FITTINGS THEREFOR

Field of Invention

The invention relates to improvements in and relating to battery power supply and parts and fitting therefor. In particular, in one aspect a battery power supply configurable between a primary electric vehicle battery pack and a portable electrical power station, and a console to be provided to a battery pack to form a portable electrical power station.

Background to the Invention

Portable electrical power stations are generally configured for electrically powering or recharging the batteries of appliances such as power tools, portable radios and the like at a remote location such as a building site or in ‘the outdoors’ where a mains power supply is unavailable.

Portable power supplies typically provide a number of electrical connectors/sockets for connecting appliances to the power supply, and a user interface including a display and an on/off switch for turning the power supply on and off.

A portable power station includes a bank of rechargeable battery cells. The cells are charged via a mains power supply at a location where a mains supply is available, to be subsequently discharged when powering an appliance in use.

Portable power stations are dedicated units with a sole function of providing a charged power supply for powering portable devices at a remote location or when a mains supply becomes unavailable. The battery cells remain permanently within the portable power supply together with the portable power supply electrical connectors and user interface. Portable power stations typically provide a low voltage output from the power supply electrical connectors, for example 5V, 9V or 12V, for powering small appliances.

It would be useful if the battery cells of a portable power station could be provided by a battery pack that is configured for use separately from the portable power station. For example, it would be useful if the battery cells of a portable power station could be provided in a standalone battery pack configured for powering various electrical motor vehicles.

Electric motor vehicles have a number of benefits and are generally considered environmentally friendly as having a lower carbon footprint compared to internal combustion motor vehicles using fossil fuels. However, a downside of electrical vehicles is the requirement to dispose of a vehicle’s batteries at the end of its life. Batteries can be dangerous and are made up of materials harmful to the environment. Disposal of batteries can therefore present significant challenges. Object of the Invention

It is an object of the invention to address one or more of the above disadvantages, or to at least provide the public with a useful choice.

Summary of the Invention

The term ‘portable power supply’ as used herein refers to an electrical power supply which can be provided by a battery pack and/or a portable power station. The term portable power supply therefore covers the battery pack alone, or in combination with a console which together form the portable power station.

The term ‘portable power station’ as used herein refers to a regulated source of electrical power which is derived from a battery pack via a console.

Battery pack and detachable console forming a portable electrical power supply

According to a first aspect of the invention, there is provided a portable power supply comprising: a battery pack including:

^■ a plurality of battery cells;

^■ a sealed outer casing in which the plurality of battery cells is housed; and

^■ one or more battery pack electrical connectors electrically connected to the plurality of battery cells; a console comprising: one or more console electrical outlets for providing electrical power from the plurality of battery cells to one or more loads in use;

^■ a user interface;

^■ an electrical connection assembly for electrically connecting the console to the battery pack to be powered by the plurality of battery cells; and

^■ a body to which the one or more console electrical connectors and the user interface are mounted; the console is configured to be attached to the battery pack: in a first configuration, wherein the battery pack is provided without the console, for providing electrical power to a load in use via the one or more battery pack electrical connectors; and in a second configuration, wherein the battery pack is provided together with the console electrically connected and attached to the battery pack to form a portable electrical power station for providing electrical power to a load in use via one or more console electrical connectors.

In some embodiments, the battery pack comprises a battery management system electrically connected between the plurality of battery cells and the one or more battery pack electrical connectors.

In some embodiments, the one or more battery pack electrical connectors comprises: a first battery pack electrical connector for connecting to an electrical load in use; and a second battery pack electrical connector for electrically connecting the console to the battery pack.

In some embodiments, the battery pack comprises a cap to cover the second battery pack electrical connector when provided in the first configuration.

In some embodiments, the battery pack is configured to provide a first electrical power level from the first battery pack electrical connector and a second electrical power level from the second battery pack electrical connector.

In some embodiments, the first power level is higher than the second power level.

In some embodiments, the battery pack is configured to provide power to an electrical vehicle via the first battery pack electrical connector.

In some embodiments, the battery pack and/or power station is or are configured so that the portable electrical power supply may be configured to provide substantially 5VDC to 150VDC via the one or more electrical connectors.

In some embodiments the battery pack and/or power station may be configured to be connected in series to one or more further battery packs and/or power consoles to provide the required power output.

A battery pack and/or power station substantially as described above battery pack and/or power station wherein the battery pack or power station is configured to provide substantially 0.1 - 300 Amps.

However, it is envisaged the voltage or current output can adjusted up or down by varying the number of cell pack assemblies, number or type of cells within, or way (i.e. parallel and/or series) that one or more cell pack assemblies, or battery packs, are connected together. In some embodiments, the console comprises a handle for a user to carry the portable electrical power station.

In some embodiments, the handle is fixed to the sealed outer case via fasteners extending through the body of the console with the body secured between the handle and the sealed outer case.

In some embodiments, the handle comprises or is formed from a metal plate.

In some embodiments, when the portable power supply is lifted by the handle, substantially no weight is taken by the body.

In some embodiments, the handle of the console is secured to walls of the sealed outer case. In some embodiments, the battery pack outer casing is a metallic outer casing.

In some embodiments, the battery pack has at least an IP66 enclosure rating.

In some embodiments, the portable electrical power station has at least an IP65 enclosure rating.

In some embodiments, the one or more battery pack electrical connectors comprises a battery pack electrical connector for electrically connecting the console to the battery pack, wherein in the second configuration with the console connected to the battery pack, the console body covers said battery pack electrical connector.

In some embodiments, in the first configuration with the console connected to the battery pack, a seal is provided or formed between the console body and the outer casing of the battery pack.

The battery pack and detachable console forming a portable power supply may have a number of advantages which can include one or more of the following:

• The ability to be configured to provide a vehicle battery or a portable power station (i.e. out of vehicle power supply);

• Reducing electronic waste as the battery pack has multiple uses and is not just a dedicated power supply for a vehicle;

• Reducing electronic waste as the battery pack has multiple uses and is not just a dedicated power supply for a power station.

It will be appreciated that other advantages may be apparent from the description and drawings.

