Patent Abstract:
Methods of and apparatus for removing heat generated by cells of a battery pack. The method and apparatus may employ one or more fan modules disposed between or next to cells of the battery pack, or one or more fans directly mounted to the battery pack or battery pack case housing the cells. Further, a motor controller isolation system operates to electricity isolate the motor controller of the electric vehicle when the battery pack is being charged. The motor controller isolation system may be integrated with the integrated battery pack and thermal and ventilation system. The integrated system, or “integrated battery unit (IBU),” is preferably manufactured in a manner that requires no, modifications to the electric vehicle in which the IBU is installed.

Full Description:
FIELD OF THE INVENTION 
     The present invention relates to electric vehicles. More specifically, the present invention relates to adapting electric vehicles for fast charging technology, and to providing thermal and ventilation management for battery packs used in electric vehicles. 
     BACKGROUND OF THE INVENTION 
     Recreational and industrial vehicles are prevalent in today&#39;s world. Examples include golf carts, forklifts, and airport transport and luggage handling carts. Because electric vehicles create less pollution than internal combustion (i.e., gasoline and diesel powered) vehicles, they are an environmentally friendly, and increasingly acceptable, alternative. 
     As shown in  FIG. 1 , electric vehicles are typically powered by a battery pack comprised of a plurality of rechargeable batteries (or “cells”)  100 . The battery pack cells  100  are housed in a battery pack case (or “tray”)  102 . The cells  100  are usually connected in series by way of electrical connectors  104 . The battery pack case  102  is typically semi-permanently mounted on or inside the electric vehicle. 
     A necessary operational aspect of electric vehicles is the periodic recharging of the battery pack. In some applications the battery pack may be recharged without having to remove the battery pack from the vehicle. However, in other applications the depleted battery pack must be removed and replaced with a fully charged replacement battery pack. In factory operations, for example, the electric vehicles (typically forklifts) are powered by high-capacity batteries. High-capacity batteries have amp-hour ratings of 1000 Amp-hrs or more, and require six to eight hours of charging to restore the battery to full charge. Hence, to avoid rendering the vehicle unavailable for use during the six to eight hours needed to recharge the depleted battery pack, the depleted battery pack is typically lifted out of the vehicle and replaced with a fully charged replacement pack. Because the battery packs can weight up to 4,000 lbs, special hydraulically powered lift machines are used to complete the battery pack swapping operation. 
     In recent years, engineers have developed what is known as “fast charging” technology. Fast charging reduces the recharge time of a 1000 Amp-hr battery, from the typical six to eight hours required using conventional battery charging techniques, to about an hour. Fast charging thereby allows recharging to be performed, for example, during an operator&#39;s lunch break, or during other opportune times when the vehicle may not be needed. For this reason, fast charging technology is sometimes referred to as “opportunity charging”. Fast charging also eliminates the need to repeatedly swap out and replace depleted battery packs with charged battery packs. 
     While fast charging improves operational efficiencies, its use generates temperatures and thermal gradients in a battery pack, which if not properly controlled contribute to degraded performance and a shortened lifespan of the battery pack.  FIG. 2  shows a graph of the effective internal resistance and heat generation observed in a typical thirty-six-volt industrial battery at different inrush currents and states of charge (SOC). The “Fast Charge Zone,” which is defined by the lowest resistance region, is located between about 20 and 70% SOC. The graph shows that in the Fast Charge Zone, fast charging at 600 amps generates up to ten times as much heating as conventional charging at 200 amps. This excessive heating results in significantly higher temperatures in the fast charged battery pack. 
     Heating of cells of a battery pack, whether attributable to fast charging or heavy-load use, is exacerbated by the fact that the various cells of the battery pack are typically arranged in a grid pattern and housed in a battery pack case, similar to that shown in  FIG. 1 . This substantially enclosed configuration does not allow for any significant cooling paths, especially for cells disposed in the center of the pack. While the cells closest to the metal case can cool to some extent through the case wall, the center cells have to cool through their neighbor cells or by radiating heat from their top surfaces. 
     Because the center cells of a battery pack endure higher temperatures than cells forming the periphery of the battery pack, the center cells are plagued with diminished performance and are even prone to fail more often compared to the peripheral cells.  FIG. 3A  shows cell voltages of a battery pack of eighteen cells (which are arranged as shown in  FIG. 3B ) during discharge at 20% SOC, before and after equalization (EQ) of a battery pack that has undergone fast charging during a life cycle test. Overall, it is seen that the cell voltages of all cells are higher after EQ compared to before EQ. However, even after EQ the cell voltages of the “middle-cell group,” which comprises cells  8  through  11 , tend to remain lower than the cell voltages of peripheral cells  1  through  6  and  13  through  18 . 
