Patent Description:
Accordingly the present invention discloses a cell agnostic battery module according to the appended claims. The cell agnostic battery module comprises a chassis having compartments for receiving sub-modules of a first type and a second type. The sub-modules include lithium-ion cells and can be connected in series, parallel or series and parallel. The battery module further comprises a battery pack controller, and internal interconnects adapted for coupling the sub-modules received in the compartments to the battery pack controller. The internal interconnects includes a sub-module power bus adapted for coupling a power connector on the battery pack controller with complementary power connectors on the sub-modules and a sub-module communication bus adapted for coupling at least one communication connector on the battery pack controller with complementary communication connectors on the sub-modules. The internal interconnects comprise low voltage power adapted for coupling with a power and ground connector on the battery pack controller with complementary power and ground connectors on the sub-modules to supply low voltage power to the sub-modules. In other aspects, the internal interconnects further comprise a digital I/O adapted for coupling a digital I/O connector on the battery pack controller with complementary digital I/O connectors on the sub-modules to receive/send a digital I/O signal. In some aspects, the battery pack controller further comprises external interconnects adapted for coupling with signal and power connectors on the battery pack controller.

In some aspects, the sub-modules of the first type and the second type comprise lithium-ion battery cells of different form factor type. The form factor type is one of cylindrical type, pouch type or prismatic type. In other aspects, the sub-modules of the first type and the second type include sub-modules from different suppliers. In yet other aspects, the sub-modules of the first type and the second type include sub-modules using different cell technologies.

In some aspects, the chassis further comprises one or more fans to provide airflow through an interior of the chassis. In further aspects, the chassis can comprise a metal bezel attached to a front end. The metal bezel may have a ventilation pattern to provide airflow through the interior of the chassis.

In accordance with some embodiments, a battery module comprises a chassis having at least two compartments configured to receive at least two sub-modules. Each sub-module may comprise lithium-ion cells of cylindrical type, pouch type or prismatic type. The at least two sub-modules may be connected in series or parallel to provide a target pack voltage and a target energy density. The battery module includes a battery module controller disposed in the chassis. The battery module controller may be electrically coupled with the at least two sub-modules via internal interconnects comprising a bi-directional power bus, a bi-directional communication bus, a sub-module power and ground line and a digital input/output line.

In some aspects, the battery module may comprise a backplane connector for signal and power connections. The chassis of the battery module may also comprise one or more fans to provide airflow through an interior of the chassis. In some aspects, a metal bezel may be attached to a front end of the chassis. The metal bezel may comprise a ventilation pattern to provide airflow through an interior of the chassis. Contactors adapted to control connection of a DC voltage output to a DC high voltage power bus of an energy storage system may be disposed in the chassis in some aspects.

In accordance with some embodiments, a plurality of sub-modules of a first or second type may be interconnected to a battery pack controller in a battery pack by connecting a plurality of sub-modules of a first type in series, parallel or both to create a high voltage power bus. The plurality of sub-modules of the first type may be replaceable with a plurality of sub-modules of a second type to create the power bus. The example method may further comprise electrically coupling the plurality of sub-modules of the first or second type to a battery pack controller via a bi-directional high voltage power bus and a power supply bus. In some aspects, the example method may further comprise communicatively coupling the plurality of sub-modules to the battery pack controller via a sub-module communication bus and one or more digital I/O connections.

In some aspects, the plurality of sub-modules of the first type comprises lithium-ion cells of cylindrical form factor and the plurality of sub-modules of the second type comprises lithium-ion cells of prismatic or pouch form factor. In other aspects, voltage on the high voltage power bus is 300V or at least 48V. The voltage on the high voltage power bus may be electrically coupling to a load. In some aspects, the battery pack controller may be coupled to an external communication bus separate from the sub-module or internal communication bus.

In accordance with some embodiments, a sub-module configured to be connected with one or more other sub-modules to create a battery pack with a targeted pack voltage and energy density may comprise lithium ion cell sub-modules comprising lithium ion cells of the same type, components for executing cell monitoring and balancing functions, a sub-module interface adapted for interconnecting with a battery pack controller including a power terminal for coupling with a bi-directional DC power bus, a power terminal for coupling with a power supply bus, one or more digital I/O terminals for coupling one or more digital I/O links and a communication terminal for coupling with a communication bus.

