High voltage junction box for battery packs

Abstract

The battery pack assembly for an electric aircraft includes a battery pack including a battery pack housing and one or more battery cells. The battery pack assembly further includes a junction box including a junction box housing including a base wall, four side walls, and an open end. The battery management unit, at least one fuse, and at least one switch may be mounted to the base wall. Furthermore, the four side walls of the junction box housing are secured to the battery pack housing.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This disclosure claims priority to and benefit of U.S. Provisional Application No. 63 / 383,660, filed November 14, 2022, entitled "Systems and Methods for Improved Battery Assemblies for eVTOL Aircraft" (Attorney Docket No. 16163.6005-00000), the contents of which are incorporated herein in their entirety for all purposes. [Technical Field]

[0002] The present disclosure relates generally to the field of powered airborne vehicles. More specifically, but not by way of limitation, the present disclosure relates to innovations in aircraft using electric propulsion systems. Certain aspects of the present disclosure generally relate to high voltage power supply (HVPS) systems and battery assemblies used in airborne vehicles. Summary of the Invention

[0003] An embodiment of the present disclosure provides a battery pack assembly including a battery pack having a battery pack housing and one or more battery cells. The battery pack assembly further includes a junction box having a junction box housing including a base wall, four side walls, and an open end. A battery management unit, at least one fuse, and at least one switch may be attached to the base wall. Furthermore, the four side walls of the junction box housing are fixed to the battery pack housing.

[0004] Further, an embodiment of the present disclosure provides an aircraft wing including a battery pack including a battery pack housing and one or more battery cells. The aircraft wing further includes a junction box including a junction box housing including a base wall, four side walls, and an open end. A battery management unit, at least one fuse, and at least one switch may be attached to the base wall. Furthermore, the four side walls of the junction box housing are fixed to the battery pack housing. [Brief explanation of the drawings]

[0005] [Figure 1a] 1 illustrates an exemplary eVTOL aircraft consistent with embodiments of the present disclosure. [Figure 1b] 1 illustrates a diagram of a high voltage distribution system for an eVTOL aircraft, consistent with an embodiment of the present disclosure. [Figure 2a] 1 illustrates a circuit diagram of a high voltage junction box (HVJB) consistent with an embodiment of the present disclosure. [Figure 2b] 1 illustrates a diagram of a high voltage junction box (HVJB) consistent with an embodiment of the present disclosure. [Figure 3a] 1 illustrates a battery pack housing consistent with an embodiment of the present disclosure. [Figure 3b] 1 illustrates a high voltage junction box (HVJB) component consistent with an embodiment of the present disclosure. [Figure 3c] 1 illustrates an exploded view of a battery pack consistent with an embodiment of the present disclosure. [Figure 4] 1 illustrates a cross-sectional view of an aircraft wing having a battery pack installed within the wing, consistent with an embodiment of the present disclosure. [Figure 5] 1 illustrates a home system consistent with an embodiment of the present disclosure. [Figure 6] 1 illustrates a home charging system consistent with an embodiment of the present disclosure. [Figure 7] 1 illustrates an electric vehicle consistent with an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0006] The present disclosure primarily addresses components of electric vertical take-off and landing (eVTOL) aircraft for use in non-traditional aircraft. For example, an eVTOL aircraft of the present disclosure may be intended for frequent (e.g., more than 50 flights per workday), short-duration flights (e.g., less than 100 miles per flight) in and out of densely populated areas. The aircraft may be intended to carry four to six passengers or commuters who expect a low-noise and low-vibration experience. Therefore, it may be desirable for the components to be configured and designed to withstand frequent use without wear, to generate less heat and vibration, and for the aircraft to include mechanisms for effectively controlling and managing the heat or vibration generated by the components. Furthermore, some of these aircraft may be intended to operate in close proximity to each other over congested metropolitan areas. Therefore, it may be desirable for the components to be configured and designed to generate low levels of noise both inside and outside the aircraft and to have various safety and backup mechanisms. For example, for safety reasons, it may be desirable for an aircraft to be propelled by a distributed propulsion system, avoiding the risk of a single point of failure, and capable of conventional takeoff and landing on runways. Furthermore, it may be desirable for an aircraft to be able to safely take off and land vertically from relatively restricted spaces (e.g., vertical takeoff and landing airports, parking lots, or private roads) while transporting commuters with four to six passengers or accompanying baggage, as compared to conventional airport runways. These usage requirements may impose design constraints on the size, weight, and operational efficiency (e.g., drag, energy use) of the aircraft, which may affect the design and configuration of aircraft components.

[0007] The disclosed embodiments provide new and improved configurations of aircraft components not observed in conventional aircraft and / or identified design criteria for components that differ from conventional aircraft components. Such alternative configurations and design criteria have resulted in the disclosed embodiments herein for various configurations and designs of eVTOL aircraft components, in combination to address shortcomings and challenges of conventional components.

[0008] In some embodiments, the disclosed eVTOL aircraft may be designed to be capable of both vertical and conventional takeoff and landing with a distributed electric propulsion system that enables vertical flight, forward flight, and transition. Thrust may be generated by supplying high-voltage power to the distributed electric propulsion system's electric engines, each of which may convert the high-voltage power into mechanical shaft power for rotating a propeller. The embodiments disclosed herein may involve optimizing the energy density of the electric propulsion system. The embodiments may include an electric engine connected to an onboard power source, which may include a device capable of storing energy, such as a battery or capacitor, or one or more systems for harnessing or generating electricity, such as a fuel-powered generator or a solar panel array. Some disclosed embodiments provide for reduced component weight and space within the aircraft, thereby increasing the aircraft's efficiency and performance. Focusing on safety in passenger transportation, the disclosed embodiments implement new and improved safety protocols and system redundancies in the event of a failure to minimize any single point of failure in the aircraft's propulsion system. Some disclosed embodiments also provide new and improved approaches to meeting aviation and transportation laws and regulations.

[0009] Aircraft battery cell stacks may experience gradual degradation of battery characteristics and may become unusable onboard the aircraft over time. Typical parameters indicative of this degradation are a reduction in energy storage capacity below a threshold, an increase in temperature rise under conditions of higher stress (current, power) encountered in aircraft use, an increase in battery internal resistance / impedance, and a reduction in power delivery capacity to levels below the requirements of the aircraft's host devices. However, even if the battery cell stack is unusable onboard the aircraft, it may remain useful in other secondary applications. Meanwhile, the high-voltage junction box associated with the battery cell stack may still be usable onboard the aircraft.

[0010] Embodiments of the present disclosure may provide easy connection and disconnection between the battery cell stack and the high voltage junction box (HVJB) and between the battery cell stack and other components of the aircraft. Thus, the battery cell stack may be easily removed and installed in a secondary application. Furthermore, the battery cell stack may be designed in a manner that ensures it is compatible in the secondary application.

[0011] Aircraft battery junction boxes may also deteriorate and become unusable in aircraft over time. However, the junction boxes may still be useful in other secondary applications. Embodiments of the present disclosure may provide easy connection and disconnection between battery cell stacks and high-voltage junction boxes (HVJBs), and between the HVJBs and other components of the aircraft. Thus, the HVJBs may be easily removed and installed in secondary applications. Furthermore, the HVJBs may be designed in a manner that ensures they are compatible in secondary applications.

[0012] FIG. 1A illustrates an exemplary eVTOL aircraft consistent with embodiments of the present disclosure. As shown in FIG. 1A, in some embodiments, the distributed electric propulsion system of the eVTOL aircraft 100 may include twelve electric engines 110, which may be mounted on forward and aft booms of the aircraft's 100 wings. The forward electric engine 110 may be tiltable during flight between a horizontally oriented position (e.g., to generate forward thrust) and a vertically oriented position (e.g., to generate vertical lift). The forward electric engine 110 may be of a clockwise or counterclockwise type relative to the direction of propeller rotation. The aft electric engine 110 may be fixed in a vertically oriented position (e.g., to generate vertical lift) and may also be of a clockwise or counterclockwise type relative to the direction of propeller rotation.

