embodiments, a first cooling force can be applied when a first activation temperature is detected, and a second higher cooling force can be applied when a second higher activation temperature is detected after a predetermined time after activation of the cooling force for cooling the battery assembly.

[0226] To be able to detect the temperature within the battery compartment without providing a thermal sensor for each battery, a substantially smaller number of thermal sensors than the number of batteries are dispersed to detect the temperature within the discharge chamber. The thermal sensors in this example are dispersed within the discharge chamber, proximate to the safety vents of the batteries, and are configured to detect the temperature of the discharge compartment, which is a portion of the battery compartment that defines the discharge chamber.

[0227] To reduce the mixing of the high-temperature gaseous discharge emitted from the battery and the air within the discharge chamber, the discharge chamber is configured such that the gaseous discharge can flow to the ventilation opening in a short distance. For example, the ventilation openings and the thermal sensors are dispersed on the ceiling of the discharge chamber, whereby the high-temperature gas emitted from the battery can move upward to the ceiling and then move to the exhaust opening where the thermal sensor is disposed or near it.

[0228] To minimize the distance that the high-temperature gaseous discharge has to travel to reach the thermal sensor or the ventilation opening, the axial range of the discharge chamber is configured to be substantially smaller than the axial range of the battery compartment. For example, the axial range of the air chamber may exceed 5%, 10%, or 15% of the axial range of the battery compartment, and may be less than 20%, 25%, or 30%. The axial range of the discharge chamber may be less than 20%, 25%, 30% or 40% of the axial range of the battery assembly, and may exceed 5%, 10% or 15%.

[0229] The high-temperature gaseous discharge can be guided to move only through a short distance within the discharge chamber before reaching the nearest thermal sensor or the nearest ventilation opening closest to the discharge battery. A plurality of fluid movement guides are formed on the ceiling so as to surround the ventilation opening. Each fluid movement guide defines a guide track extending radially with respect to the ventilation opening, and the guide tracks formed by the plurality of fluid movement guides define a plurality of tapered channels that taper as each extends toward the ventilation opening. The guide tracks extend orthogonally to the axial direction of the battery assembly, which is also the axial direction of the battery, so that the high-temperature gaseous discharge moves a short distance from the safety vent of the battery to the ventilation opening 232, and the temperature of the high-temperature gaseous discharge is substantially maintained when it reaches a thermal sensor, also known as a temperature sensor, providing a guide to minimize the mixing of the high-temperature gaseous discharge with the air in the air chamber.

[0230] The end tab portion 118a of the inter-column connector of the end row of the battery assembly is connected to the power input and power output terminals of the module. The end tab portion of the inter-column connector of the middle row is connected to the battery management circuit to facilitate the management of the battery voltage in each battery row.

[0231] In an exemplary embodiment, the control circuit is configured to monitor the temperature of the battery by monitoring the temperature of a plurality of ventilation openings, for example, by a thermal sensor. When the temperature detected at the ventilation opening exceeds a predetermined threshold value, safety measures can be activated by the control circuit. The safety measures can include shutting down the battery module, for example, separating the battery or battery group by a fuse, or activating cooling measures by the operation of a fan. When the battery cooling means is activated within a short time of detecting the warning temperature, preferably, the damaged battery or damaged batteries are rapidly cooled to below the critical temperature, and the movement of cooling air through the air compartment occurs. When the critical temperature is exceeded, the risk of melting of the battery due to thermal runaway may substantially increase.

[0232] In some embodiments, active cooling means, such as by use of a thermoelectric cooling device, e.g., a Peltier device, can further facilitate the cooling process. Advantageously, the active cooling element can be attached to the bottom of the heat exchange device and / or the housing.

[0233] The inter-battery connectors are directly connected to the battery terminals, particularly when the battery safety vents are located, so the network of inter-battery connectors functions as a heat transfer network for transferring heat from inside the battery to the heat exchange device. Further, the configuration of the inter-battery connectors, particularly the configuration of the intermediate link portion with an exposed metal flap, also helps to dissipate heat during normal operation of the battery assembly and helps to maintain the battery operating at a preferred or desirable operating temperature.

[0234] During operation, if the operating temperature is detected by a thermal sensor, the control circuit activates measures to cool the battery assembly to prevent or mitigate the risk of thermal runaway and possible meltdown. In an exemplary embodiment, when a critical temperature, such as 80 °C or 90 °C, is detected by the thermal sensor, a fan activates to accelerate heat exchange between the battery module and the air within the air compartment, and the process helps to cool the battery assembly. In some embodiments, active thermal cooling can be additionally or alternatively used. In some embodiments, an external fan can be used and cold air can be supplied by an external source. The battery group may also be shut down, for example, by a fusible link upon detection of the critical temperature. In some embodiments, the control circuit can be operative to shut down the battery module or the battery assembly when the temperature reaches a second, higher temperature, such as 100 °C. The battery module can be shut down, for example, by insulation by an electronic switch such as a semiconductor switch or a fuse. Further, the control circuit can generate a warning signal when the critical temperature is reached. The warning signal can include, for example, a local warning on the module and / or a remote warning sent from the module via an electrical communication network through the electrical communication front end of the module.

