Patent ID: 12249680

The drawings are not necessarily to scale and may be illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to perceive may have been omitted.

DETAILED DESCRIPTION

At a high level, aspects of the present disclosure are directed to power source assembly systems and methods. Assembling a power source assembly efficiently and accurately is desirable. Furthermore, providing, for example, a high-density power assembly that can provide power to various systems in a compact form increases versatility of the power source assembly.

In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, that the present invention may be practiced without these specific details. As used in this disclosure, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described in this disclosure as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure. For purposes of description in this disclosure, the terms “top,” “bottom,” “upper,” “lower,” “front,” “rear,” “right,” “left,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented inFIG.1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed in this disclosure are not to be considered as limiting, unless the claims expressly state otherwise.

As used in this disclosure, an electrochemical cell is a device capable of generating electrical energy from chemical reactions or using electrical energy to cause chemical reactions. Further, voltaic or galvanic cells are electrochemical cells that generate electric current from chemical reactions, while electrolytic cells generate chemical reactions via electrolysis.

Aspects of the present disclosure describe a compact power source, for example, a high-energy density battery module, for a vehicle such as an eVTOL aircraft. For example, power source may provide electric power to at least a portion of an eVTOL aircraft for manned and/or unmanned flight. In an embodiment, power source may include a plurality of battery cells wired together in series and/or in parallel. In one or more embodiments, power source may be disposed in or on a vehicle such as an eVTOL aircraft, and may provide power to at least a portion of the vehicle. Power source may include thermal management systems and onboard computers to manage power output and general operation. Power source, as a whole, may include hardware for mechanical and electrical connections to at least a portion of a vehicle.

Power source mentioned in this disclosure may be a high energy density battery module. Energy density, as used in this disclosure, is defined as the amount of energy stored in a given system or region of space per unit volume and colloquially, energy per unit mass (also known as “specific energy”), the units of which may be presented in Joules per kilogram (J/kg), kilocalories per gram (kcal/g), British Thermal Units per pound mass (BTU/lb), and in SI base units, meters squared per seconds squared (m2/s2), and for the purposes of this disclosure Watt hours per kilogram (Wh/kg). In this way, a battery module having a high-energy power density is accomplished. For example, configured as discussed above, power source may include an energy density equal to or greater than 150 Wh/kg. High energy density battery modules may be consistent with disclosure of high energy density battery modules in U.S. patent application Ser. No. 16/948,140 and titled “SYSTEM AND METHOD FOR HIGH ENERGY DENSITY BATTERY MODULE,” which is incorporated by reference in its entirety herein. Furthermore, a stack battery may be consistent with disclosure of stack battery packs in U.S. patent application Ser. No. 17/404,500 and titled “STACK BATTERY PACK FOR ELECTRIC VERTICAL TAKE-OFF AND LANDING AIRCRAFT,” which is incorporated by reference in its entirety herein.

Referring now to the drawings,FIG.1shows a semi-transparent isometric view of an exemplary power source assembly system100used for assembling various types of power sources, such as a power source104(also referred to in this disclosure as a “power source”) shown inFIG.2D. Power source assembly system100(also referred to in this disclosure as a “system”) includes a compression mechanism108that applies a compressive force112to a plurality of battery cells116during the assembly of power source104. For the purposes of this disclosure, “a compression mechanism” is a device that applies a compressive force to an object. For example, and without limitation, compression mechanism is used to compact battery cells.

In one or more embodiments, system100may include a compression mechanism108. As previously mentioned, compression mechanism108may be used to apply a compressive force112to plurality of battery cells116(also referred to in this disclosure as “battery cells”) during assembly of power source104. Compressive force112may be applied on opposing sides of plurality of battery cells116, as shown inFIG.1. Such as, without limitation, compressive force112may be applied to opposing sides of battery cells116by applying pressure on a top layer of battery cells116and on a bottom layer of battery cells116to compress all the battery cells116. For instance, without limitation, battery cells116may be decreased in cross-sectional area due to the size of battery cells116being reduced along a vertical axis for insertion of battery cells116into a container120, as discussed further in this disclosure.

Compression mechanism108may use various techniques to apply compressive force. For example, compression mechanism108may be configured to use electrical power, pneumatic pressure, hydraulic pressure, magnetic forces, or any combinations thereof to apply compressive force112to battery cells116. Compression mechanism108may include a solenoid, servomotor, motor, electric motor, magnets, ratchet, screw, presser, weights, or the like.