[0013] The aircraft 100 may have various combinations of forward and aft electric engines 110. For example, in some embodiments, the aircraft 100 may have six forward electric engines 110 and six aft electric engines 110. In some other embodiments, the aircraft 100 may include four forward electric engines 110 and four aft electric engines 110, or any other combination of forward engines 110 and aft engines 110. In some other embodiments, the number of forward electric engines and aft electric engines is not equal.

[0014] In some embodiments, for vertical takeoff and landing (VTOL) missions, the forward electric engine 110 and the aft electric engine 110 may provide vertical thrust during takeoff and landing. During flight phases when the aircraft 100 is in forward flight mode, the forward electric engine 110 may provide horizontal thrust, while the propeller of the aft electric engine 110 may be stowed in a fixed position to minimize drag. The aft electric engine 110 may be actively stowed with position monitoring.

[0015] In some embodiments, for conventional takeoff and landing (CTOL) missions, the forward electric engine 110 may provide horizontal thrust for fixed-wing takeoff, cruise, and landing. In some embodiments, the aft electric engine 110 need not be used to generate thrust during CTOL missions, and the aft propeller may be stowed in place.

[0016] Transition from vertical flight to forward flight and vice versa can be achieved via a tilt propeller subsystem that can redirect thrust between a primarily vertical direction during vertical flight mode to a primarily horizontal direction during forward flight mode. A variable pitch mechanism can vary the collective angle of the propeller hub assembly blades of the forward electric engine for operation during hover, transition, and cruise phases.

[0017] The tilting propeller system may include a linear or rotary actuator for changing the orientation of the propulsion system during operation. In some embodiments, the pitch of the propulsion system may be changed as a function of the orientation of the propulsion system. In some embodiments, the rotary actuator may include a motor, an inverter, and a gearbox. In some embodiments, the gearbox may include various types of gears that interface to provide a gear reduction that can orient the propulsion system. In some embodiments, the tilting propeller system may include a redundant configuration in which multiple motors, inverters, and gearboxes are present and interface using gears. In some embodiments, a configuration utilizing multiple motors, gearboxes, and inverters may allow a failed portion of the redundant configuration to be driven by a motor, inverter, and gearbox of another portion of the configuration. In some embodiments, the gearbox configuration may also allow the tilting propeller system to maintain the orientation of the propulsion system with or without the aid of additional power provided by the system.

[0018] In some embodiments, the electric engine 110 may be housed in or connected to the boom of the aircraft 100 and may include a motor, an inverter, and a gearbox. In some embodiments, the motor, inverter, and gearbox may be interfaced such that they share a central axis. In some embodiments, torque due to the motor may be sent to the gearbox, away from the propeller of the propulsion system. In some embodiments, the gearbox may provide a gear reduction and then send torque back to the propeller via the main shaft through bearings positioned inside the motor. In some embodiments, the inverter may be mounted to the rear of the gearbox so that the main shaft does not move past the inverter when outputting torque to the propeller.

[0019] As shown in FIG. 1A, the aircraft 100 may be configured with a distributed electric propulsion system that enables vertical flight, forward flight, and transition. The six forward electric engines 110 (numbered 1 through 6 from left to right) tilt controllable pitch propellers to achieve vertical takeoff and landing, transition flight, and full fixed-wing flight. The six aft electric engines 110 (numbered 7 through 12 from left to right) are equipped with fixed pitch propellers that operate during vertical takeoff and landing and transition, and are stowed within a minimum drag position for conventional flight. Flight control is an integrated fly-by-wire system featuring envelope protection and structural load limiting capabilities. The aircraft 100 is equipped with advanced cockpit avionics, a flight management system, and sensors necessary to support intended operation and system function.

[0020] In some embodiments, the electric propulsion system (EPS) described herein may generate thrust by supplying high-voltage (HV) power to electric engines 110, which in turn convert the HV power into mechanical shaft power used to rotate propellers. As mentioned above, the aircraft 100 described herein may have multiple electric engines 110 boom-mounted forward and aft of the wings. The amount of thrust generated by each electric engine 110 may be controlled by torque commands from a flight control system (FCS) via a digital communication interface to each electric engine 110. Embodiments may include forward electric engines 110, which may be capable of changing their orientation, or cant. Additional embodiments include forward engines, which may be of a clockwise (CW) or counterclockwise (CCW) type. The forward electric engine propulsion subsystem may consist of a multi-blade adjustable pitch propeller as well as a variable pitch subsystem.

[0021] In some embodiments, aircraft 100 includes a high-voltage power supply (HVPS) system for providing high-voltage (HV) electrical power. The HVPS system is a source of electrical power on aircraft 100 and is configured to convert electrical power into mechanical rotating shaft power and distribute stored electrical energy to other systems on aircraft 100, including an electric propulsion system (EPS) for generating thrust. As shown in FIG. 1a, aircraft 100's HVPS system may include six battery packs 120 (numbered 1 through 6 from left to right) installed in battery bays in the wings of aircraft 100. In some embodiments, the six battery packs 120 may have the same design to simplify design, manufacturing, and logistics. The battery packs 120 may power one or more electric engines 110.

[0022] In some embodiments, a single battery pack 120 may be electrically connected to and power multiple electric engines 110. For example, in some embodiments, battery pack 120 may power electric engines 110 on either side of a longitudinal axis. In some embodiments, battery pack 120 may power electric engines 110 on either side of a horizontal axis. In some embodiments, as shown in FIG. 1a, battery pack 120 may power two diagonally opposed electric engines 110. For example, battery pack 1 may power electric engines 1 and 12. Battery pack 2 may power electric engines 5 and 8. Battery pack 3 may power electric engines 3 and 10. Battery pack 4 may power electric engines 4 and 9. Battery pack 5 may power electric engines 2 and 11. Battery pack 6 may power electric engines 6 and 7. Thus, upon loss of battery pack 120, impacts to roll or pitch moments may be reduced because the loss of lift is balanced. In some embodiments, battery pack 120 may power different arrangements of electric engines 110 to reduce roll, pitch, or yaw moments that may be caused by the loss of battery pack 120. For example, in some embodiments, battery pack 120 may be connected to electric engines 110 in any manner that balances lift and / or thrust across the longitudinal and horizontal axes of the aircraft.

[0023] Additionally, the HVPS system includes a cross-link 130 with fuses that allows pairing of two or more battery packs 120. Through the cross-link, power for the electric engine 110 can be shared between the paired battery packs 120. Thus, multiple battery packs 120 can simultaneously power multiple electric engines 110. This arrangement provides redundancy and avoids a single point of failure because each paired battery 120 can act as a backup for the other battery(ies). In the event of a battery pack 120 failure, one or more connected battery packs 120 can continue to power the electric engine 110 connected to the failed battery pack.

[0024] 1a, the pair of battery packs 120 may include two battery packs 120. In some embodiments, the pair of two battery packs 120 may power a total of four electric engines 110. For example, battery pack 1, which provides power to electric engines 1 and 12, may be cross-linked to battery pack 4, which provides power to electric engines 4 and 9. Battery pack 2, which provides power to electric engines 5 and 8, may be cross-linked to battery pack 5, which provides power to electric engines 2 and 11. Battery pack 3, which provides power to electric engines 3 and 10, may be cross-linked to battery pack 6, which provides power to electric engines 6 and 7.

[0025] In some embodiments, three or more battery packs 120 may be cross-linked together. For example, in some embodiments, three battery packs 120 may be cross-linked. Thus, in some embodiments, three battery packs 120 may power six electric engines 110. In some embodiments, four battery packs 120 may be cross-linked. Thus, in some embodiments, four battery packs 120 may power eight electric engines 110. In some embodiments, different arrangements of battery packs 120 and cross-links may be selected to optimally balance aircraft power needs, system redundancy, and fault tolerance.