[0235] The heat exchange assembly of the present disclosure is configured as a heat sink, more specifically, a distributed heat sink comprising a distributed heat transfer network formed by inter-battery connectors. The heat exchange assembly as a distributed heat sink has an inherent ability to equalize the temperature of the batteries forming the battery module or the battery assembly. The temperature equalization ability can be enhanced by active cooling by forced air movement or by thermoelectric cooling to facilitate heat exchange with the heat exchange assembly.

[0236] A battery typically has a specific operating temperature range defined between a minimum operating temperature and a maximum operating temperature. Most Li-ion cells are manufactured to be operable at temperatures below a maximum temperature of about 60 - 65 °C. An operating temperature that is sufficiently lower than the maximum temperature is generally preferred for longer battery life and longer-term safety.

[0237] An exemplary module may be configured such that the battery operates within a preferred operating temperature range that is an intermediate temperature range selected between the maximum temperature and the minimum temperature. For example, the module may be configured to operate such that the operating temperature of the battery is maintained at or below an upper limit temperature, such as 40 °C or 42 °C. When the battery reaches the upper limit temperature, the control circuit activates a cooling device to lower the battery temperature towards the lower limit of the intermediate temperature range, for example, lower it to the upper limit temperature or a few degrees below it, such as 1, 2, or 3 degrees, and the process continues to repeat. Generally, an intermediate temperature range of 25 °C - 42 °C has been found to be preferred.

[0238] Controlling the operating temperature of the battery within an intermediate temperature range selected between the maximum temperature and the minimum temperature requires a more extensive and accurate battery temperature monitoring. To facilitate more extensive and accurate battery temperature monitoring, multiple temperature sensors, such as temperature probes, are placed inside the battery receptacle to monitor the battery temperature and control the operation of the cooling device by the control circuit.

[0239] The temperature sensors can be used to control the temperature imbalance between the batteries in a battery assembly or module. For example, when a temperature imbalance exceeding an imbalance threshold is detected, the control circuit activates the cooling device to lower the battery temperature and the temperature imbalance is alleviated. An exemplary imbalance threshold can be selected, for convenience, between 3 - 5 °C.

[0240] The heat transfer network comprises a matrix of heat transfer members physically connected to the battery assembly and extending through the battery receptacles of the battery assembly. The heat transfer members have a first end physically connected to the first battery terminal of one battery and a second end connected to the second battery terminal of the other battery. The second end of the heat transfer member is also connected to a main heat exchange device physically connected to the axial end of the battery assembly. The main heat device has a heat contact surface that is physically in contact with the heat transfer network but electrically insulated therefrom. The main heat exchange device has a heat exchange surface physically connected to the heat contact surface for efficient heat transfer. In an exemplary embodiment, the heat exchange surface and the heat contact surface are opposing main surfaces of a conductive plate such that the heat exchange surface and the heat contact surface are integrally connected by a heat and conductive material. In some embodiments, the heat contact surface is depicted in a plurality of insulated or separated conductive regions, each conductive region for making a thermal but not electrical contact with a group of heat transfer members such as an array of heat transfer members. The heat transfer member is connected to the heat contact surface by an electrically insulating heat conductive medium so as to block electrical contact between the heat transfer network and the main heat exchange device. The heat transfer members are arranged in an array or column, and the array or column of heat transfer members extends axially substantially perpendicular to the heat contact surface to form a three-dimensional heat transfer assembly. An exemplary heat transfer member is also an inter-battery connector comprising a first battery terminal tab physically and electrically contacting the first battery terminal and a battery-to-battery link extending through the inside of the battery receptacle to reach the heat contact surface.

[0241] This disclosure is written with reference to examples and embodiments, but the examples and embodiments are not intended to be limiting.

Claims

1. A battery module, comprising: a plurality of battery units held in corresponding plurality of battery receptacles; a plurality of inter-battery connectors interconnecting the plurality of battery units; a battery tray having the plurality of battery receptacles; and a power interface for facilitating power input and power output, wherein the plurality of inter-battery connectors include a plurality of inter-group connectors configured as a plurality of inter-row connectors, wherein the plurality of battery units include a first group of battery units housed in a first plurality of battery receptacles and a second group of battery units housed in a second plurality of battery receptacles, and a first group of battery units and a second group of battery units are connected in series by one of the plurality of inter-row connectors, - The inter-row connector is integrally formed and configured as a heat dissipation member extending through the first plurality of battery receptacles to interconnect corresponding plurality of battery units, the battery module.

2. The inter-row connector includes a main portion and a plurality of branch portions joined to the main portion, wherein the plurality of branch portions include a first group of branch portions configured to connect cell terminals of a first polarity of battery units in one row and a second group of branch portions configured to connect cell terminals of a second polarity of battery units in another row, wherein the main portion includes an elongated row connector extending in the row direction, and the elongated row connector is integrally formed from a single metal sheet, The battery module according to claim 1.

3. One of the plurality of branch portions includes a cell contact terminal and a finger portion, the finger portion having a first end which is a proximal end joined to the main portion and a second end which is a distal end joined to the cell contact terminal, and the elongated row connector and the finger portion are integrally formed from a single metal sheet, The battery module according to claim 2.