Console

According to a first aspect of the invention, there is provided a console for a portable electric power station comprising: ^■ one or more console electrical connectors;

^■ a user interface;

^■ an electrical connection assembly for electrically connecting, in use, the console to a battery pack so as to be powered by a plurality of battery cells therein; and

^■ a body to which the one or more console electrical connectors and the user interface are mounted; wherein the console is configured to:

• be physically attached to the battery pack; and

• when the battery pack is provided together with the console electrically connected and physically attached to the battery pack this forms a portable electrical power station capable of providing electrical power to a load in use via one or more console electrical connectors.

According to a second aspect there is provided a console for a portable electric power station comprising: a body for mounting/housing; one or more console electrical connectors; a user interface; an electrical connection assembly, for in use, electrically connecting the console to a battery pack powered by the plurality of battery cells, so as to provide electrical power to the console electrical connectors; and wherein the body is also adapted to in use, to be physically secured the body of console to the battery pack in a releasable manner.

According to a third aspect there is provided a console for a portable electric power supply comprising: at least one handle forming part of, or connected to, said body. wherein the body is configured to be physically secured to the battery pack so as to enable the combined weight of both the console and battery pack to be carried by the handle(s).

A console substantially as described above wherein the weight of the battery pack may be in the region of substantially 15Kg - 25Kg.

In relation to a further aspect a console may be adapted for physically securing to the battery pack in a releasable manner via electromagnetic coupling. The electromagnetic coupling of a console to a battery pack via the power of the battery can help provide a physical confirmation the battery pack has a minimum level of power reserves or else a coupling between the console body or the pack will not occur.

In one preferred embodiment the electromagnetic coupling may be achieved via at least two opposed solenoids which have push pins which extend into apertures or the like on the console body or battery pack case depending on where the solenoids are located.

Once there is electrical connectivity between the battery pack and the console this then activates the solenoids. to securely attach the console and battery pack to one another.

Other ways of releasably securing the console body to a battery pack are also envisaged an include:

• apertures and associated fasteners;

• a clip arrangement on body which engages lip or such like on battery pack; and/or

• a lip on body which clips on the battery pack can engage.

According to a fourth aspect there is provided a console substantially as described above wherein the console further comprises a battery management system (BMS) which receives electrical power from the electrical connection assembly and supplies power to one or more electrical connectors.

A console including the BMS therein provides for easier maintenance, repairs, and upgrades to be provided a power station. It also enables a console to be configured to be retrofittable by comsumer, to other battery packs or vehicle batteries manufactured by third parties.

It should be appreciated the console may include any one or more features of the console described with reference to the first aspect of the invention.

The console may have a number of advantages which can include one or more of the following:

• The ability to transform a battery pack for a vehicle into a portable power station - i.e. make a battery multi-use;

• Providing multiple varied pawer outlets to maximise options for the end user;

• Reducing electronic waste as the battery pack has multiple uses and is not just a dedicated power supply for a vehicle;

• Reducing electronic waste as the battery pack has multiple uses and is not just a dedicated power supply for a power station;

• Increasing the ease of maintaining and repairing a portable power station by swapping out consoles; • Easy lightweight transportation and/or shipping of a portable battery management system (BMS) for maintenance updates, repairs, or swapping out.

• Providing the ability to easily and quickly change from a power station and operate in situ within an electric vehicle as a vehicle power supply, in some vehicles even when the console remains attached.

It will be appreciated that other advantages may be apparent from the description and drawings.

Battery Pack

According to a first aspect of the invention, there is provided a battery pack comprising:

• a plurality of battery cells;

• a battery management system (BMS);

• a sealed outer casing in which the plurality of battery cells and BMS are housed; and one or more battery pack electrical connectors mounted to the sealed outer casing and electrically connected to the plurality of battery cells.

According to a second aspect of the invention battery pack comprising:

• a plurality of battery cells;

• a sealed outer casing in which the plurality of battery cells are housed; and

• one or more battery pack electrical connectors mounted to the sealed outer casing and electrically connected to the plurality of battery cells; wherein the battery pack further comprises a mounting plate, the mounting plate being secured to one or more walls of the sealed outer case.

In some embodiments, the battery pack comprises a mounting plate on which the BMS is mounted, the mounting plate located between the plurality of battery cells and the BMS to form a protection structure to mechanically shield the BMS from the plurality of battery cells.

In some embodiments, the mounting plate may be directly or indirectly secured to one or more walls of the sealed outer case.

In some embodiments, the battery pack comprises suspension elements between the BMS and the mounting plate.

In some embodiments, the battery pack comprises a frame surrounding the BMS, wherein the mounting plate and the frame together form a protection structure to mechanically shield the BMS from the plurality of battery cells.

In some embodiments, the protection structure may be secured to walls of the outer sealed case. In some embodiments, the sealed outer case comprises an open topped outer case with a lid provided over the open topped outer case, and wherein the lid is secured to the open topped case via the mounting plate or protection structure.

In some embodiments, at least one handle is provided to the battery pack for lifting the battery pack, and wherein the handle is secured to the mounting plate or protection structure via fasteners passing through apertures in the lid of the case.

In some embodiments, when the battery is lifted by the handle, substantially no weight is taken by the lid of the sealed outer case.

In some embodiments, the battery pack comprises a first cell pack assembly comprising a first plurality of battery cells and a second cell pack assembly comprising a second plurality of battery cells.

In some embodiments, each of the first and second cell pack assemblies comprises a pair of frames with the battery cells supported between the pair of frames.

In some embodiments, the pair of frames support the battery cells in an array.

In some embodiments, the battery cells are arranged in a plurality of groups, with the battery cells within each group electrically connected in parallel, and the plurality of groups electrically connected together in series.

In some embodiments, the first and second cell pack assemblies are electrically connected together in series.

In some embodiments, parallel connection of the battery cells within a group of battery cells is provided by a pair of contact plates, wherein the battery cells within a group of battery cells are held by the frames between and in contact with the pair of contact plates.

In some embodiments, wherein at least one of the contact plates bridges over to an adjacent group of battery cells to provide the series electrical connection between adjacent groups of battery cells.

In some embodiments, at least one contact plate provides an electrical fuse at each battery cell in electrical connection with the contact plate.