In one or more embodiments, compression mechanism108may use direct contact with battery cells116to apply compressive force112, as shown inFIG.1. For instance, and without limitation, compression mechanism108may have one or more moveable arms124with abutting surfaces that each contact a corresponding surface of battery cells116. For example, compression mechanism108may use an abutting surface of each arm124to apply compressive force112on a portion of battery cells116. In one or more embodiments, the abutting surface of arm124may be a form relatively similar to a surface of plurality of battery cells116such that the surface of compression mechanism108may contact an entire surface of the top layer of plurality of battery cells116. In other embodiments, the abutting surface may have a surface area less than the surface area of the top layer of battery cells116so that the abutting surface only contacts a portion of a surface of the top layer, as shown in inFIG.1. As understood by one skilled in the art, compression mechanism108may have one or more pairs of opposing arms depending on the length of battery cells116and the method of insertion of compressed battery cells116into container120.

In one or more embodiments, compression mechanism108may use indirect contact with battery cells116to apply compressive force112on battery cells116. For example, magnetic or superconductive pads may be used to apply compressive force112to battery cells116, which may be positioned between magnetic pads.

In an exemplary embodiment of system100, system100may include a frame128. Moveable arms (also referred to herein as “arms”) of compression mechanism108may be attached to frame128and extend therefrom. Moveable arms124may be moved in various directions relative to frame128. For example, moveable arms may move linearly, moveable arms may be pivoted or rotated about a point for a desired amount, and moveable arms may be slidably displaced relative to frame128. Arms124of compression mechanism108may be used to apply a pressure, such as a compressive force112, to battery cells116during the assembly of power source104, as discussed in this disclosure further below. For purposes of this disclosure, a “compressive force” is a force applied on an object that compacts the object.

In another exemplary embodiment, frame128may include one or more guides132. Guides132may provide support for arms124. For instance, and without limitations, arms124may traverse along guides132to move battery cells116toward container120(as indicated by directional arrow136). Arms124may also transverse through guides132toward battery cells116(as indicated by directional arrows140) to accurately apply compressive force112to battery cells116. In one or more embodiments, once compressed battery cells116have been moved by arms124toward an opening144of container120, each arm124may be retracted from battery cells116as each corresponding portion of battery cells is inserted into container120through opening144. For example, front arms124amay be moved away from a corresponding front portion of battery cells116as first portion approaches or is inserted into opening144of container120. Additionally, rear arms124bmay be removed from second portion of battery cells116as second portion is advanced through opening144of container120. In one or more embodiments, frame128may include a rear panel (not shown) to push battery cells116forward into container120. In other embodiments, container120may include a slot152(shown inFIGS.2C-2D) so that arms may traverse along slot152and continue to apply compressive force112to battery cells116as battery cells116are advanced into container120. For example, arms124may maneuver through slot152so that arms124of compression mechanism108may remain in physical contact with plurality of battery cells116until battery cells116are fully secured within container120.

Still referring toFIG.1, frame128may include side panels (not shown) that may abut one or both sides of battery cells116to prevent lateral movement of battery cells116. For instance, the side panels may contact a right side and a left side of battery cells116to prevent battery cells116from sliding out of position from a predetermined arrangement. For instance, and without limitation, when battery cells116are compressed, side panels may abut the left and right sides of battery cells116to prevent individual cells (e.g., a battery cell116a-nshown inFIGS.2A-2D) from shifting out of a stacked arrangement. For the purposes of this disclosure, a predetermined arrangement of battery cells refers to a specific desired assortment, such as orientation and quantity, of battery cells. A protective wrapping156may also be used to maintain the predetermined arrangement of battery cells116, as discussed further below. Though battery cells116are shown as a single stacked column, as understood by one skilled in the art, a plurality of columns of stacked battery cells116may be inserted and fitted into container120. In other embodiments, battery cells116may be in a staggered arrangement. The staggered arrangement allows more battery cells116to be disposed closer together than in square columns and rows like in a grid pattern. The staggered arrangement may also be configured to allow better thermodynamic dissipation. In other embodiments, container120may be assembled about compressed battery cells116.

Now referring toFIGS.2A-D, the method of assembly of power source104is illustrated. As shown inFIG.2A, battery cells116may include individual battery cells116a-n(also referred to in this disclosure as a “battery cell,” “each battery cell,” or “one of the plurality of battery cells”). Furthermore, battery cells116may be placed in a predetermined arrangement, as previously discussed in this disclosure. For example, battery cells116may be stacked in layers where battery cell116asits atop battery cell116b, which in turn sits atop a desired number of intermediary battery cells until the bottom battery cell116n. As understood by one skilled in the art, battery cells116may include any number of individual battery cells without changing the scope or spirit of the invention.