4. One of the plurality of battery receptacles includes an outer peripheral wall and a passage formed parallel to the row direction in the outer peripheral wall, wherein the row connector is housed inside the passage, The battery module according to claim 2. **Claim 5**: The inter-column connector is integrally formed from a single metal sheet. The battery module according to claim 1. **Claim 6**: The column connector has a thickness in the range of 0.1 mm to 0.6 mm. The battery module according to claim 1. **Claim 7**: The inter-column connector includes a column connector and a plurality of finger portions, and the column connector and the plurality of finger portions cooperate to define an intermediate portion of the inter-column connector. The intermediate portion has a form factor of a sheet and fits between adjacent columns of battery units. The battery module according to claim 1. **Claim 8**: The inter-column connector extends through the first group of battery receptacles and the second group of battery receptacles. The battery module according to claim 1. **Claim 9** - One group of inter-group connectors among the plurality of groups of inter-group connectors includes a first connector portion extending from the battery unit of the first group to a third connector portion and a second connector portion extending from the third connector portion to the battery unit of the second group. And - The first connector portion extends inside the battery receptacle of the first group, the second connector portion extends inside the battery receptacle of the second group, and the third connector portion extends through the battery receptacles of the first group and the second group. The first connector portion includes a first plurality of spaced-apart first battery unit connectors interconnecting the battery unit of the first group and the third connector portion, and the first battery unit connectors include first sheet connectors extending inside the battery receptacle of the first group. The second connector portion includes a second plurality of spaced-apart second battery unit connectors interconnecting the battery unit of the second group and the third connector portion, and the second battery unit connectors include second sheet connectors extending inside the battery receptacle of the first group. The battery module according to claim 1. **Claim 10** The third connector portion includes a third sheet connector or a plurality of third sheet connector portions that interconnect the first connector portion and the second connector portion, the battery module according to claim 9.

11. The first connector portion extends to physically and electrically connect a battery terminal of a first polarity of the first group of battery units to the third connector portion, and the second connector portion extends to physically and electrically connect the third connector portion to a battery terminal of a second polarity of the second group of battery units, the first and the second polarities being opposite electrical polarities, the battery module according to claim 9.

12. A battery unit includes a first electrical terminal of a first electrical polarity, a second electrical terminal of a second electrical polarity opposite to the first electrical polarity, and a battery body extending in an axial direction and physically interconnecting the first electrical terminal and the second electrical terminal, the inter-group connector being thermally connected to the battery bodies of the plurality of battery units of the first group of battery units and the plurality of battery units of the second group of battery units, the battery module according to claim 9.

13. The first connector portion is thermally connected to the battery bodies of the plurality of battery units of the first group of battery units, the second connector portion is thermally connected to the battery bodies of the plurality of battery units of the second group of battery units, and / or the third connector portion is thermally connected to the battery bodies of the plurality of battery units of the first group of battery units and the second group of battery units, the battery module according to claim 12.

14. The first group of battery units and the first group of battery units are separated by a partition wall, the partition wall being a common wall shared by the first group of battery receptacles and the second group of battery receptacles, the battery module according to claim 9.

15. - The first connector portion includes N spaced sheet conductors arranged in a first array extending in a first column direction, and the connector portion of the inter-group connector includes M spaced sheet conductors arranged in a second array extending in a second column direction which is a column direction parallel to the first column direction, where N and M are natural numbers greater than 1, and - the N spaced sheet conductors and the M spaced sheet conductors are alternately arranged along the first column direction. The battery module according to claim 9.

16. The battery receptacles of the first group and the battery receptacles of the second group are in contact, and the inter-column connector is an inter-group connector extending through both the battery receptacles of the first group and the battery receptacles of the second group. The battery module according to claim 1.

17. The battery receptacle is configured as a receptacle cell and includes an outer peripheral wall surrounding a battery unit held within the receptacle cell. The outer peripheral wall includes a shared wall portion shared among a plurality of receptacle cells, and the inter-battery connector extends through the shared wall portion. The battery module according to any one of claims 1 to 16.

18. The outer peripheral wall is shared by 3 to 7 receptacle cells. The battery module according to claim 17.

19. A slit having an opening end is formed in the shared wall portion, and the inter-battery connector extends in contact from one receptacle cell to the other receptacle cell through the slit. The battery module according to claim 17 or 18.

20. The battery units of the first group have battery terminals of a first polarity connected to the inter-group connector, and the battery units of the second group have battery terminals of a second polarity connected to the inter-group connector. The first polarity and the second polarity are opposite electrical polarities. The battery module according to any one of claims 1 to 19.

21. The battery receptacles of the first group form a first receptacle row, and the battery receptacles of the second group form a second receptacle row parallel to the first receptacle row, the battery module according to any one of claims 1 to 20.

22. A power supply device comprising the battery module according to any one of claims 1 to 21, or a plurality of battery modules electrically interconnected, each battery module of the plurality of battery modules being the battery module according to any one of claims 1 to 21, the battery module or the plurality of battery modules being held in a main housing.

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