RELATED PATENT DATA

This application claims the benefit of U.S. Provisional Patent

Application Serial No.62/393,446, filed September 12, 2016, and titled "Battery Modules and Methods of Use," the disclosure of which is incorporated herein by reference. TECHNICAL FIELD

This disclosure relates to rechargeable battery modules and associated methods including rechargeable battery module handling methods. BACKGROUND OF THE DISCLOSURE

Rechargeable battery systems are used in varied applications which have different requirements for electrical energy. Rechargeable battery systems comprise rechargeable cells which receive electrical energy during charging operations and supply electrical energy to a load during discharging operations. Rechargeable cells may have different chemistries in different implementations, and may include Lithium Ion cells in one example. The number of rechargeable cells used in different applications is varied depending upon the requirements of the load, and the number of cells utilized in a given system may be numerous in some implementations including, for example, transportation and remote power applications. Accordingly, rechargeable battery systems may be designed and configured differently for use in different applications.

At least some aspects of the disclosure described below are directed to rechargeable power systems and associated methods.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments of the disclosure are described below with reference to the following accompanying drawings. Fig. 1 is an illustrative representation of a rechargeable power system according to one embodiment.

Fig. 2 is a functional block diagram of a rechargeable power system coupled with an external device according to one embodiment.

Fig. 3 is an illustrative representation of a rechargeable battery module according to one embodiment.

Fig.4 is an illustrative representation of use of a lift assembly to provide vertical lifting of a battery module according to one embodiment.

Fig.4A is an illustrative representation of an attachment member according to one embodiment.

Fig.5 is an illustrative representation of use of a lift assembly to provide horizontal lifting of a battery module according to one embodiment.

Figs.6A-6E are illustrative representations of attachment of a lift member to a housing of a battery module according to one embodiment.

Fig.7 is an illustrative representation of a positive terminal cover spaced from a main body of a housing of a battery module according to one embodiment.

Fig. 8 is an illustrative representation of a lower portion of the positive terminal cover of Fig.7 according to one embodiment.

DETAILED DESCRIPTION OF THE DISCLOSURE

Example embodiments of rechargeable power systems and associated methods thereof are described below. Some rechargeable power systems described below are implemented using a plurality of rechargeable battery modules which individually house one or more rechargeable cells. Different numbers of battery modules may be used and coupled in series or parallel with one another in different applications of the power systems. Example battery modules provide electrical energy at a voltage within the range of 12V - 48V, although other arrangements are possible.

Referring to Fig. 1, one example embodiment of a rechargeable power system 10 is shown. The depicted power system 10 includes a rack system 12 configured to house a plurality of rechargeable battery modules 20. The illustrated rack system 12 includes a front aperture 14 through which the battery modules 20 may be inserted into and stacked within the rack system 12 and removed therefrom, for example for servicing or replacement. Other embodiments of power system 10 are possible including, for example, arrangements which use a single battery module 20 in a standalone application and/or otherwise do not use a rack system 12. Battery modules 20 may be mounted horizontally, for example as shown in rack system 12 of Fig. 1, or in side or vertical mounting orientations in other implementations (not shown).

The battery modules 20 individually include a housing 22 which is configured to house one or more rechargeable battery cells of the respective module 20. The housing 22 may be mounted and attached to rack system 12 in one embodiment. Housing 22 is non-conductive and may be plastic, such as C6600 available from Sabic of Saudi Arabia, in one example embodiment. Housing 22 may be metal with a non-conductive coating in other embodiments.

The modules 20 include a front portion 24 which may be outwardly exposed through the front aperture 14 of the rack system 12. As described below, the front portion 24 of the battery modules 20 include a plurality of terminals which are configured to output and receive electrical energy. Accordingly, cables and other connections to the battery modules 20 are accessible to a user via the front portions 24 when the modules 20 are installed within rack system 12.

Referring to Fig.2, the battery modules 20 individually include at least one and typically a plurality of rechargeable cells 30 which are individually configured to receive, store and discharge electrical energy. Example rechargeable cells are Lithium cells, available from Valence Technology, Inc., although any other suitable cells which are configured to store electrical energy may be used. Example cells which may be used may have different form factors, such as cylindrical, prismatic, pouch, etc. and sizes. Additional circuitry and components (not shown in Fig . 2) may be included withi n a given module, such as monitori ng or control electronics.