In some embodiments, the fuse is provided by a leg extending between a contact region in contact with the battery cell and a supporting region of the contact plate.

In some embodiments, the outer case is constructed from a metallic material.

In some embodiments, the case comprises a thermal vent to release pressure and/or heat to avoid an explosion in the event of a cell failure. In some embodiments, the thermal vent comprises a metallic wool member retained a housing mounted to a wall of the case and in communication with an aperture through the wall of the case.

In some embodiments, the battery pack has at least an IP66 enclosure rating.

According to a third aspect of the invention there is provided a battery pack comprising: a plurality of battery cells; a sealed outer casing in which the plurality of battery cells are housed; and at least two electrical connectors mounted to the sealed outer casing and electrically connected to the plurality of battery cells; wherein at least one electrical connector is capable of providing power from the battery cells to a console; wherein at least one electrical connector is capable of providing power from the battery to a vehicle.

In one preferred embodiment the electrical connector capable of providing power from the battery to a console is located on the top face of the sealed outer casing and the electrical connector capable of providing power to the vehicle is located on a side face of the sealed outer casing.

Preferably, the power provided from the battery pack to the console may be regulated by a BMS.

Preferably, the power provided from the battery pack to the vehicle may be provided directly. In other words, power is provided to the vehicle without regulation by the battery pack.

According to a fourth aspect of the invention there is provided a plurality of battery packs each comprising:

• a plurality of battery cells;

• a battery management system (BMS);

• a sealed outer casing in which the plurality of battery cells and BMS are housed; and

• one or more battery pack electrical connectors mounted to the sealed outer casing and electrically connected to the plurality of battery cells; wherein the battery packs are connected series or parallel, or combination thereof, dependent on the power output required. The battery pack may have a number of advantages which can include one or more of the following:

• banks of battery cells connected in series to enable a user to easily swap out battery banks with a low charge with a bank of fully charged battery cells;

• ability to vary the number of banks of battery cells housed within the battery pack outer casing to adjust (raise or lower) the power supplied by the battery pack;

• a physical fuse for each battery cell in a bank of battery cells;

• discrete components in a bank of battery cells providing for easy disassembly to reduce electronic waste at end of battery life to provide more options for repurposing components and recycling thereof;

• extending the life of a portable power station beyond the life of the batteries;

• ability to connect a plurality of battery packs either in series or parallel, or a combination of series and parallel, as required to provide power to an electric vehicle;

• ability to retrofit a plurality of connected battery packs to provide power to electric vehicle and replace the existing electric battery power supply of the vehicle.

It will be appreciated that other advantages may be apparent from the description and drawings.

Exoskeleton and parts therefor

According to a first aspect of the invention, there is provided an exoskeleton assembly for a portable power station, wherein the exoskeleton comprises:

- a base portion;

- at least two opposed upright portions extending from opposite sides of the base portion; a portion which is removable, in use, to allow a portable power station to be placed into, or removed from, the exoskeleton assembly; wherein the top portion is adapted to connect the at least two opposed upright portions; and wherein the base portion and at least two opposed upright portions are dimensioned, in use, to receive the portable power station therein; and wherein the exoskeleton assembly includes at least three pairs of opposed cushioning elements (OCEs) with said pairs of OCEs located on the x, y and z axes so as to contact the outer surface of the portable power station.

In some embodiments, the upright portions are in the form of two pair of opposed elongate members each elongate member extending from a corner of the base portion.

In some embodiments, the base portion has a cross sectional profile having two lower sections on either side of a central raised section. In some embodiments, the assembly includes at least one OCE in the form of a rectangular resilient frame (RRF) which is dimensioned to surround and contact the outer surface of the portable power station and wherein the corner connection portions of the RRF connect to the opposed upright portions and are configured to: flex; and/or partially move relative to the upright portions; in at least two directions.

In some embodiments, the corner connection portions include: a receiving- part which is substantially C-shaped, the receiving part including at least one rib extending from an outside surface of the C-shape and connected to the RRF; a resilient bumper element which is connected at either end thereof to a distal end of the C-shaped receiving part.

According to a second aspect of the invention, there is provided cushioning element for a portable power station in the form of a sheet of resilient material (SRM) which is configured to include indentations covering an outer surface of said SRM said indentations being dimensioned and profiled to assist with absorption of any impact forces experienced by the exoskeleton.

According to a third aspect of the invention, there is provided OCE in the form of a rectangular resilient frame (RRF) which is dimensioned to surround and contact the outersurface of the portable power station and wherein the corner connection portions of the RRF connect to the opposed upright portions and are configured to: flex; and/or partially move relative to the upright portions; in at least two directions.

In some embodiments, the corner connection portions include: a receiving- part which is substantially C-shaped, the receiving part including at least one rib extending from an outside surface of the C-shape and connected to the RRF; a resilient bumper element which is connected at either end thereof to a distal end of the C- shaped receiving part.

In some embodiments, wherein there are two pairs of spaced apart ribs, each pair of ribs radially extending to a respective interconnecting sides of the RRF at the corner of the RRF where corner portion is located. The Exoskeleton and parts and fittings therefor may have a number of advantages which can include one or more of the following:

• increasing the structural strength of a portable power supply;

• increased safety due to increased structural strength;

• allows for integration with the vehicle without having to necessarily having to remove the exoskeleton;

• improves the lifecycle of the portable power station by reducing vibration;

• simulates protection offered by a vehicle to a power supply;

• offers drop protection in most directions meaning the portable power station is suitable for most environments.

It will be appreciated that other advantages may be apparent from the description and drawings.

Further aspects of the invention, which should be considered in all its novel aspects, will become apparent to those skilled in the art upon reading of the following description which provides at least one example of a practical application of the invention(s) detailed herein.