       FIG. 3A  also shows that temperatures of the cells of the middle-cell group are significantly higher than the temperatures of the peripheral cells after EQ. These temperature differentials for center cells of a typical eighty-volt industrial battery pack during fast charging are illustrated in  FIG. 4 . As can be seen, there is up to a thirty-degree temperature gradient between cells in the center of the battery pack and cells that form the periphery of the battery pack. 
     As the foregoing demonstrates, without adequate cooling a battery pack is beset with reduced capacity and run time. Cell-to-cell imbalances can also lead to over-discharging during use and overcharging during recharging, both of which further affect the performance and lifespan of the battery pack. Therefore, there is a need for methods and apparatus for providing adequate cooling to battery packs, particularly, but not limited to, those used in industrial applications. 
     The operational efficiencies gained by fast charging introduce additional problems beyond that of just thermal and ventilation management. For example, the motor drive systems of most electric vehicles are not designed to withstand the high voltages employed by fast charging techniques. Accordingly, there is also a need for methods and apparatus to prevent these high voltages from being coupled to the motor drive system of an electric vehicle while the battery pack is being fast charged. 
     There are also safety and damage concerns relating to connecting a charger to the charging connections of a battery pack. Typically, a battery pack is located under a hood of the electric vehicle, and has charging connections that are not easily accessible by an operator. These undesirable characteristics expose the operator to the possibility of coming into contact with battery acid and/or increasing the risk of electrical shock when the operator is connecting charger connectors to the battery pack. Further damage and injury can result when the operator inadvertently fails to disconnect the battery charge connector from the charging connections of the electric vehicle, but then drives the vehicle away from the charger. Accordingly there are also needs for improved access and safety measures for use in charging battery packs of an electric vehicle. These needs would preferably be met by not having to make any modifications to the electric vehicle. 
     Finally, satisfactory solutions to integrating fast charging technology into electric vehicles are not available in the prior art. Rather, prior art solutions are ad hoc and require that modifications be made to the vehicle. For example, holes must be drilled and tapped to mount fans for cooling and to configure, route and mount fast charge connectors to the vehicle. Holes must also be cut into the battery compartment to allow the fast charging battery cables to pass through to the outside. In addition to the expense and tedium required to make such modifications, modifications themselves are undesirable since they can potentially void the vehicle&#39;s warranty and/or UL listing. Modifications also result in a reduction in the resale value of the vehicle, or a possible financial penalty being assessed against the lessee of a leased vehicle. Further, the ad hoc nature of prior art approaches results in a lack of uniformity, failing to provide a unique, integrated solution that can be consistently and successfully performed to accommodate fast charging technology without the need for operator intervention. Accordingly, there is a need for methods and apparatus for accommodating fast charging technology that do not require having to make modifications to the vehicle. 
     SUMMARY OF THE INVENTION 
     Methods of and apparatus for removing heat generated by cells of a battery pack are disclosed. The methods and apparatus may employ one or more fan modules disposed between or next to cells of the battery pack, or one or more fans directly mounted to the battery pack or battery pack case housing the cells. The fan modules or direct-mounted fans may be controlled by, for example, a thermostat, a battery mounted monitor and controller associated with the battery pack, a key switch, or a charger interlock. Methods of manufacturing the integrated battery pack and thermal and ventilation system are also described. 
     According to another aspect of the invention, a motor controller isolation system for an electric vehicle is disclosed. The motor controller isolation system operates to electrically isolate the motor controller of the electric vehicle when the battery pack is. being charged. The motor controller isolation system can therefore be used to prevent high voltages from a fast charger from being coupled to the motor drive system of an electric vehicle when the battery pack is being fast charged. The motor controller isolation system, or portions thereof, may be included as part of one or more battery pack connectors that connect to connectors of a charger during charging. When the connectors are mated, the isolation system, which may include a mechanical or electrical control element, isolates the motor controller of the electric vehicle from both the battery pack and the battery charger. Hence, when the connectors are mated the vehicle cannot be driven, and injury to the operator or others and/or damage caused by driving the vehicle while still connected to the charger are avoided. 
     Although not required, the motor controller isolation system may be integrated with the integrated battery pack and thermal and ventilation system. In either or both embodiments, the integrated system is preferably, although not necessarily, manufactured in a manner that requires no, or substantially no, modifications to the electric vehicle in which the integrated system is installed. 
     According to an embodiment of the invention, the thermal management and ventilation and motor controller isolation systems may be housed in a single integrated battery unit (IBU), which can be easily installed in existing electric vehicles, without requiring any substantial modifications to be made to the vehicle. A charge port that is easily accessible by an operator, and/or a watering solenoid valve may also be integrated in the IBU. The charge port avoids having to access the battery pack from under a hood, and the watering solenoid valve permits an on-board watering supply to maintain watering levels in the various cells of the battery pack at appropriate levels. Finally, a battery mounted monitor and controller status indicator and/or a motor controller connected/disconnected status indicator (e.g. LEDs) may be integrated in the IBU. 