The depiction of rechargeable cells 30 is illustrative in Fig. 2, and the nu mber and arrangement of the rechargeable cells 30 within a single battery module 20 may be varied in different implementations. For example, the rechargeable cells 30 of a given module 20 may be connected with one another in series or in parallel with terminals 31 , 33 of opposite electrical polarity (i.e. , positive and negative) of the module 20 i n some embodiments (example termi nals 31 , 33 of an example module 20 are shown in Fig. 3) . The battery modules 20 and the rechargeable cells 30 therein are configu red identically to one another in some implementations of power system 1 0.

The positive and negative terminals 32, 34 are configu red to conduct electrical energy with respect to one or more external devices 40 which are external of the power system 1 0 in the illustrated embodiment. Terminals 32, 34 are directly electrically con nected with respective electrical conductors 35, 37, such as power cables, in the example of Fig . 2.

Battery modules 20 may be arranged differently within different configu rations of power system 1 0. For example, battery modules 20 may be arranged i n series and/or parallel between terminals 32, 34 of the power system 1 0. Electrical conductors, such as wires or cables, may be directly connected with terminals 31 , 33 of the modules 20 to couple the modules i n series and/or parallel with terminals 32, 34 of power system 1 0 in one embodiment.

Du ring charging of power system 1 0, the power system 1 0 receives electrical energy from one or more external devices 40, and conversely, power system 1 0 outputs electrical energy to one or more external devices 40 du ring discharging of power system 1 0. I n some arrangements, one of the external devices 40 is a charger and another of the external devices 40 is a load.

I n additional arrangements, power system 1 0 is con nected with only one external device 40 which both provides electrical energy to charge power system 1 0 and receives electrical energy du ring discharging of power system 1 0. I n a more specific example, one or more of the battery modules 20 may be installed within an electrical vehicle and provide stored electrical energy from i nternal cells 30 to an electric motor of the electrical vehicle and receive electrical energy from an alternator of the electrical vehicle or an electric motor operati ng in a regenerative mode.

I n some arrangements, a discon nect device (not shown) , such as a contactor, relay and/or circuit breaker, may be implemented between one of the terminals 32, 34 and external devices 40.

Referring to Fig. 3, details of an i ndividual rechargeable battery module 20 are shown accordi ng to one embodiment. Battery module 20 includes positive and negative terminals 31 , 33 which are electrically coupled with rechargeable cells (not shown) internal of housi ng 22. The positive and negative terminals 31 , 33 of module 20 are configu red to be directly mechanically and electrically coupled with respective external conductors (not shown) , such as wires or cables, which may be coupled i n series or parallel with external devices, such as other battery modules, a load or a charger, for example.

The illustrated housing 22 of modu le 20 i ncludes a positive terminal cover 36 and a negative termi nal cover 38 which are cou pled with a main body 82 of housing 22. Portions of the positive and negative termi nals 31 , 33 are outwardly exposed throug h the respective covers 36, 38 in the depicted embodi ment. I n some arrangements, at least one of the positive and negative terminal covers 36, 38 may be oriented differently with respect to the main body 82 of housing 22 to provide fused or non-fused operation of battery module 20 at different moments in time as described i n additional detail below.

Referring to Figs. 4, 4A and 5, details of example lift assemblies which are configu red to assist with the handling of a battery module 20 are described accordi ng to example embodi ments. The lift assemblies of the depicted battery modules 20 i n Figs. 4 and 5 include a plu rality of lift members 50 and one or more handles 60 which are configu red to removably engage the lift members 50. The lift assemblies may be used by a user to lift, move and lower a module 20, for example, du ri ng removal of a module 20 from packaging and installation of the module 20. The lift assemblies may be used with battery modules 20 of different weights from 0-35 kg in illustrative embodiments described herein . I n addition, the example lift assemblies described herein are relatively light weight, small in size, strong, and easy to transport and use.