Lithium-ion battery packs or modules can be made using any of a number of cell technologies such as, but not limited to: lithium-ion Iron Phosphate (LFP), lithium-ion Nickel Manganese Cobalt Oxide (NMC) and lithium-ion Nickel Cobalt Oxide (NCA). The lithium-ion cells are available in different form factors (e.g., cylindrical, prismatic, pouch). One of the disadvantages of existing lithium-ion battery packs is that they are designed for a specific cell technology and form factor offered by a cell manufacturer (e.g., Sony). This level of customization means that it is not possible to switch from cells made by one cell manufacturer to another without changing the battery pack design. Consequently, the battery pack would need to be redesigned to accommodate the new cells without affecting the output voltage, energy density, and/or other characteristics such as performance and reliability. Once the battery pack is redesigned, it becomes necessary to bring the battery pack under regulatory compliance (e.g., Underwriters Laboratories (UL) certification). Certification for lithium-ion battery packs having voltages greater than 60V is already a challenging process, but with the certification standards generally varying from country to country, re-certification can require significant time and effort. Thus, changing the cell technology/form factor/supplier for a battery pack can involve not just a redesign of the battery pack but also recertification, all of which can be time consuming and costly. Because of these inefficiencies, battery pack manufacturers are often stuck with the same cell supplier which can impact their ability to produce battery packs at a competitive cost or resolve cell quality issues.

The battery pack described in the present disclosure has a sub-module based architecture, which helps make the battery pack effectively "cell agnostic," thereby addressing the challenges of existing battery packs. The cell agnostic battery pack comprises sub-modules connected to a battery pack controller via an internal interconnect interface. The sub-modules comprise lithium-ion cells of any cell technology and type (e.g., cylindrical, pouch, prismatic), and as such can be supplied by any cell supplier. The sub-modules can be interconnected in series, parallel or both series and parallel to create a power bus (e.g., 150V, 300V). Moreover, the sub-modules can be individually certified (e.g., by cell suppliers that manufacture the sub-modules), which reduces the burden on the battery pack manufacturer to recertify the battery pack when switching from a sub-module made by one cell supplier to another cell supplier.

These and various other embodiments, aspects and advantages of the cell agnostic battery pack will now be described in detail.

<FIG> is a block diagram illustrating example components of a cell agnostic battery pack <NUM>. The battery pack <NUM> comprises multiple sub-modules <NUM> connected in series, parallel or series and parallel to provide a target pack voltage and energy density. By way of example, a target pack voltage and energy density of an example battery pack having multiple modules can be 300V and 7kWh.

The sub-module <NUM> comprises cells and cell assembles. As depicted in <FIG>, the sub-module <NUM> comprises one or more lithium-ion cell sub-modules <NUM>. The lithium-ion cell sub-modules <NUM> in turn comprise lithium-ion cells of a specific form factor (e.g., cylindrical, pouch, prismatic) and cell technology. <FIG> depicts an example arrangement of <NUM> cylindrical cell sub-modules 104A disposed in a sub-module <NUM>. Similarly, <FIG> depicts an example arrangement of <NUM> pouch cell sub-modules 104B disposed in a sub-module <NUM>.

In some aspects, the sub-module <NUM> further comprises control and monitoring electronics for safety and/or operational efficiency. By way of example, the sub-module <NUM> can include a cell voltage monitoring and balancing circuit <NUM> and cell temperature monitoring circuit <NUM> including temperature and/or other sensors. The cell voltage monitoring and balancing circuit <NUM> can monitor cell voltage and temperature (via cell temperature monitoring circuit <NUM>) as these are generally indicative of impending faults or failure, and balance cell and string voltage based on external command (e.g., from battery pack controller <NUM>).

The sub-module <NUM> also comprises a power supply module <NUM> and a communication module <NUM>. The power supply module <NUM> supplies power and ground <NUM> to the control and monitoring electronics. The communication module <NUM> supports receiving and sending of data over a communication bus <NUM>. In some aspects, the communication bus <NUM> can be a Controller Area Network (CAN) bus. The sub-module <NUM>, in some aspects, includes one or more digital I/O pins through which digital I/O link <NUM> can be communicated. By way of example, emergency fault (e.g., cell over voltage) can be reported through a digital I/O link <NUM>.

The battery pack <NUM> also comprises a battery pack controller <NUM>. Embodiments of the battery pack controller <NUM> can include various modules for controlling and managing the battery pack <NUM>. By way of example, the battery pack controller <NUM> can include modules for power supply <NUM>, a pack disconnect contactor control <NUM>, monitoring <NUM>, fault and protection <NUM>, state machine and algorithms <NUM>, data storage <NUM>, light emitting diode control <NUM> and communication <NUM>.