     According to an aspect of the invention, electric vehicles not having fast charging capabilities may be equipped with an integrated battery unit (IBU) having all the necessary components necessary to allow fast charging of the vehicle&#39;s battery pack. According to this aspect of the invention, the IBU is designed so that no modifications need be made to the electric vehicle. Among other features, a battery connection, electric vehicle power connection, thermal management and ventilation subsystem may be incorporated or integrated into the IBU. 
     Other aspects of the inventions are described and claimed below, and a further understanding of the nature and advantages of the inventions may be realized by reference to the remaining portions of the specification and the attached drawings. The same reference indicators will be used throughout the drawings to refer to the same or similar parts. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a prior art battery pack comprising a plurality of series-connected cells housed in a battery pack case; 
         FIG. 2  is a graph showing the internal resistance (left vertical axis) and heat generation (right vertical axis) of a typical flooded industrial battery pack at different inrush currents and states of charge (SOC) of the battery pack; 
         FIG. 3A  is a graph showing cell voltages of a plurality of cells of a battery pack before and after an equalization process (EQ), and the cell temperatures of each of the plurality of cells at the end of the EQ; 
         FIG. 3B  is a map of the locations of the plurality of cells for the data represented in the graph of  FIG. 3A ; 
         FIG. 4  is a temperature gradient graph of a plurality of cells of a typical industrial battery pack during fast charging; 
         FIGS. 5A-5D  are side, front, top and isometric views, respectively, of a fan module for use in a battery pack, according to an embodiment of the present invention; 
         FIG. 6A  is a side-interior view of a fan module, illustrating: an air inlet port, an airflow path, a fan, fan protectors, and an air outlet port of the fan module, according to an embodiment of the present invention; 
         FIG. 6B  is a side-exterior view of the fan module shown in  FIG. 6A , which illustrates metal cut-outs through the fan module side panels, according to an embodiment of the present invention; 
         FIG. 7  is a side-interior view of a fan module, illustrating an air inlet port, an airflow path, a fan, and an air outlet port, according to an embodiment of the present invention; 
         FIG. 8  is a side-interior view of a fan module, illustrating an air inlet port, an airflow path, fans, and an air outlet port, according to an embodiment of the present invention; 
         FIG. 9  is a side-interior view of a fan module, illustrating an air inlet port, an airflow path, a fan, fan protectors, and an air outlet port of the fan module, according to an embodiment of the present invention; 
         FIGS. 10A-10J  are a sequence of drawings, illustrating the manner by which the battery pack/fan module embodiment of the invention is assembled; 
         FIG. 11  is an isometric view of a completed battery pack/fan module assembly, illustrating exemplary airflow paths, according to an embodiment of the present invention; 
         FIGS. 12A and 12B  show front and isometric views of an alternative battery pack temperature and ventilation management system, according to an embodiment of the present invention; 
         FIG. 13  is an illustration of a battery pack having a direct mounted cooling fan box installed in an electric vehicle, according to an embodiment of the present invention; 
         FIG. 14A  shows an electric vehicle motor controller isolator that can be used to guarantee motor controller isolation during fast recharging by a fast charger, according to an embodiment of the present invention; 
         FIG. 14B  is an illustration of an electric vehicle motor controller isolator for a charging system, according to an alternative embodiment of the present invention; 
         FIGS. 15A-15E  illustrate an exemplary mechanical disconnect system that is operable to electrically isolate a motor controller of an electric vehicle from a battery pack and fast charger during fast charging, according to an embodiment of the present invention; 
         FIG. 16  shows a conceptual view of an integrated battery unit (IBU) containing the charging and motor controller isolation assembly described in  FIG. 15 , according to an embodiment of the present invention; 
         FIG. 17  shows an alternative embodiment of an IBU, according to an embodiment of the invention; 
         FIG. 18  shows a second perspective drawing of the IBU shown in  FIG. 17 , and how the IBU may also contain a watering solenoid valve to control water flow into the cells of the battery pack; and 
         FIG. 19  illustrates how the integrated battery unit (IBU) in  FIGS. 16 ,  17  or  18  may be installed in an electric vehicle, according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     According to a first embodiment of the present invention, a thermal and ventilation management system for a battery pack is disclosed. The system includes one or more “fan-modules” that are inserted between cells of a battery pack, which may be housed in a battery pack case (i.e., “tray”). The battery pack may be a custom-made battery pack or may be a standard battery pack, as shown, for example, in  FIG. 1 . 