I n one embodi ment, lift members 50 are straps made of a flexible material , such as Nylon . Portions 56 of the lift members 50 are configu red to extend outwardly from the housi ng 22 du ring use i n some embodiments. The lift members 50 provide a plu rality of lift points for the battery module 20 which enable the module 20 to be lifted , moved and lowered in a plu rality of different orientations with respect to grou nd . Handles 60 may also be coupled with different ones of the lift members 50 at different moments in ti me to enable the modu le 20 to be conveniently lifted , moved and lowered i n the different orientations with respect to the g rou nd. The lift members 50 and handle 60 are arranged i n Fig . 4 to assist a user with lifting the module 20 in a su bstantially vertical orientation with respect to the grou nd while the lift members 50 and handles 60 in Fig. 5 assist a user with lifting of module 20 in a substantially horizontal orientation with respect to the grou nd .

I n one embodi ment, the lift members 50 are positioned at different locations of housi ng 22 to provide the different lift points. I n some implementations, the lift members 50 are positioned at different locations at or adjacent to the periphery of housi ng 22. I n the illustrated examples of modules 20 shown in Figs. 4 and 5, housi ng 22 is generally in the shape of a cuboid and the lift members 50 are located adjacent to the fou r corners of opposing top and bottom su rfaces 52, 54 of the housing 22.

Portions 56 of the lift members 50 are configu red to be extended from different su rfaces of the housing 22 to assist with the lifting of module 20 i n different orientations with respect to grou nd in one embodiment. A user may configu re the lift members 50 to extend from the different su rfaces of housi ng 22 at different times to assist with moving of the module 20 in the different orientations. For example, in the vertical lifti ng arrangement of Fig . 4, portions 56 of two lift members 50 extend outwardly from one of the top and bottom su rfaces 52, 54 of housing 22. I n the horizontal lifti ng arrangement of Fig . 5, portions 56 of fou r lift members extend outwardly from top su rface 52 of housi ng 22.

I n addition , the lift members 50 are flexible and outwardly extendi ng portions 56 thereof may be bent or folded adjacent to the housing 22 following i nstallation of the battery module 20 i n one embodiment, for example to permit stacking of plu ral modules 20 i n rack system 1 2. Additional details regarding example configu rations of lift members 50 are set forth below.

I n some arrangements, handles 60 are not used and extended portions 56 of lift members 50 may be used to lift the module 20 by hand. For example, i n lifti ng a module 20 in the horizontal orientation with respect to grou nd , two people standing on opposite sides of the module may lift the module by grabbing or slidi ng their hands or fingers through the extended portions 56 of the lift members 50.

I n Fig. 4, a si ngle handle 60 is coupled with two lift members 50 to assist a user with vertical lifting of the battery module 20. Opposite ends of handle 60 include attach ment members 62 which are configu red to be removably coupled with respective lift members 50 of battery module 20 i n one embodi ment. I n one example, handles 60 are implemented using rope, Nylon or cable and lift members 50 form respective loops which receive the attachment members 62.

Attachment members 62 may be implemented in different ways, such as hooks, clasps, ri ngs, etc. , to provide removable coupling of handle 60 with lift members 50. Referri ng to Fig. 4A, an example attachment member 62 i n the form of a ri ng is shown which includes a movable portion 63 to enable the attachment member 62 to be removably connected with lift member 50 and handle 60.

Attachment of handle 60 to the lift members 50 which extend from opposite su rfaces 52, 54 of the housi ng allows the battery module 20 to be lifted i n a su bstantially vertical orientation without tilting . Attachment of the handle 60 to lift members 50 which are adjacent to front portion 24 of housing 22 allows the battery module 20 to be lowered into place while providing easy access of the user to the attachment members 62 to remove the handle 60 from housing 22 after appropriate placement of the battery modu le 20.

I n Fig . 5, two handles 60 are cou pled with portions 56 of fou r lift members 50 which extend from su rface 52 to provide horizontal lifti ng of battery module 20. In the depicted example, a first of the handles 60 is coupled with two lift members 50 which are adjacent to a left su rface of housing 22 while a second handle 60 is cou pled with two lift members 50 which are adjacent to a right su rface of housi ng 22. Portions 56 of lift members 50 may also be extended from su rface 54 if desired for handling.