In one or more embodiments, a stack of battery cells116may include various battery cells and non-cell layers. For example, battery cells may include a non-cell layer of protective wrapping156. In one or more embodiments, each battery cell116a-nof the plurality of battery cells116may include protective wrapping156. For example, cell and non-cell layers may alternate in a stacked arrangement of battery cells116. In other embodiments, the plurality of battery cells116may be wrapped as a whole in protective wrapping156. In one or more embodiments, protective wrapping156may include a thermally insulating material. In one or more embodiments, protective wrapping156may be woven between the plurality of battery cells116. Protective wrapping156may provide fire protection, thermal containment, and thermal runaway during a battery cell malfunction or within normal operating limits of one or more battery cells116and/or potentially, power source104as a whole. Protective wrapping156may be woven between each battery cell116a-nand be configured to thermally insulate each battery cell116a-nfrom another. Protective wrapping156can be configured to provide thermal containment for each battery cell116a-nwithin power source104. In embodiments, protective wrapping156may be woven in a plurality of ways including plain weaving, oxford weaving, braiding, and plaiting, among others. In this way each battery cell116a-nmay be captured in its own wrapping, thermally isolating each battery cell116a-nfrom the next. Protective wrapping156may be configured to prevent thermal runaway due to heat energy generated by battery cells116. Protective wrapping156may include fire protection material configured to contain a fire in an area in which it surrounds. Fire protection material, in general, may include fire-retardant and/or fire-resistant materials. Fire-retardant material is designed to burn slowly and therefore slow down the movement of fire through the medium of the material, thereby protecting components on the other side of it in time for countermeasures to be deployed, amongst other mitigation methods. Fire-resistant materials are configured to resist burning and withstand heat and, in the application of protective wrapping, may contain fire and heat energy in the location it is present, thereby preventing it from damaging other locations in power source104or surrounding areas. Fire-retardant materials used in textiles similar or the same to protective wrapping may include aramids, FR cotton, coated nylon, carbon foam (CFOAM), polyhydroquinone, dimidazopyridine, melamine, modacrylic, leather, Polybenzimidazole (PBI), and the like.

Physical separation of each battery cell116a-nserves to thermally insulate each battery cell116a-n. It should be noted as well that with a serpentine wrapping, a full wrap of each cell may be accomplished using a single sheet (or unit in which it is produced or cut) of protective wrapping156. An advantage of this single protective wrapping156may include ease of installation and maintenance and in no way limits the assembly from individually wrapping cells with material or precludes the use of more than one protective wrapping in a similar or unique arrangement.

In one or more embodiments, battery cells116may include a liquid electrolyte. In one or more embodiments, a battery cell116a-nmay be configured to include an electrochemical reaction that produces electrical energy sufficient to power various systems. For example, and without limitation, battery cells116may power at least a portion of an electric aircraft, such as an eVTOL aircraft. In other exemplary embodiments, power source104may be used to power a vehicle or a smaller system, such as a drone or computing device. Battery cell116a-nmay include electrochemical cells, galvanic cells, electrolytic cells, fuel cells, flow cells, voltaic cells, or any combination thereof.

In one or more embodiments, each battery cell116a-nmay be electrically connected in series, in parallel, or a combination of series and parallel. Series connection, as used in this disclosure, includes wiring a first terminal of a first cell to a second terminal of a second cell and further configured to include a single conductive path for electricity to flow while maintaining the same current (measured in Amperes) through any component in the circuit.

Battery cells116may use the term “wired,” but one of ordinary skill in the art would appreciate that this term is synonymous with “electrically connected,” and that there are many ways to connect electrical elements like battery cells116together. As an example, battery cells116can be connected via prefabricated terminals of a first gender that mate with a second terminal with a second gender. Parallel connection, as used in this disclosure, includes wiring a first and a second terminal of a first battery cell to a first and a second terminal of a second battery cell, respectively, and further configured to have more than one conductive path for electricity to flow while maintaining the same voltage (measured in Volts) across any component in the circuit. Battery cells116may be wired in a series-parallel circuit which combines characteristics of the constituent circuit types to this combination circuit. Battery cells116may be electrically connected in any arrangement which may confer onto the system the electrical advantages associated with that arrangement such as high-voltage applications, high-current applications, or the like.