[0026] FIG. 1b illustrates a diagram of a high-voltage power supply system for an eVTOL aircraft consistent with embodiments of the present disclosure. As shown in FIG. 1b, the eVTOL aircraft may include a battery assembly with electrically isolated battery pack units (e.g., 160, 162, and 164). Each battery pack unit may include a battery pack 120 cross-linked together, as described above. In some embodiments, the battery pack units may include battery packs 120 that ensure aircraft controllability is maintained upon loss of a battery pack unit. Thus, upon loss of a battery pack unit, the aircraft may still be controllable. In some embodiments, the battery pack units may include battery packs 120 that power electric engines 110 on either side of one or more axes of symmetry. Thus, upon loss of a battery pack unit, impacts to roll, pitch, or yaw moments may be reduced because the loss of lift and / or thrust is balanced. In some embodiments, the loss of power or reduction in power caused by a failure of a battery pack unit has a substantially symmetric effect with respect to the roll, pitch, and / or yaw of the aircraft (e.g., asymmetry of <±5%, <±10%, <±15%, <±20%, or <±25%). Additionally, in some embodiments, the battery pack unit may include battery packs 120 that reduce the amount of high-voltage wiring between the batteries.

[0027] In some embodiments, as shown in FIG. 1b, the HVPS system may include three electrically isolated battery pack units. For example, in some embodiments, battery pack unit 160 may include battery packs 1 and 4 that power electric engines 1, 4, 9, and 12. Battery pack unit 162 may include battery packs 2 and 5 that power electric engines 2, 5, 8, and 11. Battery pack unit 164 may include battery packs 3 and 6 that power electric engines 3, 6, 7, and 10. Thus, each battery pack unit may include two paired battery packs 120 that simultaneously power four electric engines 110. In the event of a failure of one battery pack 120 in a battery pack unit, the other paired battery pack 120 continues to power the four electric engines.

[0028] In some embodiments, each battery pack unit 160, 162, 164 may include a high-voltage bus for cross-linking the battery packs 120 within the battery pack unit. In some embodiments, the cross-link 130 connects two high-voltage channels, each supplying one or more electric engines 110. For example, in some embodiments, the cross-link 130 may be connected to the high-voltage channels of each battery pack before the channels split to supply power to multiple electric engines 110 (e.g., supplying power to two electric engines). The cross-link may further include a bus connecting the negative voltage channels.

[0029] In some embodiments, each cross link 130 may include at least one fuse for disconnecting the cross link in the event of a cross link failure. For example, fuses 131, 132, and 134 may be positioned on the cross link connections of the positive high voltage channels in battery pack units 160, 162, and 164. In some embodiments, fuses 150, 152, and 174 may be positioned on the cross link connections of the negative high voltage channels in battery pack units 160, 162, and 164. In some embodiments, the fuses may be pyrotechnical fuses. As described in further detail below, the battery management system of the connected battery pack 120 may determine a fault in the cross link, such as a short circuit or overcurrent condition, and trip one or more associated pyrotechnical fuse(s). Thus, the cross link can be disconnected, avoiding further damage to HVPS system components (e.g., electric engine, battery, EPUS). Furthermore, the electric engine 110 will still receive power from the paired battery pack 120 in the battery pack unit. For example, in the event of a cross-link failure, pyrotechnical fuses 131 and 150 may be tripped, but electric engines 1 and 12 still receive power from battery pack 1, and electric engines 4 and 9 still receive power from battery pack 4.

[0030] In some embodiments, the HVPS system may include load disconnection devices for disconnecting a portion of the HVPS circuitry upon a fault (e.g., a short circuit or overcurrent condition) of a downstream electric engine, downstream EPU, or other downstream distribution circuitry. In some embodiments, the load disconnection devices may be located directly upstream of the electric engines. For example, in some embodiments, load disconnection devices 109, 111, 112, and 113 may be located on the high-voltage channels powering engines 1, 12, 4, and 9, respectively. Load disconnection devices 114, 115, 116, and 117 may be located on the high-voltage channels supplying engines 2, 11, 5, and 8, respectively. Load disconnection devices 118, 119, 121, and 122 may be located on the high-voltage channels supplying engines 3, 10, 6, and 7, respectively.

[0031] In some embodiments, the load disconnection device is a pyrotechnical fuse. In the event of a failure of a downstream component, the pyrotechnical fuse may receive a signal (e.g., from the battery management system of the connected battery) and trip the fuse. Thus, the downstream component can be disconnected, and further damage to other equipment (e.g., the electric engine, the battery, the EPUS) can be avoided. Furthermore, the remaining electric engines 110 in the battery pack unit will still receive power from the connected battery packs 120. For example, in the event of a failure of a device or wiring downstream of the pyrotechnical fuse 109, the pyrotechnical fuse 109 may trip, but the electric engines 12, 4, and 9 will still receive power from the battery packs 1 and 4. Furthermore, in some embodiments, the load disconnection device may include a contactor, and the battery management system may instruct the contactor to disconnect the circuit. In some embodiments, both the contactor and the fuse may be used to provide additional redundancy, and the pyrotechnical fuse may act as a backup for the contactor.

[0032] In some embodiments, the HVPS system may include a high-voltage charging channel that allows all battery packs 120 to be charged from the same charging port. The high-voltage charging channel may include a charge disconnect device. In some embodiments, the charge disconnect device may be positioned downstream of the common charging bus on the positive charging side. For example, disconnect devices 140, 142, 144, 146, 148, and 150 may provide disconnection for battery packs 1, 4, 5, 2, 3, and 6, respectively. Similarly, in some embodiments, additional charge disconnect devices may be positioned on the negative charging side. For example, disconnect devices 141, 143, 145, 147, 149, and 151 may provide disconnection for battery packs 1, 4, 5, 2, 3, and 6, respectively.

[0033] In some embodiments, the charge disconnect device is a contactor, such as K4 positive and K4 negative in FIG. 2a. The charge contactor may function as a redundant measure to disconnect battery pack 120 from charging. As described in further detail below, battery pack 120 may report a charging problem to a charge control unit (CCU). For example, battery pack 120 may report a short circuit or overcurrent condition within battery pack 120 or within the high-voltage charging channel. In some embodiments, if the CCU fails to stop charging, battery pack 120 may instruct the charge contactor to disconnect the charging channel. In some embodiments, battery pack 120 may automatically instruct the charge contactor to disconnect the charging channel without waiting for the CCU to fail. In some embodiments, after instructing the CCU to stop charging and / or disconnecting the battery pack 120 that detected a charging problem, battery pack 120 and / or the CCU may instruct other battery packs 120 to disconnect from the charging channel. Disconnecting battery pack 120 when a charging problem is detected can avoid damage to HVPS components.

[0034] FIG. 2a illustrates a circuit diagram of a high-voltage junction box (HVJB) consistent with embodiments of the present disclosure. The HVJB 222 may be electrically connected to the HV loads 210 to provide high-voltage power. Specifically, a DC / DC converter and a storage element BT1 (e.g., parallel and series connected battery cells) in a battery management system (BMS) may be used to provide the high-voltage power. The DC / DC converter and the storage element BT1 are connected to each of the HV loads 210 through a combination of pre-charge resistor(s) (e.g., resistor R1) or current-sensing resistor(s) (e.g., resistors R2-R6), switching devices K1-K5 (e.g., HV contactors), and active and passive fuses (e.g., F1-F7) for protection against various fault conditions (e.g., overcurrent, short circuit, etc.). In some embodiments, the fuses F1-F7 may be one or more of the fuses described above with respect to FIG. 1b. For example, in some embodiments, fuses F2 EE1, F3 EE2, and F4 Xlink may correspond to fuses 109, 111, and 131 detailed in FIG. 1b.

[0035] Fuse F1 may be a pack fuse for disconnecting a failed battery pack 120 from the rest of the HVPS system. In some embodiments, F1 may be a pyrotechnical fuse. Upon failure of battery pack 120, pyrotechnical fuse F1 may receive a signal (e.g., from an associated battery management system) and trip fuse F1. Thus, further damage to other equipment (e.g., electric engine, EPU, connected battery packs) may be avoided. Furthermore, electric engine 110 will still receive power from the paired battery pack 120 in the battery pack unit. For example, upon battery pack failure, pyrotechnical fuse F1 of battery pack 1 may trip, but electric engines 1, 12, 4, and 9 may still receive power from battery pack 4.