Brief Description of the Drawings

One or more embodiments of the invention will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which:

Figures 1A and 1B illustrate a battery pack viewed from above and from opposite ends; Figures 2A and 2B illustrate the battery pack of Figures 1 A and 1 B but with a pair of handles removed;

Figures 3A and 3B illustrate a console from above and from opposite ends; Figures 4A and 4B illustrate the console of Figures 3A and 3B with a handle of the console removed, viewed from above and below;

Figure 5 provides an exploded view of the console of Figures 3A and 3B;

Figure 6A and 6B illustrate a portable electrical power supply comprising the battery pack as shown in Figures 2A and 2B and the console of Figures 3A and 3B;

Figure 7 provides an exploded view showing an outer case and two cell pack assemblies of the battery pack of Figures 1A and 1 B. Figure 8 provides an exploded view showing a plurality of battery cells and a pair of supporting frames of a cell pack assembly of the battery pack of Figures 1A and 1 B.

Figure 9 provides a partially exploded view of a cell pack assembly of the battery pack of Figures 1A and 1B.

Figure 10 shows two connection plates of a cell pack assembly of the battery pack of Figures 1 A and 1 B.

Figure 11 provides a partially exploded view of the battery pack of Figures 1A and 1 B.

Figure 12 shows a partially exploded view of the battery pack of Figures 1A and 1 B, showing a BMS PCBA and a mounting plate for the BMS PCBA.

Figure 13 provides a partially exploded view of the battery pack of Figures 1A and 1 B, showing a mounting frame, outer case, lid and lid seal;

Figure 14A shows a plan view of the battery pack of Figure 1 A and 1 B; Figure 14B shows a sectional partial view of an upper portion of the battery pack of Figures 1A and 1 B, the section plane on line A-A in Figure 13A, with various components omitted to clarify a BMS protection structure of the battery pack;

Figure 14C shows an exploded view of Figure 14B; Figure 15 provides a block diagram illustrating the system architecture for the portable power supply of Figures 6A and 6B;

Figures 16A and 16B illustrate an exoskeleton assembly with and without a power supply therein;

Figure 17 provides an exploded view of the exoskeleton assembly shown in Figures 16A and 16B;

Figures 18A and 18B illustrates an opposed cushioning element (OCE) in the form of a resilient rectangular frame (RRF);

Figure 19 shows an opposed cushioning element (OCE) in the form of a sheet of resilient material SRM;

Figure 20 is cross sectional view along line A of Figure 19; Figures 21 A and 21 B illustrates an alternate exoskeleton assembly to that shown in Figures 16 - 20, with Figure 21 A showing a power supply therein and Figure 21 B showing an exploded view of the alternate exoskeleton in Figure 21A;

Figure 22 shows a power supply in the form of a battery pack as shown in the Figures above and as described in relation to inter alia the first and seventh aspects of the present invention;

Figure 23 shows the power supply in the form of a battery pack as shown and described in the Figures above but connected in series to provide power to a four wheeled electric vehicle;

Figure 24 illustrates the concept how a battery pack of the present invention can be used either: alone to power an electric motorbike; or how a number of battery packs of the present invention can be connected together to power a larger four wheeled electric vehicle.

Brief Description of Preferred Embodiments of the Invention

In at least one aspect, the present invention relates to a portable power supply 100 (shown in Figures 5, 6A, 6B) that is configurable, in a first configuration, as a battery pack 1 (see Figures 1A, 1 B, 2A, 2B), and in a second configuration, as a portable power station 100 (see Figures 6A, 6B).

The fasteners used in the present invention may generally be in the form of bolts which engage with either threaded apertures or nuts. For non-load bearing connections the fasteners may alternatively be in the form of rivets.

Figures 1A and 1B illustrate the battery pack 1 which is also shown in more detail in Figure 12.

The battery pack 1 comprises a sealed outer casing 2 in which a plurality of battery cells (described below) are housed.

Battery pack electrical connectors 3, 4, electrically connected to the plurality of battery cells, are provided on the outer casing 2, to provide electricity from the battery pack 1 to one or more electrical power loads in use.

In the illustrated embodiment there are two electrical connectors 3, 4. However, there may be one, two or more electrical connectors.

The illustrated embodiment further comprises a third electrical connector in the form of a socket 5 for use in recharging the battery cells from an external electrical power source. In a most preferred embodiment, at least one battery pack 1 and/or power stations 100 (or a combination thereof) may be suitable for powering, via at least one of the battery pack electrical connectors, an electric motor of an electric motor vehicle, such as:

- an electric motorbike; or

- an electric vehicle when a plurality of battery packs and/or power stations are connected in series.

It will be appreciated that the battery pack and/or portable power station of the present invention can also be used to power other electrically driven machines or apparatus. One non-limiting example being electric fences.

Therefore, preferably the battery pack is capable of providing a suitable power output for powering an electric motor of a motor vehicle. An example power output is substantially 50VDC to 150VDC and 50 - 300 Amps.

In use, the battery pack 1 is typically provided in an assembly together with an electrical power load - i.e. the battery pack is provided in a motor vehicle to power one or more electrical loads of the vehicle, such as the electric motor(s) of the motor vehicle.

In such a configuration, the battery pack 1 typically remains within the vehicle assembly and therefore is not considered a portable power supply as such.

One or more handles 6 may be provided to the battery pack to allow the battery pack to be lifted into and out of an assembly such as a motor vehicle. The handles 6 are secured to the battery pack 2 via fasteners 21 However, typically the battery pack remains within an assembly for the life of the assembly and/or battery pack 1.

In the second configuration the battery pack 1 is provided together with a console 10 to form a portable electrical power supply 100, as shown in Figures 6A and 6B.

A console 10 according to at least one embodiment of the invention is illustrated in Figures 3Ato 5. The console 10 has a body 11 configured to be attached to the battery pack 1.

In the illustrated embodiment, as shown in Figures 2A and 2B, the one or more handles 6 of the battery pack may be removed to allow the body 11 to be attached to the battery pack 1.

The console 10 has one or more console power outlets.

In this embodiment the console 10 has one power outlet in the form of a USB socket 12, and another power outlet in the form of a universal 12V socket 13.

The power console 10 also has a first user interface in the form of an on/off button 14 and a second user interface in the form of a battery charge indicator 15. The power outlets 12, 13 and interfaces 14, 15 are mounted to the body 11. The console power outlets 12, 13 provide electrical power from the battery pack 1 to one or more electrical loads in use.

In the Figures the electrical connectors 12, 13 have caps or covers fitted when not connected to a load.