Referring to Figs. 6A-6E, additional details of lift members 50 and attachment thereof to housing 22 of battery module 20 are shown accordi ng to one embodi ment. I n the example of Fig. 6A, a plu rality of apertu res 70 in the form of slots or channels extend between opposi ng top and bottom su rfaces 52, 54 of housing 22 and the apertu res 70 are configu red to receive a lift member 50.

I n Fig. 6B, an end of lift member 50 is i nserted into the i nnermost apertu re 70 to a position such that opposi ng ends 51 of the lift member 50 extend outwardly of opposing su rfaces 52, 54 of the housi ng 22.

Fig. 6C is a cross-sectional view wherein the opposing ends 51 of lift member 50 have been folded and inserted into the outermost apertu re 70 and d rawn through an apertu re 72 in the housing 22.

I n Fig. 6D, the opposi ng ends 51 of lift member 50 are joined together to form a closed loop about a rib 74 of housing 22 which affixes the lift member 50 to housi ng 22. The opposi ng ends 51 of lift member 50 may be joined by stitchi ng or welding in example embodiments. Portions of the lift member 50 may be extended outwardly from either su rface 52, 54 in the described embodiment. An attach ment member 62 of a handle 60 may be coupled with portions of the lift member 50 which extend outward of the housing 22, for example, as shown in Figs. 4 and 5. I n Fig. 6E, the lift members 50 are flexible and an outwardly extendi ng portion 56 of the lift member 50 may be folded flush with one of the su rfaces 52, 54 of housing 22 (i .e. , su rface 52 i n the example of Fig. 6 E) , for example followi ng installation of the module 20 within rack system 1 2 and to allow stacki ng of another module 20 adjacent to su rface 52.

The lift members 50 are configu red i n the above-described embodiments such that the outwardly extendi ng portions 56 thereof may extend from different su rfaces of the housi ng at different moments in time. As shown in Fig. 4, outwardly extending portions 56 of the lift members 50 extend from opposi ng su rfaces 52, 54 while outwardly extendi ng portions 56 of the lift members 50 extend from the same surface 52 of housi ng 22 i n Fig. 5. Accordi ngly, lift members 50 may be extended outwardly from housing 22 and retracted i nwardly with respect to housi ng 22 by a user as desired .

As mentioned above with respect to Fig. 3, one of the positive and negative terminal covers 36, 38 may be oriented differently with respect to mai n body 82 of housing 22 at different moments in ti me to provide fused or non-fused operation of battery module 20 as described in additional detail below. For example, the positive terminal cover 36 is shown i n two different positions with respect to the mai n body 82 of housing 22 of the battery modules 20 shown in Figs. 1 and 3. I n one embodiment, the positive and negative terminal covers 36, 38 are configu red differently such that they cannot be used to cover the termi nals 31 , 33 of the opposite polarity, for example by use of different groves or keys (not shown) in the covers 36, 38 and/or main body 82 of housi ng 22.

Referring to Fig . 7, an example embodi ment is described where positive terminal cover 36 may be oriented in different positions relative to main body 82 of housi ng 22 to provide the fused or non-fused operation of battery module 20 at different moments in ti me. More specifically, du ring fused operation of battery module 20, a fuse is provided in series between the positive terminal 31 and the rechargeable cells of the module 20 while a fuse is not utilized between the positive terminal 31 and the rechargeable cells during non-fused operation of battery module 20.

In Fig. 7, the illustrated positive terminal cover 36 is shown spaced from a main body 82 of the housing 22. Positive terminal cover 36 has a plurality of apertures 84 located at the respective corners thereof as well as an interior aperture 86 in the illustrated embodiment. The apertures 84, 86 receive respective screws (not shown) which are used to secure the cover 36 to the main body 82 of housing 22 during use of the battery module 20. Aperture 86 is aligned with one of the apertures 87 in terminal connections 90, 92 (described below) when cover 36 is positioned in the different orientations with respect to main body 82 of housing 22 in the illustrated embodiment.

Positive terminal 31 includes a plurality of terminal connections 90, 92 in the depicted embodiment. Terminal connections 90, 92 are configured to be directly electrically coupled with external electrical conductors, such as wires and cables, in one embodiment. For example, the external electrical conductors may be electrically connected with terminals 31, 33 of other modules 20 and/or terminals 32, 34 of power system 10. Furthermore, a fuse 94 is electrically coupled between the terminal connections 90, 92 of positive terminal 31. In other embodiments, negative terminal 33 may be configured as shown in Fig.7 to include fuse 94 instead of inclusion of the fuse 94 at positive terminal 31 as depicted.