[0036] FIG. 2b illustrates a diagram of a high-voltage junction box 222 (HVJB) consistent with embodiments of the present disclosure. In some embodiments, each battery pack 120 contains a battery management system (BMS 270) housed within the HV distribution unit 211 and the HVJB 222. The battery management system 270 may include one or more processors, microprocessors, and / or controllers. The BMS 270 may be configured to monitor voltage, temperature, current, and isolation resistance. The BMS 270 may control battery pack contactors and pyrotechnical fuses to protect against fault conditions. As described in further detail below, the BMS 270 may communicate with various systems within and outside the HVJB 222. The BMS 270 may include a battery management unit (BMU 271) that may receive voltage, current, resistance, and temperature sensing signals from the cell stack assembly 224 and / or the HV distribution unit 211.

[0037] The BMS 270 may further include a cell management unit (CMU) 272 to monitor the voltage of each set of parallel cells connected in series within the cell block. The CMU 272 may also monitor the temperature and current of the cell block. In some embodiments, the CMU 272 obtains measurements for all cell groups within the battery pack 120 and communicates the measurements to the BMU 271 via isoSPI in a daisy-chain configuration. In some embodiments, the CMU 272 does not have an active management or control mechanism for the cells within the cell block, but the CMU 272 can perform passive cell balancing of the series cell block when commanded by the BMU 271. The BMU system architecture may provide the flexibility to command passive balancing both on the ground and in the air.

[0038] The BMU 271 may monitor the output current for each connected load. The BMU 271 may be internally powered by the battery cell stack assembly 224 and may continuously monitor the status of the batteries, even when the batteries are not installed in the aircraft 100. By monitoring battery pack 120, cell block, and cell group parameters, the BMU can protect against conditions that adversely affect safety or performance, such as overvoltage, undervoltage, overheating, underheating, loss of electrical insulation, short circuits, and overcurrent. The diagnostic capabilities of the BMU 271 enable fault detection and isolation through built-in tests (BITs). Additionally, the BMU 271 performs calculations of the battery pack 120's state of charge (SOC), state of health (SOH), fault conditions (e.g., short circuit or overcurrent), state of power (SOP), state of energy (SOE), and state of temperature (SOT). The BMU 271 also controls and monitors bus precharge, provides fuse and contactor commands, and communicates with various systems within and outside the HVJB 222. Additionally, the BMU 271 may communicate with the aircraft switches 250 and the flight control system 230 and may modify operation based on commands received.

[0039] The HV distribution unit 211 within the HVJB 222 may house an HV contactor 212 and a combination of active and passive fuses (e.g., pyrotechnical fuses 213 and 214) to protect against overcurrent and short-circuit conditions. In some embodiments, the contactor 212 may correspond to one or more of the switching devices K1-K5 (e.g., HV contactors) detailed in FIG. 2a. Similarly, the pyrotechnical fuses 213 and 214 may correspond to one or more fuses F1-F7 detailed in FIG. 2a. The HV distribution unit 211 may further include (or receive information from) current sensors (e.g., resistors R2-R6, Hall effect sensors, shunt current sensors, or other sensors).

[0040] In some embodiments, BMU 271 may include a pyrotechnical fuse redundant trigger board (PRT 280). BMU 271 may detect fault events and send command signals to PRT 280 for corresponding pyrotechnical fuse drivers to trip fuses. For example, in some embodiments, HV distribution unit 211 may receive sensor signals from current sensors (e.g., resistors R3-R6) and provide BMU 271 with information about the condition (e.g., voltage, current, or temperature) of connected loads at a point in the HVPS system. Based on the received information, BMU 271 may determine a fault condition (e.g., because a value is outside a predetermined range) and send a command to PRT 280 to trip the associated pyrotechnical fuse. Thus, the fault condition can be disconnected from the rest of the HVPS circuit, protecting the remaining devices and wiring. In some embodiments, BMU 271 may monitor the sensors directly instead of receiving information through HV distribution unit 211.

[0041] In some embodiments, battery packs 120 may communicate with each other, for example, through BMS 270. Battery packs 120 may use information about the status of one or more paired battery packs 120 within a battery pack unit to help determine if an overcurrent condition has occurred. For example, battery pack 120 may determine an expected operating range (e.g., voltage, current, etc.) based on the battery pack status and the communication status of battery packs 120 within a battery pack unit. In some embodiments, HVJB 222 may further provide a redundant active trigger board configured to enable a pyrofuse driver to activate one or more pyrotechnical fuses when BMS 270 fails to enable the pyrofuse driver. See U.S. Pat. No. 11,710,957, incorporated by reference.

[0042] The control MCU (CCU 263) in the charge port assembly 262 interfaces with the external battery charger and may communicate with the BMU 271 on the battery pack 120. This unit may be a hardware device such as a computer, processor, or microprocessor. In some embodiments, the CCU 263 may be a single PCBA with one microcontroller that manages the overall power delivery to each battery pack 120 during charging. As shown in FIG. 2, the CCU 263 may perform the handshake between the ground charging subsystem 274 and the BMU 271 and command the BMU 271 to open and close contactors 212, such as contactors K4 positive and K4 negative detailed in FIG. 2a. The CCU 263 may perform active detection and protection functions for overvoltage protection. The BMU 271 in each battery pack 120 retains complete control and may continuously monitor its battery pack 120 during charging operations.

[0043] FIG. 3a illustrates a housing of a battery pack 120 consistent with embodiments of the present disclosure. As shown, the battery pack 120 includes an HVJB 222 and a cell stack assembly 224. The cell stack assembly 224 includes a housing 370 having a base wall 370a and a side wall 370b. The housing 370 may be made of a plastic material, a thermoplastic composite material, a metal, or a metal alloy. Similarly, the HVJB 222 includes a housing 380 having a base wall 380a and four side walls 380b. The housing 380 may be made of a plastic material, a thermoplastic composite material, a metal, or a metal alloy. In some embodiments, the side wall 380b may include a flange 380c opposite the base wall 380a. In some embodiments, the flange 380c may be continuous along the periphery of the HVJB housing 380. In some embodiments, the base wall 380a, the side walls 380b, and / or the flange 380c are formed from a single, continuous sheet of material. While in other embodiments, they are separate pieces that are fastened together.

[0044] As shown, HVJB housing 380 is secured to cell stack assembly housing 370. In some embodiments, flanged sidewall 380c is screwed, bolted, fastened, or otherwise connected to housing 370. Thus, all cell stack assembly 224 and HVJB 222 components are enclosed and protected. Connectors such as 390a, 390b, and 390c may be secured to sidewall 380b of HVJB housing 380. Connector 390 may provide high-voltage and low-voltage connections to HVJB 222. The low-voltage connector may enable communication between BMS 270 and other aircraft components. As noted with reference to FIG. 2b, low-voltage connector 390 may enable communication between BMS 270 and flight control system 230, between BMS 270 and aircraft switch 250, and / or between BMS 270 and charge port assembly 262. Further, in some embodiments, when the inverters (inv1, inv2) are within the HVJB 222 and the associated controller is external to the HVJB 222, the low-voltage connectors 390 enable the controller to send commands to the inverters. Thus, in some embodiments, one, two, three, four, or five low-voltage connectors may be provided. However, any different number of low-voltage connectors may be provided to meet the needs of the HVJB 222. Similarly, with reference to FIGS. 2a-2b, the high-voltage connectors may enable high-voltage power channels for powering the electric engine 110, cross-links between battery packs, and tilt actuators. Furthermore, one or more high-voltage connectors 390 may enable charging of the cell stack assembly 224. Thus, in some embodiments, one, two, three, or more high-voltage battery connectors may be provided to meet the needs of the battery pack 120.