An electrical connection between the console 10 and the battery pack 1 (Figures 2B, 4B) shows an electrical connector 4 on the battery pack 1 which is in the form of a socket which connects to an electrical connector in the form of a plug 17) on the console 10.

Thus, achieving an electrical connection between the console 10 the plurality of battery cells of the battery pack 1.

In the illustrated embodiment, as shown in Figures 2A and 2B the battery pack has a first electrical connector 3 for connecting to an electrical load (such as a vehicle described further below in relation to Figure 22) when provided in the first configuration as the battery pack 1 , and a second electrical connector 4 for connecting to the console 10 when configured in the second configuration as the portable power supply 100 as shown in Figures 6A and 6B.

Preferably, when the console 10 is connected to the battery pack 1 , the second electrical connector 4 is covered by the body 11 of the console 10.

Preferably a seal is provided or formed between the console body and the sealed outer case of the battery pack, so that internal components of the console are enclosed in a sealed environment formed by the console body and sealed outer case.

A cap may be provided over the first electrical connector when in the second configuration, and/or a cap may be provided over the second electrical connector when in the first configuration.

The battery pack 1 is configured to provide a relatively high-power output from the one or more battery pack electrical connectors when in the first configuration.

Preferably, the battery pack is configured to provide a relatively high-power output from the first connector 3.

In some embodiments the electrical connector 3 may supply 50V output particularly useful if coupled to an inverter for converting to provide an AC supply.

In the second configuration, the portable power supply is configured to provide a relatively low power output from the one or more console electrical connectors.

For example, and as described above, in the first configuration, the battery pack 1 is configured to power an electric motor of a motor vehicle. In the second configuration, the portable power supply 100 may be configured to provide 5V to 24V from the one or more console power outlets 12, 13.

The portable power station 100 may include a plurality of console power outlets 12, 13 and be configured to provide a different power output from each of the console power outlets 12, 13.

For example, the console may include a 5V, 12V and/or 24V output from two or more connectors.

The battery pack 1 may be configured to provide a first electrical power level from the first battery pack electrical connector 3 for powering a load in the first configuration, and a second electrical power level from the second battery pack electrical connector 4 for providing power from the console power outlets in the second configuration. The first power level may be higher than the second power level.

Figure 15 is a block diagram illustrating an example system architecture or power distribution for the portable power supply 100 with like reference numerals used to indicate elements previously described in relation to the power supply.

The battery pack 1 includes a Battery Management System (BMS) 40. The BMS being a gateway for electrical connection with the cells 30 provides a number of functions, including:

• Short circuit protection;

• Temp sensors (x4) for detecting cell pack temperature;

• Voltage regulation - BMS detects cell voltages (for each cell group) and cuts off when high or low voltage is measured;

• Cell balancing - cells balance over time through charge and discharge cycles;

• Sleep mode - BMS switches to low power mode (microprocessor slows down) after about 0.5 hours on inactivity;

• 12V @15A converter (short circuit protected) for providing power to console;

• Onboard 5V @3A converter (short circuit protected) for providing power to console;

• Charge detection - to prevent discharge to power console connectors and battery pack connectors when a charger is connected to the charger electrical connector;

• Real time performance and safety;

• Monitoring;

Temperature monitoring; Coulomb counting micro-processor;

• (SOC);

• Over-current and over-voltage protection;

• Surge protection;

• Cell balancing;

• Plug detection;

• Transportation mode detection

• Overcharging protection.

In the illustrated embodiment, the battery pack 1 provides 12V to the console 10 via the battery pack electrical connector 4 and the console electrical connector 17.

The console 10 includes a PCBA 50 configured to convert the 50V power supply from the battery pack 1 to power level(s) to be provided from the battery pack electrical outlet 3.

In the illustrated embodiment, the console PCBA 50 provides a multi-voltage platform via one console power outlet 12.

The power outlet 12 comprises a USB C socket providing 5V @5A, 9V @3A, 12V @3A and 20V @3A and/or a USB A socket providing 5V @3A.

The 12V supply from the battery pack 1 is provided from the console power outlet 12. The 12V supply may be routed through the PCBA 50. The console PCBA also provides an output to the user interface battery level display 14.

The battery pack 1 together with the console 10 forming the portable power station 100 provides a ‘standalone’ portable power station assembly that may be transported and carried, for powering electrical devices such as power tools and the like where a mains power supply is unavailable.

For example, the portable power station is suitable for use in remote locations, or in environments such building sites and the like.

In preferred embodiments the console 10 provides a handle 18 for carrying the portable power station 100 by hand. The body 11 comprises or provides a base 11c, housing 11a at one end, and a housing 11b at an opposite end, each housing 11a, 11b for containing internal components of console. The handle 18 extends between the two housings 11a, 11 b. The base and housings are preferably integrally formed together.

For example, the body is a unitary moulded component, for example a plastic moulded component. The handle 18 must be robust to carry the weight of the battery pack 1 when lifted by the handle 18.

Further, robust connection must be provided between the console 10 and the battery pack 1 to enable the battery pack 1 to be picked up by the handle 18.

A connection or fixing arrangement between the console 10 and the battery pack 11 is illustrated in the exploded view of Figure 5.

The console 10 comprises the body 11 and the handle 18 secured to the body 11 . The handle 18 is fixed to the battery pack 1 by fasteners 19 that extend through the console body 11 to engage brackets 20 underneath the body 11.

The brackets 20 are fixed to the battery pack 1 via fasteners 21. The handle 18 is formed from or comprises a metal plate 18a.

The illustrated embodiment also comprises a moulded component 18b provided beneath the metal plate 18a to contact a user’s hand when lifting the portable power supply.

The handle 18, fasteners 19, brackets 20 and fasteners 21 take the weight of the battery pack 1 when lifted by the handle 18, with the body 11 secured between the handle 18 and the battery pack 1.

When the portable power supply 100 is lifted by the handle 18, substantially no weight is taken by the body 11.

Further discussion of attachment of the console handle to the battery pack is provided below with reference to Figures 5, 14A and 14B.

Battery pack construction

A preferred construction for the battery pack 1 is described with reference to Figures 7 to 14B. As described above, the battery pack 1 comprises a plurality of battery cells housed within the sealed outer case 2 (Figures 1 A to 2B).