       FIGS. 5A-5D  are side, front, top and isometric views, respectively, of a fan module  500  for use in a battery pack, according to an embodiment of the present invention. An air inlet port  502  is configured to receive fresh air from the environment. A first filter  504  (e.g. a mesh screen) prevents dirt and other particulate matter from entering the fan module  500  through the air inlet port  502 . An air outlet port  506  is configured to eject heated air out into the environment and away from the battery pack and battery pack case. As shown in  FIGS. 5C and 5D , a second filter (e.g. a mesh screen)  508  is included at the air outlet port  506 , to prevent dirt and other particulate matter from entering the interior of the fan module  500 . The fan module  500  may also include an inlet port extension  510 , which as explained and shown below, extends laterally over and outside the upper edge of the battery pack case. The inlet port extension  510  allows the drawing in of fresh air into the fan module  500 . 
     The side panels of the fan module  500  are made of a conductive material, e.g. metal, so that when inserted between cells of the battery pack they are capable of conducting heat away from the battery pack cells. One or more slots or “cut-outs”  512  are made through the side panels. These cut-outs  512  allow air in the fan module  500  to come into intimate contact with the battery pack cell walls, thereby allowing heat generated by the cells to be transferred to the contacting air. As shown and explained in more detail below, the side panels of the fan module  500  are preferably pressed up firmly against the exterior walls of associated battery pack cells. In this manner, airflow is maintained within, and directed through, the fan module  500  in a predetermined manner, and heat transfer from the cells to the passing air is enhanced. 
       FIG. 6A  is a side-interior view of a fan module  600  illustrating an exemplary airflow path into, through, and out the fan module  600 . According to this fan module embodiment, the air inlet port  604  and the air outlet port  608  are reversed compared to the fan module embodiment shown in  FIG. 5 . A fan  602 , which is affixed near the bottom interior of the fan module  600 , operates to draw fresh air from the environment through an air inlet port  604  into the interior of the fan module  600 . The drawn in air is circulated and directed through the fan module  600  by operation of the fan  602 . One or more fan protectors  606  protect the fan  602  from being exposed to dirt and water, which might enter the air inlet port  604 . Any dirt and water that may enter the fan module  600  is captured at the bottom of the fan module  600 , where it can be subsequently removed by an access or drainage port (not shown) during maintenance and servicing. The angles of the fan protectors  606  also facilitate draining and remove the dirt and water from the main airflow path, thereby reducing the likelihood that the dirt and water will be ejected from the air outlet port  608  of the fan module  600 . As explained and shown in more detail below, because the fan module  600  is interposed between battery pack cells, and the side panels of the fan module  600  are in direct contact with the exterior walls of associated cells, heat from the cells is transferred to the circulating air and then ejected out the air outlet port  608 . As shown in  FIG. 6B , one or more cut-outs  610  may be made through the side panels of the fan module  600  to facilitate heat transfer from the cells to the circulating air. 
       FIG. 7  is a side-interior view of an alternative fan module  700 . A squirrel cage type fan  702 , or other fan, is affixed near the top interior of the fan module  700 , and draws fresh air from the environment into an air inlet port  704 . The height of the fan module  700  is dimensioned so that when inserted in the battery pack case, the air inlet port  704  is above the upper edge of the battery pack case. Although not shown in the drawing, the fan module  700  may also include an inlet port extension (similar to that shown in  FIG. 5 ), which extends laterally over and outside the upper edge of the battery pack case. The drawn in air is circulated and directed through the fan module  700  by operation of the fan  702 . Heat from the cells is transferred to the circulating air and then ejected out an air outlet port  706 . Similar to other fan module embodiments, because the air is constrained within the fan module  700 , it is forced to exit the air outlet port  706  at the top of the fan module  700 . Also similar to other fan module embodiments, one or more cut-outs may also be made through the side panels of the fan module  700  to facilitate heat transfer from the cells to the circulating air. 
       FIG. 8  is a side-interior view of an alternative fan module  800 , according to an embodiment of the present invention. The fan module  800  is similar to the fan module  700  shown in  FIG. 7 . It has an air inlet port  802 , an air outlet port  804 , and two or more fans  806  affixed near the top interior of the fan module  800 . The principles of operation are similar to that described in connection with the fan module  700  described above. 
       FIG. 9  is a side-interior view of an alternative fan module  900 , according to another embodiment of the present invention. The fan module  900  is similar to the fan module  600  shown in  FIG. 6 , except that it employs a squirrel cage type fan  902 . The fan  902 , which is affixed near the bottom interior of the fan module  900 , operates to draw fresh air from the environment through an air inlet port  904  into the interior of the fan module  900 . The drawn in air is circulated and directed through the fan module  900  by operation of the fan  902 . One or more fan protectors  906  protect the fan  902  from being exposed to dirt and water, which might enter the air inlet port. Any dirt and water that may enter the fan module  900  is captured at the bottom of the fan module  900 , where it can be subsequently removed by an access or drainage port (not shown) during maintenance and servicing. The angles of the fan protectors  906  also facilitate draining and remove the dirt and water from the main airflow path, thereby reducing the likelihood that the dirt and water will be ejected from the air outlet port  908  of the fan module  900 . As explained and shown in more detail below, because the fan module  900  is interposed between battery pack cells, and the side panels of the fan module  900  are in direct contact with the exterior walls of associated cells, heat from the cells is transferred to the circulating air and then ejected out the air outlet port  908 . Similar to the other fan embodiments, one or more cut-outs may be made through the side panels of the fan module  900  to facilitate heat transfer from the cells to the circulating air. 