[0045] FIG. 3b illustrates HVJB 222 components consistent with embodiments of the present disclosure. As shown, the components of HVJB 222 are mounted on base wall 380a. Base wall 380a includes associated components such as BMS 270 and battery management unit 271. Additionally, base wall 380a includes HV distribution 211 components such as contactors, pyrotechnical fuses, and / or other fuses. As detailed with reference to FIG. 2a, base wall 380a may include any and all converters, capacitors, resistors, fuses, contactors, sensors, inverters, and inverter control components included within HVJB 222. In some embodiments, all devices and circuits for HVJB 222 may be mounted on base wall 380a.

[0046] Base wall 380a may include connection points for providing current transfer between cell stack assembly 224, HV distribution 211 components, and HV load 210. In some embodiments, as described in further detail below, negative bus bar 334a may enable connection between HVJB 222 and the negative side of cell stack assembly 224. Positive bus bar 334b ​​may enable connection between HVJB 222 and the positive side of cell stack assembly 224. In other embodiments, electrical couplers, terminals, or other connection points may be provided to make these connections.

[0047] The base wall 380a may include a connection point for providing communication transfer between the cell stack assembly 224 and the BMS 270. In some embodiments, the connection point(s) may enable communication transfer between the BMU 271 and one or more cell management units (CMUs) 272, as described in further detail below. In some embodiments, the base wall 380a may include a single connection point 338b for all CMUs 272 to communicate with the BMU 271. In some embodiments, this connection point may be an electrical terminal, interface, and / or other type of connector. The BMU 271 may receive voltage, temperature, and current readings across the cell stack assembly 224 through this connection point. In some embodiments, the communication transfer may be through an isoSPI communication cable wired from the CMUs 272 to the BMU 271. The isoSPI communication cable may be attached to the positive or negative bus bar to facilitate manual connection of the cable, and the connection point may be an isoSPI interface.

[0048] The HV distribution system 211 may include high-voltage channels for supplying power to the HV loads 210. In some embodiments, the high-voltage channels are bus bars attached to the base wall 380a, while in other embodiments, the high-voltage channels may include cables or other types of high-voltage wiring. The high-voltage channels may be bolted, screwed, or otherwise secured to the base wall 380a. In some embodiments, the high-voltage channels may be secured at regular intervals. Similarly, resistors, switching devices, fuses, and inverters may be bolted, screwed, soldered, glued, or otherwise connected to the base wall 380a. The HV distribution 211 may be secured to the base wall 380a in any manner that allows for the removal of a cell stack assembly 224 from the HVJB 222 and the connection of a new cell stack assembly 224 to the HVJB 222 without interfering with the HV distribution 211.

[0049] Similarly, BMS 270 and related components may be secured to base wall 380a. BMS 270 may include multiple microcontrollers, processors, and / or microprocessors to receive information, perform calculations, and control high-voltage contactors and fuses. These controllers and / or processors may be mounted on one or more circuit boards that are bolted, screwed, soldered, or otherwise connected to base wall 380a. BMS 270 may be secured to base wall 380a in any manner that allows cell stack assembly 224 to be removed from HVJB 222 and a new cell stack assembly 224 to be connected to HVJB 222 without interfering with BMS 270.

[0050] FIG. 3c illustrates an exploded view of battery pack 120 consistent with embodiments of the present disclosure. As shown, HVJB housing 380 may include a cutout 320a in base wall 380a to allow for manual connection and disconnection of high voltage and communication connections between HVJB 222 and cell stack assembly 224. In some embodiments, there may be three cutouts 320a. The first cutout 320a may provide for manual connection and disconnection of HVJB negative bus bar 334a to cell stack assembly negative bus bar 334c. The second cutout 320a may provide for manual connection and disconnection of HVJB positive bus bar 334b ​​to cell stack assembly positive bus bar 334d. The third cutout 320a may provide for manual connection and disconnection of communication cable 338a to communication interface 338b. In some embodiments, two cutouts 320a may be present, and the cutout for the negative bus bars (334a, 334c) may also serve as the cutout for the communication cable connection (338a, 338b). In some embodiments, two cutouts may be present, and the connection between the positive bars (334b, 334d) may also serve as the cutout for the communication cable connection (338a, 338b). In some embodiments, all connections may share a single cutout 320a. The cutout(s) 320a may be sized to allow for manual connection and disconnection. In some embodiments, the cutouts may be sized large enough to allow for manual connection and disconnection, for example, based on manual access attempts. Thus, the integrity of the HVJB housing 380 may be maintained.

[0051] An access panel cover 320b can cover the cutout 320a. The access panel cover 320b can be bolted, screwed, or otherwise secured to the HVJB housing 380. In some embodiments, the access panel cover 320b can be a recessed panel, a plug, a hinged door, a sliding insert, or any other device that covers the cutout 320a. In some embodiments, the access panel cover 320b can be made of the same material as the HVJB housing 380, while in other embodiments, different material(s) can be used.

[0052] The battery cell stack housing 370 may also have a cutout portion 370a. In some embodiments, the cutout portion 370a is approximately (e.g., within 5%, 10%, 15%, 20%) the same area as the open side of the HVJB housing 380. In some embodiments, the cutout portion 370a is the same size as the open side of the HVJB housing 380. Thus, the HVJB 222 is fully encapsulated, but the encapsulation material may be reduced. In other embodiments, the cutout portion 370a may be smaller or may consist of multiple cutout portions. The cutout portion 370a provides a means for manual connection of the negative bus bars (334a, 334c), communication cables (338a, 338b), and positive bus bars (334b, 334d). The pre-formed potting material 336 may provide resistance to shock and vibration and help protect the battery pack cell assemblies 224 from moisture, solvents, and corrosive agents. Additional barrier material (e.g., insulating material) may be installed between the potting material 336 and the HVJB 222. The barrier material may have one or more cutouts for the negative bus bar 334c, the communication cable 338a, and the positive bus bar 334d.

[0053] The current collector assembly 324 combines the power of the various battery pack cells into a positive busbar 334d and a negative busbar 334c. In some embodiments, the current collector assembly 334 can be a flexible circuit current collector assembly with integrated sensing components that are bonded and laser welded. In some embodiments, the sensing components can be integrated directly into a flexible printed circuit board that is part of the current collector assembly 334, without the need for bonding or welding. The current collector assembly 334 can include multiple columns of integrated cells and components on one central cell holder. In some embodiments, the current collector assembly 334 can provide a single component that integrates the current collectors and sensing wires through lamination to implement a laminated busbar with an integrated sensing layer for sensing the voltage and / or temperature of a corresponding group of cells or a corresponding block of cells. For example, in each column, voltage and temperature sensing wires can be arranged by lamination and configured to collect a voltage trace at one end of the column.

[0054] In some embodiments, the current collector assembly 324 is bolted and welded to the battery pack bus bars used to connect the positive and negative ends of the cell stack assembly 224 to the HVJB 222. In some embodiments, the current collector assembly 324 is made of nickel-plated copper conductors that attach to individual battery cells to form electrical paths for the desired cell combination. For example, the current collector assembly 324 may have a 210S7P pack architecture that houses a series of cell groups, each cell group housing parallel cells. The current collector assembly 324 may integrate both voltage and temperature sensing wires for each cell block.