The monitoring module <NUM> can monitor pack voltage, current, temperature, and/or other operating characteristics of the sub-modules <NUM>. The fault and protection module <NUM> can protect the battery pack <NUM> against over voltage, under voltage, over temperature, ground fault, and/or other fault conditions using redundant analog measurement (e.g., from the monitoring module <NUM>). The pack disconnect contactor control <NUM> can control the contactors to connect or disconnect the battery pack <NUM> from a load (e.g., high voltage power bus). The state machine and algorithms <NUM> can include logic for battery pack state machine, auto addressing, firmware upgrade, warranty model, SOC, SOH and EOL, and the like. The data storage module <NUM> can include non-volatile (NV) storage for data logging, firmware upgrade, factory data, and the like.

The light emitting diode control <NUM> can include logic for controlling an LED light pipe. In some aspects, the LED light pipe can provide an indication of the health of the sub-modules. For example, the LED light pipe can turn red from green to indicate failure of one or more sub-modules.

The communication module <NUM> can support communication with the sub-modules <NUM> over an internal communication bus <NUM>. The communication module <NUM> can also support communication with external modules (e.g., other battery packs, a battery management system) over a separate and independent external communication bus.

The battery pack controller <NUM> and the sub-modules <NUM> are electrically and communicatively connected or coupled via internal interconnects. In some embodiments, the internal interconnects coupling the battery pack controller <NUM> and the sub-modules <NUM> include a power bus <NUM>, sub-module power and ground line <NUM>, one or more digital I/O line(s)<NUM> and a communication bus <NUM>. The power bus <NUM> interconnects a power connector on the battery pack controller <NUM> with complementary power connectors on the sub-modules <NUM>. The power bus <NUM> is created by combining the sub-modules output voltages in series, parallel or series and parallel. By way of example, <FIG> depicts sub-modules <NUM>-<NUM> connected in series to create a power bus <NUM> that is coupled to the battery pack controller <NUM>.

The sub-module power and ground line <NUM> interconnects a power connector on the battery pack controller <NUM> to complementary power connectors on the sub-modules <NUM> to supply low voltage power (e.g., +12V) to the sub-modules (e.g., for operating the monitoring and balancing electronics). The one or more digital I/O lines <NUM> interconnect one or more digital I/O pins/connectors on the battery pack controller <NUM> to complementary digital I/O pins/connectors on the sub-modules <NUM>. The digital I/O line <NUM> may be utilized by the sub-modules <NUM> for reporting emergency fault (e.g., cell over voltage, cell temperature exceeding a threshold, etc.) to the battery pack controller <NUM> in some aspects. In some aspects, the pack controller <NUM> can utilize the digital I/O lines <NUM> to send the sub-modules requests and/or responses. For example, the pack controller <NUM> can send charge voltage threshold, commands (e.g., go into sleep state), or the like to the sub-modules via the digital I/O lines <NUM>. The internal communication bus <NUM> interconnects a communication connector on the battery pack controller <NUM> to complementary communication connectors on the sub-modules to communicate data. Examples of such data can include temperate, voltage, current, cell health/status, other operating characteristics and/or data from the monitoring and balancing of the sub-modules <NUM>. The battery pack controller <NUM> can, in some aspects, send commands or requests to the sub-modules <NUM> in response to reported faults or other conditions (e.g., command to balance cell and string voltage) over the internal communication bus. Referring to <FIG>, the communication bus <NUM> as depicted can be a bi-directional daisy chain bus.

The battery pack controller <NUM> comprises external interconnects including a power bus <NUM>, a chassis ground <NUM> and signal in and signal out lines which are coupled to power connector <NUM>, signal connector <NUM> and signal connector <NUM> respectively. Via the power bus and signal in/out lines, the battery pack <NUM> may be coupled with one or more other battery packs, external modules and/or load.

<FIG> depicts a cell agnostic battery pack <NUM> in accordance with some embodiments. The battery pack <NUM> comprises a chassis <NUM> having compartments for receiving sub-modules <NUM>. For clarity, the sub-modules <NUM> are not shown. The chassis <NUM> has a number of compartments to receive a number of sub-modules <NUM>. The sub-modules can be secured inside the chassis via sub-module brackets 424A, 424B, 424C. Bus bars, wires or other suitable electrical coupling means can be used for connecting the sub-module power bus in series, parallel or a combination thereof to create a desired battery pack voltage (e.g., battery voltage of 300V) and energy density. Each of the connectors (e.g., power connector <NUM>, IN signal connector <NUM> and OUT signal connector <NUM>) on the battery pack controller <NUM> can be metal connectors disposed on the outside edge of the battery pack <NUM>. The battery pack <NUM> includes one or more contactors <NUM> for selectively electrically coupling the battery pack output to that of other battery packs or to an electrical load external to the battery pack. The one or more contactors <NUM> can be actuated in response to signal from the pack disconnect contactor control module <NUM>.