     Referring now to  FIGS. 10A-10J , there is shown a sequence of drawings, illustrating the manner by which the battery pack/fan module concept of the invention is assembled.  FIGS. 10A and 10B  show top and isometric views of an empty battery pack case (or “tray”)  1000  within which battery pack cells and fan modules of the types similar to that shown and described above in  FIGS. 5-9  are inserted. Although not required the battery pack case  1000  includes one or more partitions  1002 , which add stability to the case  1000 . 
       FIGS. 10C and 10D  are top and isometric views of the battery pack/fan module assembly after six cells  1004  have been inserted into the battery pack case  1000 . According to one embodiment, a person performing the assembly first inserts cells  1004  in a first row  1006 . Because the cells  1004  are heavy (can be on the order of 200 lbs. each), a hoist or other lifting device may be used to assist in the assembly. Lead or other conducting bars  1008  are then connected between the cells  1004  in the row  1006  so that the cells  1004  are electrically connected in series. Each of the cells  1004  may also have one or more vents  1010 , which allow gases formed within the cells  1004  to escape from the cells. 
       FIG. 10E  is a top view of the battery pack/fan module assembly after a second row  1012  of six cells has been inserted into the battery pack case  1000 . This drawing and  FIG. 10F  also illustrate the insertion of a first fan module  1014  in the battery pack case  1000  next to three of the cells  1004  of the first row  1006  of cells. 
       FIG. 10G  is a top view of the battery pack/fan module assembly after the first  1006  and second  1012  rows of cells, and four fan modules  1014  have been installed in the battery pack case  1000 . As shown, the fan modules  1014  each have air port extensions  1016 , which extend laterally over and outside the upper edge of the battery pack case  1000 . As described above, these air port extensions  1016  may embody either an inlet port extension or an outlet port extension, depending on which of the various fan modules described above in  FIGS. 5-9  is adopted for use. 
       FIG. 10H  is a top view of the battery pack/fan module assembly after third  1018  and fourth  1020  rows of cells have been installed in the battery pack case  1000 .  FIG. 10I  is a top view after the final two fan modules  1014  have been installed in the battery pack case  1000 . 
       FIG. 10J  is a top view of the battery pack/fan module assembly after final assembly. End row connectors  1022  have been connected to end row cells so that all cells  1004  of the battery pack are connected in series. Positive and negative cables  1024  and  1026  have been connected and joined in a connector  1028 . In an exemplary configuration, each cell  1004  provides a voltage of two volts, so that when all twenty-four cells are connected in series the battery pack provides a standard forty-eight volts. 
       FIG. 11  is an isometric view of a completed battery pack/fan module assembly, illustrating exemplary airflow paths, according to an embodiment of the present invention. The fan modules  1014  have inlet ports  1030  with extensions that extend laterally over and outside the upper edge of the battery pack case  1000 . This configuration allows the air inlet ports  1030  to access fresh air outside the confines of the battery pack case  1000 . As explained previously, one or more fans within each fan module  1014  draw the fresh air into the air inlet ports  1030 , and circulates the air through the fan module  1014  so that heat from the battery pack cells  1004  is transferred to the air and finally directed out air outlet ports  1032  of the fan modules  1014 . 
     As explained above, the side panels of the fan modules  1014  are made of a conductive material, e.g. metal, so that when inserted between cells of the battery pack they are capable of conducting heat away from the battery pack cells. The side panels of the fan modules  1014  are preferably pressed up firmly against the exterior walls of associated battery pack cells. In this manner, airflow is maintained within, and directed through, the fan modules  1014  in a predetermined manner. Preferably, one or more slots or “cut-outs” are made through the side panels of each of the fan modules  1014 . The cutouts allow air in the fan modules  1014  to come into intimate contact with those the exterior walls of the cells in which the side panels are in contact. This configuration allows heat generated by the cells to be more readily transferred to the contacting air. 
     A significant benefit of the battery pack/fan module assembly shown and described above, in addition to its temperature and ventilation management capabilities, is that it can be installed in electric vehicles without requiring any modification to the vehicle itself. 