[0055] The battery pack cells 326 may include high-power battery cells. In some embodiments, the battery pack cells 326 are lithium-ion battery cells. In some embodiments, the battery pack cell assembly has 10 kWh to 40 kWh for each battery pack and / or 60 to 240 kWh across all battery packs. The cells may be installed in cell holders 328 to secure the cells in place. A heat exchanger 330 may be secured to the cell holders 328. The heat exchanger 330 may be bonded using a thermally conductive adhesive (e.g., a flame-retardant acrylic adhesive). The thermally conductive adhesive may be used to transfer heat generated by the cells to the heat exchanger 330. The heat exchanger 330 may allow for regulation of the temperature within the battery pack 120 using a cooling fluid (e.g., water ethylene glycol (WEG)) for heating and cooling. The heat exchanger 330 may include any number and orientation of channels to allow coolant to flow through the heat exchanger 330. The heat exchanger 330 may be sized to support the required heating or cooling needs while operating within nominal pressure and flow conditions. In some embodiments, the battery pack housing 370 may include a coupler or other disconnect device to provide for easy removal of the battery pack 120 (or battery cell stack assembly 224) from the cooling lines and easy reinstallation of a new battery pack 120 (or battery cell stack assembly 224). In some embodiments, the cooling lines may be secured to the frame of the aircraft to allow easy removal and reinstallation of the battery pack 120 (or battery cell stack assembly 224). In some embodiments, heat exchanger stiffeners 332 may be provided to help the heat exchanger 330 maintain its shape and connection to the battery cells 326.

[0056] The battery crash core 342 may be installed to protect the battery pack 120 in the event of a crash. The crash core 342 may absorb the impact of the crash to maintain the integrity of the battery housing and components. In some embodiments, the crash core may be made of aluminum honeycomb material and / or any other material capable of absorbing impact. The crash core may be selected with sufficient rigidity to avoid the addition of other reinforcement devices for the battery pack. In some embodiments, the battery pack 120 may be installed with the HVJB 222 toward the bottom of the aircraft wing and the battery cell stack assembly 224 toward the top of the aircraft wing relative to the HVJB 222, such as when the aircraft is in a normal orientation. The normal orientation may include any aircraft orientation in which the pitch and roll angles are within 90 degrees of the pitch and roll angles of the aircraft when the aircraft is grounded, for example, the orientation of the aircraft when the aircraft is grounded. In this orientation, the crash core 342 may be installed on the HVJB housing 380. In some embodiments, the battery pack 120 may be installed with the battery cell stack assembly 224 toward the bottom of the aircraft wing and the HVJB 222 toward the top of the aircraft wing relative to the battery cell stack assembly 224 when the aircraft is in its normal orientation. In this orientation, the collision core 342 may be installed on the cell stack housing 370 and / or on the heat exchanger stiffener 332. In some embodiments, installing the collision core 342 on the cell stack housing 370 and / or on the heat exchanger stiffener 332 provides a larger surface area for absorbing impact. The collision core may be sized to be substantially the same size (e.g., within 2%, 5%, 10%) as the surface of the battery pack 120 closest to the bottom of the aircraft wing when the aircraft is in normal operation.

[0057] 4 illustrates a cross-sectional view of an aircraft wing 410 with a battery pack 120 installed within the wing 410 consistent with embodiments of the present disclosure. The battery pack 120 may be secured to the aircraft wing 410 by a bracket, a channel, a beam, or any other type of mounting system. In some embodiments, the mounting system may secure the battery pack 120 to a rib and / or a spar inside the aircraft wing 410. In some embodiments, the battery pack 120 may be installed within the aircraft wing 410 such that both the junction box base wall 380a and the housing base wall 370a are substantially parallel (e.g., at 5-10 degrees) to the top and bottom surfaces of the aircraft wing.

[0058] In some embodiments, the battery packs 120 may be installed toward the front or rear of the aircraft wing 410 to allow access by aircraft maintenance staff. In some embodiments, the battery packs 120 may be positioned within the aircraft wing 410 to accommodate a desired center of gravity of the aircraft. For example, the battery packs 120 may be installed toward the rear of the aircraft wing 410 to move the center of gravity aft, and the battery packs 120 may be installed toward the front of the aircraft wing to move the center of gravity forward. In some embodiments, the sides of the battery packs 120 may be substantially parallel (e.g., between 5 and 20 degrees) to the longitudinal axis of the aircraft. In some embodiments, the sides of the battery packs 120 may be substantially parallel (e.g., within 5 to 20 degrees) to the leading edge of the aircraft wing 410 or the trailing edge of the aircraft wing 410. In some embodiments, the battery packs 120 may be evenly spaced across the wing, while in other embodiments, they may be spaced as needed to accommodate a desired center of gravity of the aircraft wing 410. In some embodiments, one or more battery packs 120 may be within the fuselage of the aircraft.

[0059] In some embodiments, the aircraft wing 410 may include an access panel 420 that allows for manual electrical connection and disconnection between the HVJB 222 and the battery cell stack assembly 224. For example, the access panel 420 may allow for connection and disconnection of high-voltage bus bars and communication cables running between the HVJB 222 and the cell stack 224, as described above with reference to FIGS. 3b-3c. In some embodiments, the cutout and associated access panel 420 may be sized large enough to allow for manual connection and disconnection, for example, based on manual access attempts. For example, in some embodiments, the access panel 420 may be 2.5 inches by 2.5 inches to 5 inches by 5 inches (approximately 0.0635 meters by 0.0635 meters to approximately 0.1270 meters by 0.1270 meters), or any range therebetween. In some embodiments, the access panel may be 5 to 20% of the upper surface area of ​​the wing. In other embodiments, the access panels 420 may be larger to allow for other service and maintenance of the battery packs 120 and / or removal of various components. For example, the access panels may be slightly wider (5 inches to 12 inches, or approximately 0.1270 meters to 0.3048 meters) than the junction box and / or battery pack cell stack. Each battery pack 120 in the aircraft wing 410 may be associated with one or more access panels 420. In some embodiments, the number of access panels 420 for each battery pack 120 matches the number of cutouts 320a in the HVJB enclosure 380.

[0060] In some embodiments, the access panel 420 may be a recessed panel, a plug, a hinged door, a sliding insert, or any other device that covers a cutout. In some embodiments, the access panel may be a recessed access panel installed flush with the skin of the aircraft. In some embodiments, the access panel may be covered with the same material as the aircraft skin or with another aerodynamic material to minimize drag losses on the aircraft wing 410.

[0061] 5-7 illustrate secondary systems that may incorporate the battery pack 120 and / or the battery cell stack assembly 224. As described above, the battery pack 120 experiences a gradual degradation of battery characteristics and becomes unusable in an aircraft over time. Typical parameters indicative of this degradation include a reduction in energy storage capacity below a threshold, an increase in temperature rise under conditions of higher stress (current, power) encountered in aircraft use, an increase in the internal resistance / impedance of the battery or battery system, and a reduction in power delivery capacity to a level below the requirements of the aircraft's host devices. However, the battery pack 120 and / or the battery cell stack assembly 224 may continue to be useful in other secondary applications, including, but not limited to, home power supply systems, local energy storage systems, vehicle systems, and backup power systems, including bulk power grid and home power grid backup systems.

[0062] In some embodiments, the battery pack cell stack assembly 224 originally used in the aircraft can be reused for secondary use with high reliability. In some embodiments, the high-voltage battery cell stack assembly 224 can be originally designed to be easily removed. As described above, the cell stack assembly 224 can be designed for easy electrical disconnection between the cell stack assembly 224 and the HVJB 222. In some embodiments, the battery cell stack assembly 224 may only require positive and negative bus connections and a single communication connection to be used in the secondary application. Also, as described above, the cell stack assembly 224 can be designed to easily disconnect cooling lines (e.g., glycol lines) running to and from the cell stack 224.

[0063] Furthermore, in some embodiments, the battery cell stack assembly 224 may be originally designed for a primary and secondary use. The cooling system (e.g., heat exchanger 330) of the battery cell stack assembly 224 may be sized and configured to serve as a heat sink for the inverter or other electronic components in the secondary use. Thus, when the battery pack cell stack assembly 224 is used in the secondary use, no additional coolant is required for the connected inverter or other electronic components. In some embodiments, the battery cell stack assembly 224 may include most or all of the sensors necessary to function properly in the secondary use. Furthermore, the CMU 272 may be configured to report sensor measurements (e.g., voltage, current, temperature) in a manner compatible with the secondary use.