In the illustrated embodiment, and as shown in Figures 7 and 8, the battery pack 1 comprises a first cell pack assembly 31 and a second cell pack assembly 32. Each cell pack (battery bank) 31, 32 has opposed plastic frame members 33a, 33b and 34a, 34b which have a plurality of apertures 31 h into which the positive and negative ends of individual battery cells 30a frictionally fit. The opposed frame members 33a, 33b and 34a, 34b have opposed upright stand-offs 33sa,33sb and 34sa, 34sb. The opposed frame members 33a, 33b and 34a, 34b are held together via nuts 330 and bolts 331 the bolts passing through horizontal stand-offs 340.

Once the cell packs 31 , 32 are placed in the case 2a they are held together by a holding plate 124 which has apertures which are positioned and dimensioned to locate on stand-offs 33sa, 33sb and 34sa, 34sb.

The two cell packs 31, 32 are separated by an insulating sheet in the form of a mica sheet 123.

The two cell pack assemblies together comprise the plurality of battery cells, with each cell pack assembly comprising a portion of the plurality of battery cells 30.

Preferably the first and second cell pack assemblies are the same and therefore comprise one half of the plurality of battery cells.

An example battery cell (30a in Figure 8) is an LG Li-ion 3500MAH 3.7V 10Amp battery, model number INR18650MJ1. The two cell pack assemblies are provided side-by-side in the sealed outer case.

With reference to Figures 8 and 9, each cell pack assembly 31 , 32 comprises the battery cells 30 supported between a pair of opposed frames 33sa, 33sb and 34sa, 34 sb - substantially as previously described opposed frames 33sa, 33sb and 34sa, 34sb support the cells 30 in an array.

An insulating covering such as a polycarbonate sheet 35 is provided between the frames to surround the plurality of cells 30.

In the illustrated embodiment, each cell pack assembly 31, 32 comprises 126 battery cells 30a, arranged in seven groups of 18 battery cells.

The battery cells 30a within each group are connected in parallel, and the seven groups are connected together in series, providing a total voltage of 25.9V per cell pack assembly. Parallel electrical connection of the cells 30a within each group is provided by a pair of contact plates, namely plates 36 and 37.

The battery cells 30a within one group are connected in parallel by being held by the frames between and in contact with plates 36, 37 spanning opposed sides of the cells.

In the embodiment shown one set of plates 36, 37 are in contact with the cell anode, and the other set of plates plate 36, 37 are in contact with the cell cathode. At least one of the edges of plates 36 bridges over to (i.e. overlaps with) an adjacent group of cells to provide a series type ( as opposed to a parallel type) electrical connection between the adjacent groups of cells.

A bus bar 38 is provided at each end of each cell pack assembly 31 , 32. The two cell pack assemblies 31 , 32 are connected together in series via the respective bus bars 38, providing a total voltage of 51.8V. A sheet of insulating polycarbonate sheet 39, profiled cut to the shape of plates 36,37, is provided to an outside surface of the connection plates 36, 37 on each side of the cell pack assembly 31 , 32.

It should be understood than more than two cell pack assemblies may be included, with the outer case 2.

Figure 10 shows two contact plates 36, 37. Each contact plate 36, 37 provides an electrical fuse at each cell 30a.

The fuse is configured to melt and break in the event of a cell failure, taking the individual failed cell out of electrical connection with the remaining cells of the battery pack.

The fuse is provided by a leg 41 extending between a contact region 42 in contact with the cell and a (planar) supporting region 40 of the plate.

The leg 41 is dimensioned to melt and separate the contact region 42 from the supporting region 40 in an over current event.

The connection plate 36, 37 may be formed by cutting and pressing the plurality of contact regions 42 from a planar blank conductive material (such as metal sheet) with the fuse or leg 41 extending between the connection region 42 and the supporting region 40.

In a preferred embodiment, the outer case 2 is constructed from a metallic material, and preferably Aluminium, to provide a robust containment of the internal components of the battery pack.

However, it is envisaged the outer case 2 could also be made of plastic and formed via injection moulding.

The electrical connectors 3, 4 are mounted to an inside of the case 2 to be accessible via a corresponding aperture through a wall of the case 2.

The case 2 comprises a thermal vent arrangement 7, as shown in Figures 1 B and 2A.

With reference to Figure 11 , the thermal vent 7 comprises a metal wool member such as a bronze wool disc 8 as used in flame arrestors, and a housing 9 for the metal wool member 8. The disc may be retained in the housing by a circlip. The housing 9 is mounted to a bracket 63 attached to a side wall of the case 2 with the metallic wool member in communication with an aperture through the wall of the case. In the event of a cell failure, the thermal vent 7 allows for pressure and thermal energy to be released from the sealed outer case 2.

The thermal vent 7 is provided to avoid over pressurisation of the outer case 2 which could result in an explosion and is considered necessary when the outer case 2 is formed from a metallic or other strong resilient material. Where the case is formed from plastic, failure of one or more cells 30a may cause the plastic case to melt thereby preventing a build-up of pressure in the case.

The case 2 further comprises a lock receiving aperture 200. The lock receiving aperture 200 helps enable the case to be secured to a vehicle or part thereof, to prevent unauthorized removal of the battery pack 1.

In a preferred embodiment the lock receiving aperture 200 receives a keyed dead bolt arrangement (not shown) therein to effect a lock to prevent removal of the case 2.

As described above, the battery pack 1 comprises a battery management system (BMS). With reference to Figure 12, the BMS is provided by a BMS PCBA 60.

The BMS PCBA (herein the BMS) is mounted on a mounting plate 61. The mounting plate 61 is preferably formed from a metallic material or other stiff or rigid material, for example steel or aluminium.

The mounting plate 61 may be secured to an inside surface of the outer case 2. For example, brackets 62,63 are provided, to secure the mounting plate 61 to a wall of the case with fasteners. The mounting plate may rest on or be secured to a top of the cell pack assemblies 31 , 32.

Rubber bushes 64 are provided between the plate 61 and the cell pack assemblies 31 , 32. The rubber bushes 64 sit on the stand-offs 33sa,33sb and 34sa, 34sb. The mounting plate 61 is located between the BMS 60 and the plurality of battery cells 30.