The chassis <NUM> includes a number of printed circuit board assemblies for the battery pack controller <NUM>, fuse circuit <NUM>, light pipe and LED circuit <NUM>. A fan assembly <NUM> may also be disposed in the chassis <NUM> to induce air flow through the interior of the chassis <NUM>. A front bezel <NUM> can be secured on to the front face of the chassis <NUM>. In some embodiments, the front bezel <NUM> can have a ventilation pattern to promote air flow through an interior of the chassis <NUM>. A removable top cover <NUM> affixes to the chassis <NUM> to form the battery pack <NUM> as depicted. An example of a battery pack <NUM> including nine sub-modules <NUM> inserted into compartments in the chassis is depicted in <FIG>. In this example embodiment, the nine sub-modules <NUM> are connected via bus bars in series and parallel configuration to create a target pack voltage and energy density. The sub-modules <NUM> are coupled with the battery pack controller <NUM> the PCB via the internal interconnects described in reference to <FIG> and <FIG>.

<FIG> is a diagram illustrating an example method of interconnecting a plurality of sub-modules of a first or second type to a battery pack controller in a battery pack. The example method comprises connecting a plurality of sub-modules of a first type in series, parallel or both to create a high voltage power bus at block <NUM>. At block <NUM>, the plurality of sub-modules of the first type can be replaced with a plurality of sub-modules of a second type to create the power bus. In some aspects, the plurality of sub-modules of the first type comprises cylindrical lithium-ion cells and the plurality of sub-modules of the second type comprises prismatic or pouch lithium-ion cells. In other aspects, the plurality of sub-modules of the first type comprises lithium-ion cells made by a first supplier and the plurality of sub-modules of the second type comprises lithium-ion cells made by a second supplier. In yet other aspects, the plurality of sub-modules of the first type comprises lithium-ion cells based on a first technology and the plurality of sub-modules of the second type comprises lithium-ion cells based on a second technology.

The example method further comprises electrically coupling the plurality of sub-modules of the first or second type to a battery pack controller via a bi-directional high voltage power bus and a power supply at block <NUM>. At block <NUM>, the example method comprises communicatively coupling the plurality of sub-modules to the battery pack controller via a sub-module communication bus and one or more digital I/Os.

Unless the context clearly requires otherwise, throughout the description and the claims, the words "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. " As used herein, the terms "connected," "coupled," or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof. Additionally, the words "herein," "above," "below," and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word "or," in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.

The above detailed description of embodiments of the disclosure is not intended to be exhaustive or to limit the teachings to the precise form disclosed above. While specific embodiments of, and examples for, the disclosure are described above for illustrative purposes, various modifications are possible within the scope of the disclosure, as defined by the claims, as those skilled in the relevant art will recognize.

These and other changes can be made to the disclosure in light of the above Detailed Description. While the above description describes certain embodiments of the disclosure, and describes the best mode contemplated, no matter how detailed the above appears in text, the teachings can be practiced in many ways. Details of the system may vary considerably in its implementation details, while still being encompassed by the subject matter disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the disclosure should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the disclosure with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the disclosure to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the disclosure encompasses not only the disclosed embodiments, but also all ways of practicing or implementing the disclosure under the claims.

Claim 1:
A cell agnostic battery pack (<NUM>) comprising:
a chassis (<NUM>) comprising:
compartments for receiving sub-modules (<NUM>) of a first type and a second
type, the sub-modules including lithium-ion cells and being connectable in series, parallel or series and parallel; and
a battery pack controller (<NUM>); characterised by: internal interconnects (<NUM>,<NUM>,<NUM>,<NUM>) adapted for coupling the sub-modules received in the compartments to the battery pack controller, the internal interconnects comprising:
a sub-module power bus (<NUM>) adapted for coupling a power connector on the battery pack controller with complementary power connectors on the sub-modules; and
a sub-module communication bus (<NUM>) adapted for coupling at least
one communication connector on the battery pack controller with complementary communication connectors on the sub-modules; wherein the battery pack controller is configured to provide low voltage power to each of the sub-modules through the sub-module power bus (<NUM>)