     The fan modules  1014  of the battery pack/fan module assembly can be configured to operate continuously, e.g., during charging as well as while the vehicle is being driven. Alternatively, the fan modules  1014  can be configured so that they are operational during certain times, for example: only during charging; during charging but also at predetermined times before or after charging; or only while the vehicle is being driven. The ON/OFF status of the fan modules may be controlled by, for example, a thermostat, a key switch, a charger interlock, or a battery mounted monitor and controller associated with the battery pack. The battery mounted monitor and controller may be in the form of a module, which can be attached to or associated with one or more cells of the battery pack. Among other capabilities, the battery mounted monitor and controller may contain temperature sensing and data collection components. The sensed temperature and/or temperature-related collected data can be used to control the ON/OFF status of one or more of the fan modules  1014 . 
     In an embodiment alternative to that shown in  FIG. 11 , the fans of the fan modules  1014  can be run in reverse, so that fresh air is drawn in from the tops of the fan modules  1014 , and air heated by the cells  1004  is ejected out the side ports of the fan modules  1014 . In this alternative embodiment, the air inlet and output ports are reversed from that initially described and shown in  FIG. 11 . 
     Turning now to  FIGS. 12A and 12B , there are shown front and isometric views of an alternative battery pack temperature and ventilation management system  1200 , according to an embodiment of the present invention. The battery pack temperature and ventilation management system  1200  comprises a battery pack  1202 , battery pack case  1203 , and a direct-mounted cooling fan box  1204  containing one or more fans  1206 . Rather than interpose fan modules between cells of the battery pack as described in the alternative embodiment above, the fan box  1204  is mounted directly to the battery pack case  1203 . This provides cooling to the battery pack case  1203  and the battery pack  1202 . The battery pack case may have cutouts (not shown) so that the forced air from the fan box  1206  can directly flow onto and through the cells of the battery pack  1202 , thereby providing enhanced cooling. 
       FIG. 13  is an illustration of a battery pack having a direct-mounted cooling fan box  1204 , which includes one or more fans  1206 , installed in an electric vehicle  1208 , according to an embodiment of the present invention. Mounting the fan box  1204  directly to the battery pack case  1203  allows the battery pack temperature and ventilation management system  1200  to be installed in the electric vehicle without having to undergo any modifications to the vehicle. 
     To further the desire of not having to make any modifications to an electric vehicle in order to accommodate fast charging, it may be necessary to provide a mechanism for isolating the vehicle motor controller from the battery pack during fast recharging. The reason for this possible requirement is due to the fact that the motor controllers of many electric vehicles are not designed to withstand the high voltages used in fast charging. Isolation of the motor controller could be performed by requiring an operator to unplug connectors installed between the motor controller and the battery pack. However, this approach has the drawback that an operator may simply forget to unplug the connectors before configuring the battery pack for fast recharging. Further, the connectors between the motor controller and the battery pack are not always easily accessible by an operator. This poses the risk that the operator might come into contact with battery acid and/or suffer electrical shock. 
       FIG. 14A  shows the concept of an electric vehicle motor controller isolator  1400  that can be used to avoid these risks and guarantee motor controller isolation during fast recharging by a fast charger  1402 , according to an embodiment of the present invention. Cables  1404  and connectors  1406  of the fast charger  1402  are connected in a parallel, and are configured to mate with dual cables  1408  and connectors  1410  of the battery pack  1412 . The dual cables  1408  and connectors  1410  of the battery pack  1412  are used to support the high currents drawn by the battery pack  1412  during fast charging. An electrical contactor (e.g. a micro switch, key switch or other switch) or mechanical disconnect  1414 , an exemplary embodiment which is described below, is operable to electrically isolate the electric vehicle motor controller  1416  when the charger connectors  1406  are plugged into the battery pack connectors  1410 . This aspect of the invention is also beneficial in that it does not allow the vehicle to be driven away from the charger  1402  when the charger connectors  1406  and battery pack connectors  1410  are still mated. The operator must first unplug the connectors  1406 ,  1410  before the vehicle can be driven away from the charger  1402 . 
       FIG. 14B  is an illustration of an electric vehicle motor controller isolator for a charging system, according to an alternative embodiment of the present invention. This embodiment is similar to the embodiment shown in  FIG. 14A , except that a single set of connectors and cables  1418 ,  1420  are used, rather than parallel-connected connectors and cables. These cables and connectors have current ratings sufficient to withstand the high currents flowing through them during fast charging. 
       FIGS. 15A-15E  show components of an exemplary mechanical disconnect system that is operable to electrically isolate a motor controller of an electric vehicle from a battery pack and fast charger during fast charging, according to an embodiment of the present invention. 
       FIG. 15A  is a drawing of an exemplary charging connector  1500 , which comprises a base  1502  and first and second electrically conducting (e.g. metal) pins  1504 —one positive and one negative. End portions  1506  of the first and second pins  1504  are covered by an electrically insulating material such as plastic or Teflon. Cables  1505  electrically couple the charging connector to a charger. The charging connector  1500  also contains electrical signal pins (not shown), which explained in more detail below are for making electrical contact to signal pin contacts on a charging and motor controller isolation assembly. A signal line  1507  comprising a plurality of signal wires that electrically couple the signal pin contacts to the charger. 