The mounting plate 61 therefore protects the BMS 60 from the cells 30, for example to mechanically shield the BMS 60 from the cells 30 in the event of a catastrophic failure of one or more cells. The mounting plate 61 forms a shield or armour plate, between the cells 30 and the BMS 60.

In the preferred illustrated embodiment, suspension elements 65 are provided between the BMS 60 and the armour plate 41.

In the illustrated embodiment, the suspension elements 65 are rubber or elastomeric blocks.

Figures 13 to 14B show further details of an upper portion of the battery pack 1.

A frame 66 is provided to surround the BMS PCBA 60. The frame 66 is located above the plate 61.

The frame 66 is preferably formed from a metallic material or other stiff or rigid material, for example steel or aluminium.

The frame 66 and the plate 61 together provide a protection structure to protect the BMS from the cells in the event of a catastrophic failure of one or more cells. Preferably the frame 66 is secured to the plate. The frame 66 is secured to an inside of the outer case 2. For example, brackets 62, 63 (Figures 11 , 12 and 14B) are provided, to secure the frame/plate protection structure 66, 61 to walls of the case with fasteners. The frame and the plate are preferably fixed together to form the protection structure for the BMS.

With reference to Figures 13, the battery pack comprises an open topped outer case 2a with a lid 2b provided over the open topped outer case.

The outer case 2a and lid 2b together form the sealed outer case 2 for containing the cells 30 and other internal components of the battery pack 1.

A seal 67 such as an elastomeric member is provided between the lid 2b and the open topped case 2a.

In a preferred embodiment the sealed outer case 2 provides an IP rating of at least IP66, however higher IP enclosure ratings may be achieved, e.g. IP67.

In the illustrated embodiment, the lid is secured to the open topped case via the mounting plate or protection structure provided by the mounting plate and frame.

As described above, the console 10 is connected to the battery pack 1 to form the portable electrical power supply 100. The console 10 is electrically connected to the battery pack 1 via the plug 17 and socket 3.

The console 10 is also physically secured to the battery pack 1 , to allow the portable electrical power supply 100 to be lifted by the console handle 18. The battery pack is heavy, weighing around 18 kilograms.

The attachment of the console 10 to the battery pack 1 must therefore be very robust. In a preferred embodiment, fasteners connect the handle of the console to a frame connected to the walls of the case, for example opposed side walls.

As described above with reference to Figure 5, the handle 18 of the console 10 is attached to brackets 20 with fasteners 19, and the brackets 20 are attached to the battery pack case 2 with fasteners 21.

With reference to Figure 5, brackets 20 include stand-offs 20a which have threaded apertures 20b at the top end thereof. In use, apertures 20b receive fasteners 19 to secure the handle 18 and console 10 to the battery pack case 2.

Now with further reference to Figures 5, 13, 14A, 14B and 14C, The fasteners 21 securing the bracket 20 (or handles 6) to the battery pack pass through apertures 22 in the lid 2b of the case 2 and engage the frame 66. The frame 66 is itself attached to opposed walls of the case 2 via fasteners 88 securing the frame 66 to brackets 62, 63. Brackets 62, 63 are secured to the walls of the case 2a via fasteners 89. The frame 66 is connected to plate 61 via fasteners 87 fitting into threaded apertures 90 in the plate 61.

The lid 2b is secured by fasteners 91 to the frame 66 which has threaded apertures

Thus, the handle 18 of the console is structurally connected to the walls of the case 2 to ensure robust connection of the handle to the case to allow the weight of the battery pack to be lifted via the handle 18 of the console 10.

The handle 18, fasteners 19, 21 , brackets 20, frame 66 and/or mounting plate 41 , brackets 62,

63 and outer case 2 take the weight of the battery pack 1 when lifted by the handle 18.

When the portable power supply 100 is lifted by the handle 18, substantially no weight is taken by the console body 11 or the lid 2b of the sealed outer case 2.

The handles 6 illustrated in Figures 1A and 1 B are also fixed to the frame 66 and/or mounting plate 61 and preferably via the same mounting holes provided through the lid of the case. When the battery pack 1 is lifted by the handles 6, substantially no weight is taken by the lid of the sealed outer case.

The construction of the battery pack provides an assembly that allows for easy disassembly, to easily break down the battery pack into its component parts.

This allows for the battery pack to be more easily disposed of at the end of its life. The lid may be removed from the open topped case by removing fasteners, to expose the internal components of the battery pack.

The BMS PCBA, frame and shield plate can be removed from the top of the open topped case to provide access to the two cell pack assemblies.

The cell pack assemblies may be lifted out of the open topped case and disassembled to remove the individual cells from the cell pack assemblies.

Exoskeleton Assembly for a Power Station

Figures 16A, 16B and 17 show an exoskeleton assembly 1 for a portable power supply (P). The exoskeleton assembly has a base portion in the form a base plate 2 and upright portions in the form of opposed rods 3 extending from the corners of the base plate 2. The opposed rods 3 at either end of the exoskeleton being connected to one another via a cross strut 3a.

The exoskeleton assembly 1 has a top portion in the form of a double-Y shaped member 4. The double -Y shaped member 4 has apertures 41 -44 therein for receiving bolts (not shown) the bolts, in use, secure into threaded apertures 31- 34 at the top of rods 3. The exoskeleton assembly 1 also has a first pair of OCEs which are in the form of two sheets of resilient material (SRM) 5a, 5b located on the top of the base plate 2 and underside of top portion 4 respectively.

The exoskeleton assembly 1 also has a second pair and third pair of OCEs 6a, 6b and 6c, 6d in the form of rectangular resilient frame (RRF) 6 and a fourth and fifth pair of OCEs 7a, 7b and 7c, 7d in the form of rectangular resilient frame (RRF) 7.

The RRFs 6 and 7 are made of plastic and are dimensioned to receive the power station therein by way of a snug fit. So the opposed sides 6a, 6b and 7a, 7b contact the side of the power console and the opposed ends 6c, 6d and 7c, 7d.