Battery cell116a-nmay take a plurality of forms, but for the purposes of these illustrations and disclosure, will be represented as a rectangular prism with a rectangle representing the cross section of one cell each. With this orientation, a rectangular prism battery cell has a long axis.

As shown inFIG.2B, battery cells116may be compressed by compressive force112applied by compression mechanism108, as previously discussed in this disclosure. In one or more embodiments, compressive force112may compact each battery cell116a-nalong the vertical axis so that a height h of battery cells116is reduced to a height h′, thus, allowing battery cells116to fit into a more compact packaging, such as container120. Battery cells116may be, for example, pouches so as to allow compression of battery cells116, as discussed in this disclosure. Battery cells116may include flexible pouches such that they may be easily compressed by compression mechanism108without breaking, tearing, or sheering.

In one or more embodiments, battery cells116may include prevention of progression of thermal runaway between battery cells116. For example, and without limitation, battery cells116may include pouch cells to contain ejecta resulting from thermal runaway of a battery cell. Additionally, in some cases, pouch battery cells may be configured to reduce weight of a power source. A pouch cells of this disclosure may be consistent with disclosure of pouch cells in U.S. patent application Ser. No. 17/348,960 and titled “BATTERY PACK FOR ELECTRIC VERTICAL TAKE-OFF AND LANDING AIRCRAFT,” which is incorporated by reference in its entirety herein.

A pouch cell may include an insulator layer. As used in this disclosure, an “insulator layer” is an electrically insulating material that is substantially permeable to battery ions, such as, for example, lithium ions. In some cases, insulator layer may be referred to as a separator layer or separator. In some cases, insulator layer is configured to prevent electrical communication directly between at least a pair of, for example, a cathode and anode of the battery cell. In some cases, insulator layer may be configured to allow for a flow of ions across it. Insulator layer may consist of a polymer, such as without limitation polyolefin (PO). Insulator layer may include pours which are configured to allow for passage of ions, for example, lithium ions.

In some cases, a pouch may include a polymer, such as and without limitation, polyethylene, acrylic, polyester, and the like. In some cases, pouch may be coated with one or more coatings. For example, in some cases, pouch may have an outer surface coated with a metalizing coating, such as an aluminum or nickel-containing coating. In some cases, pouch coating may be configured to electrically ground and/or isolate pouch, increase the pouch's impermeability, increase the pouch's resistance to high temperatures, increases the pouch's thermal resistance (insulation), or the like.

In one or more embodiments, power source104may also include an ejecta barrier. Ejecta barrier may be located substantially between a first pouch cell and a second pouch cell. As used in this disclosure, an “ejecta barrier” is any material or structure that is configured to substantially block, contain, or otherwise prevent passage of ejecta. As used in this disclosure, “ejecta” is any material that has been ejected, for example, from a battery cell. In some cases, ejecta may be ejected during thermal runaway of a battery cell. Alternatively or additionally, in some cases, ejecta may be ejected without thermal runaway of a battery cell. In some cases, ejecta may include lithium-based compounds. Alternatively or additionally, ejecta may include carbon-based compounds, such as without limitation carbonate esters. Ejecta may include matter in any phase or form, including solid, liquid, gas, vapor, and the like. In some cases, ejecta may undergo a phase change, for example ejecta may be vaporous as it is initially being ejected and then cooled and condensed into a solid or liquid after ejection. In some cases, ejecta barrier may be configured to prevent materials ejected from a first pouch cell from coming into contact with a second pouch cell. For example, in some instances, an ejecta barrier is substantially impermeable to ejecta from battery pouch cell. In some embodiments, an ejecta barrier may include titanium. In some embodiments, an ejecta barrier may include carbon fiber. In some cases, an ejecta barrier may include at least a one of a lithiophilic or a lithiophobic material or layer configured to absorb and/or repel lithium-based compounds. In some cases, ejecta barrier may include a lithiophilic metal coating, such as silver or gold. In some cases, ejecta barrier may include a sheet, a film, a foil, or the like. For example, and without limitation, ejecta barrier may be between 25 and 5,000 micrometers thick. In some cases, ejecta barrier may have a nominal thickness of about 2 mm. Alternatively or additionally, in some cases, ejecta barrier may include rigid and/or structural elements, for instance, and without limitation, which are solid. Rigid ejecta barriers may include metals, composites, and the like. In some cases, ejecta barrier may be further configured to structurally support at least a pouch cell. For example, in some cases, at least a pouch cell may be mounted to a rigid ejecta barrier.