       FIG. 15B  is an illustration of a charging receptacle  1508 , which is adapted to receive the charging connector shown in  FIG. 15A  during fast charging. The charging receptacle  1508  has first and second female sleeves  1510  designed to receive the first and second pins  1504  of the charging connector  1500 . The first and second female sleeves  1510  are mechanically supported and electrically isolated from one another by a non-conducting sleeve bridge  1512 . The first and second females sleeves  1510  are made of an electrically conducting material (e.g. metal), and have end portions  1514 , which similar to the end portions  1506  of the charging connector pins  1504 , are covered by a plastic or other electrically insulating material such as, for example, Teflon. The non-conducting end portions  1514  of the sleeves  1510  help to ensure that the pins  1504  of the charging connector  1500  are not inadvertently shorted to the charging receptacle  1508  when the charging connector  1500  is being mated with the charging receptacle  1508 . They also help to prevent exposing an operator to electrical shock when the charging connector  1500  is being mated with the charging receptacle  1508 . The charging receptacle also includes first and second contact posts  1516 , which are adapted for connecting to cables of a battery pack. 
       FIG. 15C  is an illustration of a charging and motor controller isolation assembly that includes the charging receptacle  1508  of  FIG. 15B  and a spring controlled electric vehicle drive connector  1520 . The charging receptacle  1508  is permanently mounted to a support substrate  1522 . The vehicle drive connector  1520  comprises a base  1518  and first and second electrically conducting (e.g. metal) pins  1524 , which like the charging connector pins  1504  have end portions  1526  that are covered by an electrically-insulating material such as plastic or Teflon. The vehicle drive connector  1520  is movably mounted on a slider  1528 , which allows the vehicle drive connector pins  1524  to move into and out of the charging receptacle sleeves  1510 . The slider  1528  is movably mounted on a track  1530 , which is affixed to the support substrate  1522  and aligned so that the vehicle drive connector pins  1524  can be moved into and out of the charging receptacle sleeves  1510 . The conducting portions of the vehicle drive connector pins  1524  are adapted for fitting with cables  1532 , which connect to the motor controller of the electric vehicle. One or more springs  1534 , or other actuating device(s), are installed between a fixed compression plate  1536  and a surface of the base  1518  of the vehicle drive connector  1520 . The spring(s)  1534  is(are) operable to push the vehicle drive connector  1520  along the track  1530  so that the vehicle drive connector pins  1524  are inserted into the charging receptacle sleeves  1510  when the charging connector  1500  is not mated with the charging receptacle  1508 . Alternatively, as shown in  FIGS. 15D and 15E  below, one or more springs  1538 , or other actuating device(s), may be installed between the fixed charging receptacle  1508  and the movable vehicle drive connector  1520 , so that the vehicle drive connector pins  1524  are pulled into the charging receptacle sleeves  1510  when the charging connector  1500  is not mated with the charging receptacle  1508 . 
     Also mounted on the support substrate  1522 , or integrated with the charging receptacle  1508 , are signal pin contacts  1540 , which electrically connect to the signal pins of the charging connector  1500  when the charging connector  1500  is plugged into the charging receptacle  1508 . In the exemplary embodiment shown, there are four signal pin contacts  1540 . Two of the signal pin contacts allow the charger or other electrical device to access the battery mounted monitor and controller of the battery pack when the charging connector  1500  is mated with the charging receptacle  1508 . The other two signal contacts allow an interlock redundancy function, whereby the charger is prevented from supplying a voltage to the assembly unless the charging connector  1500  is properly engaged with the charging receptacle  1508  and/or until an operator permits the charger to supply the voltage once the connector  1500  is properly engaged with the receptacle  1508 . 
       FIG. 15D  shows the charging and motor controller isolation assembly when the charging connector  1500  is not plugged into the receptacle  1508 . In this configuration, the charging and motor controller isolation assembly allows the battery pack voltage of the vehicle to be applied to the motor controller so that the vehicle can be driven. One or more springs  1538 , or other actuating device(s), pulls the vehicle drive connector pins  1524  into the receptacle sleeves  1510 . This allows the electrically conducting surfaces of the receptacle sleeves  1510  to be in electrical contact with the electrically conducting portions of the vehicle drive connector pins  1524 . 