The RRFs 6 and 7 have corner connection portions 61 , 62, 63, 64 and 71,72,73, 74. The corner connection portions 61-64 and 7i - 7 ₄ have a receiving parts 6ir - 6 ₄ r and 7i r — 7 ₄ r which are substantially C-shaped and dimensioned to frictionally fit around the rods 3.

The RRFs 6 and 7 have apertures 60 which allow fasteners to secure the RRFs 6 and 7 to the base plate 2 and cross strut 3a which have corresponding threaded apertures therein.

Figures 18A shows the RRF in greater detail and Figure 18B shows a close-up of the corner connection portion 62. In particular, ribs 6ra -6rd extending from C-shaped receiving part 62r can be seen in more detail. As can be seen, a first pair of ribs 6ra,6rb extend to a first interconnecting side 6c of the RRF. A second pair of ribs 6rc,6rd extending to a second interconnecting side 6a of the RRF.

These ribs together with the C-shape of the receiving part help the RRF move and/or flex to assist with absorbing impact forces, such as shown by double headed arrows X and Y.

The C-shaped receiving part 62r is connected at a distal end to a resilient bumper element 18.

The plastic bumper element 18 has a leg 18 ₁ which is welded to the end of the C-shaped receiving part 62r.

The combination of the leg 181 and C-shaped receiving part 62r the ability for the bumper element 18 to flex/move to absorb when an impact force is experienced by the bumper element 18.

The C-shaped receiving part 62r also enables the corner connection portion 62 to twist/partially rotate around rods 3 dependent on the direction of the impact force experienced by the bumper element 18 and/or connection portion 62.

Figure 19 shows the SRMs 5a, 5b in more detail. As can be seen the SRM has indentations 5ai on the top surface 5as thereof. The indentations are configured to have a substantially triangular cross section with a broad base and narrow tip. The power station (X) sits on SRM 5a resting on the apex of indentations 5ai which have sufficient rigidity to remain upright when supporting the 18 kg weight of the power supply.

In a preferred embodiment the SRM is made from an elastomeric like material having an elastomer durometer (i.e. hardness) in the Shore A scale.

Importantly, the indentations 5ai are dimensioned to have a height relative to maximum width at the base thereof which enables the indentations to flex when a substantially upward or downward impact force is received.

This ability for all the individual indentations on SRM 5a to flex provides a gradual deceleration of the impact force and provides shock absorption. As can be seen the height of indentations relative to height (thickness) of the sheet of material (SRM) from which they extend is around 250% taller than the thickness of the SRM.

As can also be seen In Figure 19 the thickness of the base is also around 50% thicker than the apex of the indentation.

In use, as the majority of impact forces will be received when placing the power supply on the ground the surface area of the SRM 5a on the base of the exoskeleton is larger and has more indentations than on the SRM 5b on the underside of the top portion.

Figures 21 A and 21 B show an alternative exoskeleton assembly 20. The main differences are the uprights are in the form of end plates 21 a and 21 b. The base plate 2 and top portion 4 is the same as that shown in Figures 16 and 17.

The exoskeleton assembly 20 has a first pair of OCEs in the form of SRMs 5a, 5b which are the same as shown in Figures 17, 19 and 20.

In addition, the exoskeleton also has a second pair of OCEs in the form of SRMs 22a, 22b on the inside of end plates 21a and 21 b. The surface area and number of indentations taking into account the surface area of the end plates 21 a and 21 b.

Furthermore, the exoskeleton has a third and fourth pairs of OCEs in the form of SRMS 23a, 23b located on the inside of each of the side edges 24 of the endplates 21a and 21b. The surface area and number of indentations taking into account the surface area of the side edges 24.

To increase the impact absorption capability of the exoskeleton assembly 20 it may include a fifth pair of OCEs in the same general form of SRMS the same as 22a, 22b but located on the outer surface of end plates 21 a, 21 b.

There may also be a sixth pair of OCEs in the form of SRMs with one of the pair being the same as 5b but located on the outside of the handle portion 4h of the top portion in the form of double-Y shaped member 4. The other members of the opposed pair of OCEs in the form of SRMs being located on the outer surface of feet portions 4fa and 4fb.

Further embodiments may also include seventh and eight pairs of OCEs in the form of SRMs each of these pairs being on the outside of the side edges 24 of the endplates 21a and 21b.

In relation to Figure 22 the battery pack 1 is shown being used in an electric motorbike 2200 shown in dotted outline.

The electrical connector 3 in the form of a socket receives a plug and associated power cord 220 from the motorbike depicted by dashed lines 2200.

In relation to Figure 23 there is shown a number of battery packs 1 connected in series to power a four wheeled electric vehicle depicted by dashed lines 2300. A master battery is shown with the letter M.

As can be seen the first electrical outlet in the form of socket 3a provides via a first splitter plug (not shown) a positive lead T1 which connects to - via a second splitter plug (not shown) - the negative contact in the socket 3b of a second battery B2.

The second splitter plug also provides a positive lead T2 which connects to - via a third splitter plug (not shown) - the negative contact in the socket 3c of a third battery B3.

The third splitter plug also provides a positive lead T3 which connects to - via a fourth splitter plug (not shown) - the negative contact in the socket 3d of a fourth battery B4.

The fourth splitter plug provides a positive lead T4 which goes to the vehicle 2300. An emergency cut-off controller 2301 is located on lead T4.

The first splitter plug (not shown) on the main battery M also has a negative lead N which goes to the vehicle.

In relation to Figure 24 it is shown how a battery pack 1 can be used to power a motor bike depicted by dashed lines 2200 as shown in Figure 22 or how it can be used to power a four wheeled electric vehicle depicted by dashed lines 2300.

The battery pack 1 of the present invention provides the ability including when a number are connected together to replace the existing battery power supply of an electric vehicle - i.e. the battery pack of the present invention is capable of being retrofitted to existing electric vehicles.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “include”, “including”, “comprise”, “comprising”, and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of “including, but not limited to”. The entire disclosures of all applications, patents and publications cited above and below, if any, are herein incorporated by reference.

Reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world.

The invention may also be said broadly to consist in the parts, elements, characteristics and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements, characteristics or features.

Aspects and embodiments of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined herein.