Terminal connection 92 is electrically coupled with the rechargeable cells within housing 22 while terminal connection 90 is electrically coupled with the rechargeable cells within housing 22 via the fuse 94 and terminal connection 92. Accordingly, fuse 94 is coupled between only terminal connection 90 of positive terminal 31 and the rechargeable cells of the module 20 and terminal connection 92 of positive terminal 31 conducts electrical energy with respect to the rechargeable cells of the module 20 without a fuse in the described example embodiment.

In one embodiment, each of the terminal connections 90, 92 is configured to be directly electrically connected with an electrical conductor (not shown) which conducts electrical energy between rechargeable cells of the modu le 20 and other modules 20 and/or an external device 40. Each of terminal connections 90, 92 includes one or more apertu re 93 which is configu red to con nect with the electrical conductor which conducts electrical energy to or from the battery module 20 via the respective termi nal con nection 90, 92 in the illustrated embodiment.

The housing 22 including cover 36 is configu red to allow only one of the fi rst and second terminal connections 90, 92 to be directly electrically connected with the external conductor at a given moment in time in one embodi ment. I n the depicted example embodiment, positive termi nal cover 36 outwardly exposes only one of the terminal connections 90, 92 at a given moment in time. I n particular, positive termi nal cover 36 has an offset apertu re 96 in the illustrated embodiment which is configu red to outwardly expose only one of the termi nal connections 90, 92 when the cover 36 is affixed to the main body 82 of housi ng 22. Plu ral O-rings 98 are provided about termi nal connections 90, 92 and operate to form a seal with the cover 36 about apertu re 96 when the cover 36 is affixed to the mai n body 82.

I n example i mplementations, cover 36 is attached in a first orientation or position relative to main body 82 of housi ng 22 to outwardly expose terminal con nection 92 as is shown in the modules 20 of Fig. 1 (and not outwardly expose terminal connection 90) to provide fused operation at one moment in time, for example, when battery module 20 is coupled in parallel with other battery modules. Cover 36 is attached in a second orientation or position relative to mai n body 82 at another moment in time as is shown in Fig . 7 to outwardly expose terminal connection 90 (and not outwardly expose termi nal connection 92) to provide non-fused operation, for example, when battery module is cou pled in series with other battery modules. I n some embodiments, cou pling of the fuse 94 in series with other modules may result in the voltage rati ng of the fuse 94 being exceeded , and accordi ngly, the fuse 94 is bypassed and not utilized when cover 36 outwardly exposes terminal con nection 92. Removal of positive terminal cover 36 from main body 82 of housing 22 facilitates access to and replacement of fuse 94 if needed.

In the illustrated embodiment, positive terminal cover 36 includes a plurality of mounting apertures 100 which enable other components, such as a contactor (not shown), to be mounted to housing 22. Cover 36 also includes a plurality of recesses 102 in the illustrated embodiment which may be used to pry the cover 36 from the main body 82 of housing 22. Cover 36 also includes a raised portion 104 in the illustrated embodiment to provide sufficient space for the one of the terminal connections 90, 92 which is not outwardly exposed when the cover 36 is attached to the main body 82 of housing 22.

Referring to Fig.8, a sealing gasket 110 is provided at the lower periphery of the positive terminal cover 36 which forms a seal with the main body 82 of housing 22 when cover 36 is attached to the housing 22 in one embodiment.

In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended aspects appropriately interpreted in accordance with the doctrine of equivalents.

Further, aspects herein have been presented for guidance in construction and/or operation of illustrative embodiments of the disclosure. Applicant(s) hereof consider these described illustrative embodiments to also include, disclose and describe further inventive aspects in addition to those explicitly disclosed. For example, the additional inventive aspects may include less, more and/or alternative features than those described in the illustrative embodiments. In more specific examples, Applicants consider the disclosure to include, disclose and describe methods which include less, more and/or alternative steps than those methods explicitly disclosed as well as apparatus which includes less, more and/or alternative structure than the explicitly disclosed structure.