[0064] In some embodiments, the HVJB 222 can also be repurposed for secondary uses with high reliability. In some embodiments, the HVJB 222 can be originally designed for primary and secondary uses. In some embodiments, the HVJB 222 can be designed with inverters (e.g., inv1, inv2) that are compatible with both the original and secondary uses. For example, the inverter's voltage, current, power, temperature, humidity, and other ratings can be configured such that the inverter can be suitable for both the original and secondary uses. In some embodiments, a controller associated with the inverter can be included within the HVJB 222. The controller can be designed for primary and secondary uses. For example, the controller can control the inverters (inv1, inv2) to provide a different voltage or frequency required for the secondary use.

[0065] Additionally, in some embodiments, HVJB222 may include logic within BMS270 that enables it to interface with various components in the secondary application. In some embodiments, BMS270 may store various operating modes and parameters for secondary operation. For example, BMS270 may include different thresholds for detecting fault conditions (e.g., overcurrent, short circuit, etc.) in the secondary application based on the requirements of that application. In some embodiments, BMS270 is configured to allow updates to its logic. Additionally, BMS270 may be configured to report information in a format usable by the secondary application. In some embodiments, BMS270 may report the state of charge (SOC), state of health (SOH), fault conditions (e.g., short circuit or overcurrent), state of power (SOP), state of energy (SOE), and state of temperature (SOT) in a format usable by the secondary application. For example, instead of a binary result (e.g., failed or not failed, overheated or not overheated), the BMS 270 may provide details of the measured condition so that different decisions (e.g., amount of excessive current, cell stack temperature, etc.) can be made in secondary applications.

[0066] In some embodiments, a custom DC / DC battery interface may be required because battery pack 120 or battery cell stack assembly 224 is utilized in a secondary application. HVJB 222 and / or battery pack cell stack assembly 224 may be configured to allow connection to the DC / DC battery interface. For example, additional connection points may be provided on the pack bus bar, or the pack bus bar may be positioned in a manner that is convenient for reinstallation.

[0067] FIG. 5 illustrates a home system 500 consistent with embodiments of the present disclosure. In some embodiments, the secondary use may be installed within a home system (i.e., a home power system) to supply power to the home system. In some embodiments, the home system may be a utility system that supplies power to various subsystems of a home, a group of homes, a commercial facility, or an industrial facility. In some embodiments, the home system may include an electronic switching system (ESS). In some embodiments, the battery 510, the battery interface 515, the inverter 520, and one or more line filters 525 may comprise the home system's electronic switching system. In some embodiments, the battery interface 515 may be a DC / DC interface. In some embodiments, the switching network 530 may be configured to enable powering of the home electric line 540 via the electronic switching system 560 or via an external power grid 550. In some embodiments, the entire battery pack 120, including the HVJB 222, may be used within the home system. In some embodiments, multiple battery packs 120 may be connected together in a parallel, series, or combination arrangement to meet the needs of the home system in the secondary use. For example, battery packs 120 may be connected together through connectors 390a, 390b, and 390c.

[0068] FIG. 6 illustrates a home charging system consistent with embodiments of the present disclosure. In some embodiments, a repurposed battery cell stack assembly 224 or battery pack 120 can enable increased power applications. In some embodiments, the battery cell stack assembly 224 or battery pack 120 can be utilized for DC fast charging (DCFC) applications in the home. In some embodiments, DCFC applications can include DCFC of electric vehicles (EVs) at significantly higher speeds than currently possible. For example, as described herein, two high-power battery packs 120 with high-power cells can be used in a home system to charge an EV in approximately 40-80% of the time typically required by a V3 Supercharger and approximately 25 times faster than existing home EV charging stations. In some embodiments, multiple battery packs 120 can be connected together in parallel, series, or combination arrangements to meet the needs of secondary purposes. For example, battery packs 120 can be connected together for secondary uses through connectors 390a, 390b, and 390c.

[0069] In some embodiments, battery 610 (e.g., battery cell stack assembly 224 or battery pack 120) may be installed in home charging system 600 and connected to battery interface 615, which includes a DC / DC converter for converting power as needed for the charging application. Furthermore, battery interface 615 and / or battery 610 may connect to charging interface 625. Charging interface 625 may include a power control unit for regulating the voltage and current supplied to electric vehicle 630 based on communication with a BMS on electric vehicle 630. Furthermore, charging interface 625 may include a receptor and various safety interlocks to ensure safe charging.

[0070] FIG. 7 illustrates an electric vehicle 760 consistent with embodiments of the present disclosure. In some embodiments, the battery pack 120 and / or the battery cell stack assembly 224 may be directly integrated into a different vehicle in a secondary application. For example, the battery pack 120 and / or the battery cell stack 224 may be included in an electric car, an electric construction vehicle, a drone, or any other electric vehicle. In some embodiments, the battery 710 may be the battery cell stack assembly 224 integrated into the electric vehicle 760. The vehicle interface 715 may include a DC / DC converter, an inverter, and other electronics required to power the electric motor of the electric vehicle 760. In other embodiments, the battery 710 may be the entire battery pack 120, including the HVJB 222. The battery pack 120 may include inverters (e.g., inv1, inv2) that may directly provide power to the electric motor of the electric vehicle 760. The vehicle interface 715 may monitor the battery 710 and control the inverters and / or associated controllers to meet the power requirements of the vehicle 760. Additionally, in some embodiments, the vehicle interface 715 may include an on-board charger or other charging interface that allows the charging system 720 to charge the battery cell stack assembly 224 .

[0071] The foregoing description has been presented for purposes of illustration. It is not exhaustive and does not limit the disclosure to the precise forms or embodiments disclosed. Modifications and adaptations of the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed embodiments of the present disclosure disclosed herein.

[0072] The embodiments may be further described using the following clauses. 1. A battery pack assembly comprising: a battery pack housing; a battery pack comprising one or more battery cells; and a junction box, wherein the junction box comprises a junction box housing including a base wall, four side walls, and an open end; a battery management unit attached to the base wall, at least one fuse, and at least one switch, and the four side walls of the junction box housing are fixed to the battery pack housing. 2. A battery pack assembly as described in clause 1, wherein the battery pack housing includes a cutout portion that is covered by the junction box when the junction box housing is secured to the battery pack housing. 3. A battery pack assembly as described in clause 1 or 2, wherein each side wall of the junction box housing has a flanged end that is secured to the battery pack housing. 4. The battery pack assembly of any one of clauses 1 to 3, wherein at least one switch is a contactor or a relay. 5. A battery pack assembly as described in any one of clauses 1 to 4, wherein the battery pack includes at least one cell management unit for monitoring the voltage and temperature of one or more battery cells of the battery pack. 6. The battery pack assembly of clause 5, wherein the battery pack includes at least two cell management units daisy-chained together. 7. The battery pack assembly includes a wired connection between the battery management unit and a cell management unit of the at least two cell management units; 7. The battery pack assembly of clause 6, wherein the battery management unit is configured to receive voltage and temperature measurements of each cell management unit through a wired connection. 8. A battery pack assembly as described in any one of clauses 1 to 7, wherein the junction box base wall includes at least one access panel configured to provide access for electrically connecting the junction box and the battery pack. 9. The battery pack assembly is mounted inside the aircraft wing; A battery pack assembly as described in any one of clauses 1 to 8, wherein the aircraft wing includes at least one access panel configured to provide access for electrically connecting the junction box to the battery pack. 10. The battery pack assembly of claim 9, wherein the battery pack is toward the bottom of the aircraft wing and the junction box is toward the top of the aircraft wing relative to the battery pack. 11. The battery pack assembly of any one of claims 1 to 10, wherein the battery pack assembly is mounted inside the fuselage of an aircraft. 12. An aircraft wing, a battery pack housing; a battery pack comprising one or more battery cells; a junction box, wherein the junction box a junction box housing including a base wall, four side walls, and an open end; a battery management unit mounted on the base wall, at least one fuse, and at least one switch; An aircraft wing in which the four side walls of the junction box housing are secured to the battery pack housing. 13. An aircraft wing as described in clause 12, wherein the battery pack housing includes a cutout portion that is covered by the junction box when the junction box housing is secured to the battery pack housing. 14. An aircraft wing as described in clause 12 or 13, wherein each side wall of the junction box housing has a flanged end that is secured to the battery pack housing. 15. An aircraft wing according to any one of clauses 12 to 14, wherein at least one switch is a contactor or a relay. 16. An aircraft wing according to any one of claims 12 to 15, wherein the battery pack includes at least one cell management unit for monitoring the voltage and temperature of one or more battery cells of the battery pack. 17. An aircraft wing as described in any one of clauses 12 to 16, wherein the battery pack includes at least two cell management units daisy-chained together. 18. The aircraft wing includes a wired connection between the battery management unit and a cell management unit of the at least two cell management units; 18. The aircraft wing of clause 17, wherein the battery management unit is configured to receive voltage and temperature measurements of each cell management unit through a wired connection. 19. An aircraft wing as described in any one of clauses 12 to 18, wherein the junction box base wall includes at least one access panel configured to provide access for electrically connecting the junction box and the battery pack. 20. An aircraft wing as described in any one of clauses 12 to 19, wherein the battery pack is toward the bottom of the aircraft wing and the junction box is toward the top of the aircraft wing relative to the battery pack. 21. The aircraft wing of clause 20, wherein the aircraft wing includes at least one access panel configured to provide access for electrically connecting the junction box to the battery pack.