       FIG. 15E  shows the charging and motor controller isolation assembly when the charging connector  1500  is mated with the charging receptacle  1508 . In this configuration, the vehicle cannot be driven until the charging connector  1500  is unplugged from the charging receptacle  1508 , and the motor controller is protected from high voltages from the fast charger during fast charging. Electrically conducting surfaces of the vehicle drive connector pins  1524  are entirely removed from the charging receptacle sleeves  1510 . Hence, the conducting portions of the vehicle drive connector pins  1524  are electrically isolated from the battery pack and charger. The end portions  1526  of the vehicle drive connector pins  1524  are also electrically isolated from the end portions  1506  of the charging connector pins  1504  since the end portions of both connectors are covered with an electrically insulating material. Accordingly, the vehicle drive connector  1520  is completely isolated electrically from the battery pack and faster charger and, consequently, the motor controller of the vehicle is electrically isolated from the battery pack and charger. It should also be mentioned that, although not shown in the drawing a catching mechanism of some sort is affixed to the assembly to ensure that the charging connector  1500  and charging receptacle  1508  are held in place after mating. 
     To provide a fully integrated battery pack solution, the charging and motor controller isolation assembly in  FIG. 15  and/or the thermal and ventilation management concepts described in  FIGS. 5-13  above can be integrated into the battery pack or battery pack case, thereby forming an integrated battery unit (or “IBU”).  FIG. 16  shows, for example, how an operator would perceive such an IBU  1600  containing the charging and motor controller isolation assembly described in  FIG. 15 . The IBU  1600  is shown to have a conventional vehicle connector  1602 , which is connected to positive and negative terminals of the IBU  1600  via battery cables  1604 . The IBU  1600  also contains a charge port  1606 , which is coupled to the charging and motor controller isolation assembly described in  FIG. 15 . The charging and motor controller isolation assembly is hidden (although not necessarily) from view. All that is seen by an operator is the charge port  1606 , which is configured to receive a charging connector like that shown in  FIG. 15A  or similar charging connector. 
       FIG. 17  is a perspective drawing of an alternative embodiment of an IBU, according to an embodiment of the invention. According this embodiment, the battery pack thermal and ventilation management system (similar to that shown in  FIGS. 12 and 13 ) is housed in a fan box, together with one or more of the following: a charge port  1700 , charge port connected/unconnected indicator (“Euro-connector” shown in “drive” position)  1702 , battery mounted monitor and controller status indicator  1704 , motor controller connection cables  1706 , and connector status LED  1708 . The integration is simple enough that the IBU can be added to an existing vented tray in the field if necessary. 
     The thermal and ventilation management system may be mounted to an end of the battery tray holding the battery pack or may be mounted directly onto the battery pack. In either alternative the fan housing (i.e. “fan box”) is designed so that it does not exceed the battery compartment “protection” zone. 
     When a charger connector is plugged into the charge port  1700 , the drive system is automatically disabled to prevent drive-aways that could possibly damage the charging cables and/or charger. As explained above, the motor controller (i.e. drive system) disconnect can be effected by a mechanical disconnect system (e.g. like that shown in  FIGS. 14 and 15  above), a contactor, relay or other suitable means. The IBU may also have an integrated lockout/tag out provision  1710  to prevent the vehicle from being driven or the battery pack from being charged while the vehicle is being serviced. 
     The battery mounted monitor and controller status indicator  1704  may be used to display battery state of charge (SOC), battery temperature, water level, faults, maintenance requirements, battery historical information, etc. While show as being integrated within the fan housing, the display could also or alternatively be mounted remotely (e.g. on the vehicles dash). The battery mounted monitor and controller itself may also be included within the IBU to provide the brains for communicating with the charger, controlling fan operation, activating/deactivating the watering solenoid valve, enabling/disabling the drive system, and providing status information to a display and/or vehicle controls. A diagnostic port may also be provided and integrated within or on the IBU so that the battery mounted monitor and controller historical and maintenance information can be easily downloaded. Finally, but not necessarily lastly, the IBU may also include a “shock” type of auto disconnect that could disable the drive system if the vehicle had a high enough shock incident (e.g. such as hitting a column, rack or wall). 
       FIG. 18  is a second perspective drawing of the IBU shown in  FIG. 17 . In addition to the other integrated components described in connection with  FIG. 17 , the IBU may also include a watering solenoid valve  1800  that may be configured to control the flow of water into the cells of the battery pack. 
       FIG. 19  illustrates how the IBU in  FIGS. 16 ,  17  or  18  may be installed in an electric vehicle. The IBU is open to the air, and the charge port is arranged so that an operator can easily access it to plug in and unplug a charging connector. The IBU, which as mentioned above may also contain the thermal and ventilation management systems described above in connection with  FIGS. 5-11  or  12  and  13 , can be installed in the electric vehicle without having to make any modifications to the electric vehicle. Further, the vehicle connector remains connected at all times, i.e., during charging and during operational use. If for some reason the battery pack needs to be removed (e.g. when the battery pack has come to the end of its useable lifetime), the only operation that needs to be performed before removing the IBU is the unplugging of the vehicle connector. 
     While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from this invention and its broader aspects. Accordingly, the appended claims are intended to encompass within their scope all such changes and modifications as are within the true spirit and scope of the described inventions.

Technology Classification (CPC): 1