Claims

1. 1. A battery pack assembly comprising: a battery pack housing; a battery pack comprising one or more battery cells within the battery pack housing; a junction box, wherein the junction box comprises: a junction box housing including a base wall, a sidewall structure connected to the base wall, and an open end; a battery management unit, at least one fuse, and at least one switch, each positioned within the junction box housing and attached to the base wall; the sidewall structure of the junction box housing is configured to be removably secured to the battery pack housing at the open end such that the base wall is not inside the battery pack housing; The battery pack assembly, wherein the junction box base wall includes at least one access panel configured to provide access for manually electrically connecting and disconnecting the junction box and the battery pack.

2. The battery pack assembly of claim 1 , wherein the battery pack housing includes a cutout portion that is covered by the junction box when the junction box housing is secured to the battery pack housing.

3. 3. The battery pack assembly of claim 1, wherein the sidewall structure of the junction box housing has flanged ends configured to be removably secured to the battery pack housing.

4. 3. The battery pack assembly of claim 1, wherein the at least one switch is a contactor configured to control power from the one or more battery cells.

5. 3. The battery pack assembly of claim 1, wherein the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

6. 3. The battery pack assembly of claim 1, wherein the battery pack includes at least one cell management unit mounted within the battery pack housing for monitoring the voltage and temperature of the one or more battery cells of the battery pack.

7. the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing; the at least one switch is a contactor configured to control power from the one or more battery cells; 3. The battery pack assembly of claim 1, wherein the battery pack includes at least one cell management unit mounted within the battery pack housing for monitoring the voltage and temperature of the one or more battery cells of the battery pack.

8. 3. The battery pack assembly of claim 1, wherein the battery pack includes at least two cell management units, the at least two cell management units being daisy-chained together.

9. the battery pack assembly includes a wired connection between the battery management unit and a cell management unit of the at least two cell management units; The battery pack assembly of claim 8 , wherein the battery management unit is configured to receive voltage and temperature measurements of the one or more battery cells through the wired connection.

10. 10. The battery pack assembly of claim 9, wherein the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

11. the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing; the at least one switch is a contactor configured to control power from the one or more battery cells; 3. The battery pack assembly of claim 1, wherein the battery pack includes at least one cell management unit mounted within the battery pack housing for monitoring the voltage and temperature of the one or more battery cells of the battery pack.

12. the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing; the at least one switch is a contactor configured to control power from the one or more battery cells; 3. The battery pack assembly of claim 1, wherein the battery pack includes at least two cell management units, the at least two cell management units being daisy-chained together.

13. 3. The battery pack assembly of claim 1, wherein the battery pack assembly is configured to be mounted to an inside of an aircraft wing including at least one access panel configured to provide access for electrically connecting the junction box to the battery pack.

14. 14. The battery pack assembly of claim 13, wherein the battery packs are toward a bottom of the aircraft wing, the junction box is toward a top of the aircraft wing relative to the battery packs, and the access panel is at the top of the aircraft wing.

15. 15. The battery pack assembly of claim 14, wherein the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

16. The battery pack assembly of claim 13 , wherein the battery pack includes at least one stiffener and crash core on an opposite side of the battery pack from the junction box.

17. 17. The battery pack assembly of claim 16, wherein the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

18. 1. An aircraft wing, comprising: a battery pack housing; a battery pack comprising one or more battery cells within the battery pack housing; a junction box, wherein the junction box comprises: a junction box housing including a base wall, a sidewall structure connected to the base wall, and an open end; a battery management unit, at least one fuse, and at least one switch, each positioned within the junction box housing and attached to the base wall; the sidewall structure of the junction box housing is configured to be removably secured to the battery pack housing at the open end such that the base wall is not inside the battery pack housing; the junction box base wall includes at least one access panel configured to provide access for manually electrically connecting and disconnecting the junction box and the battery pack.

19. 19. The aircraft wing of claim 18, wherein the battery pack housing includes a cutout portion that is covered by the junction box when the junction box housing is secured to the battery pack housing.

20. 20. The aircraft wing of claim 18 or 19, wherein the sidewall structure of the junction box housing has flanged ends configured to be removably secured to the battery pack housing.

21. 20. An aircraft wing according to claim 18 or 19, wherein the at least one switch is a contactor configured to control power from the one or more battery cells.

22. 20. The aircraft wing of claim 18 or 19, wherein the sidewall structure of the junction box housing has flanged ends configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

23. 20. The aircraft wing of claim 18 or 19, wherein the battery pack includes at least one cell management unit mounted within the battery pack housing for monitoring the voltage and temperature of the one or more battery cells of the battery pack.

24. 20. The aircraft wing of claim 18 or 19, wherein the sidewall structure of the junction box housing has flanged ends configured to be removably secured to the battery pack housing, the at least one switch is a contactor configured to control power from the one or more battery cells, and the battery pack includes at least one cell management unit mounted within the battery pack housing for monitoring voltage and temperature of the one or more battery cells of the battery pack.

25. 20. An aircraft wing according to claim 18 or 19, wherein the battery pack includes at least two cell management units, the at least two cell management units being daisy-chained together.

26. the aircraft wing comprises a wired connection between the battery management unit and a cell management unit of the at least two cell management units; 26. The aircraft wing of claim 25, wherein the battery management unit is configured to receive voltage and temperature measurements of the one or more battery cells through the wired connection.

27. 27. The aircraft wing of claim 26, wherein the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

28. the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing; the at least one switch is a contactor configured to control power from the one or more battery cells; 28. The aircraft wing of claim 27, wherein the battery pack includes at least one cell management unit mounted within the battery pack housing for monitoring the voltage and temperature of the one or more battery cells of the battery pack.

29. the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing; the at least one switch is a contactor configured to control power from the one or more battery cells; 28. The aircraft wing of claim 27, wherein the battery pack includes at least two cell management units, the at least two cell management units being daisy-chained together.

30. 28. The aircraft wing of claim 27, wherein the battery packs are toward a bottom of the aircraft wing, the junction box is toward an upper portion of the aircraft wing relative to the battery packs, and the upper portion of the aircraft wing includes at least one access panel configured to provide access for electrically connecting the junction box to the battery packs.

31. 31. The aircraft wing of claim 30, wherein the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

32. 20. An aircraft wing according to claim 18 or 19, wherein the battery pack includes at least one stiffener and a crash core on an opposite side of the battery pack from the junction box.

33. 33. The aircraft wing of claim 32, wherein the sidewall structure of the junction box housing has a flanged end configured to be removably secured to the battery pack housing, and the at least one switch is a contactor configured to control power from the one or more battery cells.

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