FIG.2Cshows compressed battery cells116being inserted into container120. In one or more embodiments, at least a portion of compressed plurality of battery cells116may be inserted into container120. Container120may be any shape or size that allows container120to receive battery cells116. Such as, without limitation, container120may be a rectangular prism. According to one or more embodiments, container120may include at least an end cap204and a body208. For the purposes of this disclosure, an “end cap” is a protective lid used to cover an opening of a container and/or seal the container. Container120may also include a second end cap216, as shown inFIG.2D. Container120provides a protective layer of material configured to create a barrier between internal components of power source104and environmental components. For example, container120may protect battery cells116from other aircraft components or environment. Body208may include opposite and opposing faces that form two sides, such as a left and right side, and a top and bottom of container120that encapsulate at least a portion of battery cells116. Container120may include metallic materials like aluminum, aluminum alloys, steel alloys, copper, tin, titanium, another undisclosed material, or a combination thereof. Container120may not preclude use of nonmetallic materials alone or in combination with metallic components permanently or temporarily coupled together. Nonmetallic materials that may be used alone or in combination in the construction of side container120may include high density polyethylene (HDPE), polypropylene, polycarbonate, acrylonitrile butadiene styrene, polyethylene, nylon, polystyrene, polyether ether ketone, or any combination thereof. Container120may be manufactured by a number of processes alone or in combination, including but limited to, machining, milling, forging, casting, 3D printing (or other additive manufacturing methods), turning, injection molding, or any combination thereof. One of ordinary skill in the art would appreciate that container120may be manufactured in pieces (e.g., body208and end cap204) and assembled together by screws, nails, rivets, dowels, pins, epoxy, glue, welding, crimping, or another undisclosed method alone or in combination. In one or more embodiments, container may include an electrical contact having an electrical connection with each battery cell116a-nof the at least a portion of plurality of battery cells116. Container120may include an injection molded component. The injection molded component may include a component manufactured by injecting a liquid into a mold and letting it solidify, taking the shape of the mold in its hardened form. In other embodiments, container120may be made from fiberglass. In other embodiments, container may be made from a polymer. Such as, without limitations, container120may be formed as multiple pieces or as a monolithic structure from a mold using plastic or resin. Container120may be used as a heat sink. Such as, without limitations, container120may be made from aluminum. Container120may include liquid crystal polymer, polypropylene, polycarbonate, acrylonitrile butadiene styrene, polyethylene, nylon, polystyrene, polyether ether ketone, and the like. Container120may use a boss224to seal body208using end caps204,216, a flange, or any other mechanism that allows end caps to be securely attached to body208.

Container120may be coupled to a sense board212through standard hardware like a bolt and nut mechanism, for example.

Body208is configured to provide structure and encapsulate at least a portion of battery cells116and, if applicable, protective wrapping156. End cap204may be configured to encapsulate at least a portion of battery cells116disposed within body208of container120. Each end cap204,216may be secured to body208using various mechanisms. For example, each end cap204,216may include one or more protruding bosses224and228, respectively, that click into receptacles232and236, respectively, in opposing ends of body208. Body208may provide two opposing side panels configured to encapsulate at least a portion of battery cells116.

In one or more embodiments, body208may include a vertical slit (not shown), which allows a user to readily ascertain the number of battery cells116disposed within container120without opening container120(e.g., removing an end cap). Furthermore, the slit may allow a user to determine if there is leakage from one of battery cells116a-n.

As previously mentioned, container120includes opening144, which compressed battery cells116may be inserted into. Second end cap216may be placed over opening144once battery cells are fully inserted into container120to seal container120and fully enclose battery cells116within container120. In one or more embodiments, container120may include a groove240disposed along at least one side of container120that is configured to engage at least a portion of battery cells116and align the at least a portion of plurality of battery cells116relative to container120. In one or more embodiments, at least a portion of the plurality of battery cells116is fully disposed within container120.

Container120may be configured to hold battery cells116in fixed positions once battery cells116are inserted into body208. For example, container120may have one or more fasteners252that engages complementary fasteners256on each end of a battery cell116a-nto ensure the battery cells116remain in the predetermined arrangement. For the purposes of this disclosure, a “container” is an object that holds, stores, and/or protects contents disposed therein. In one or more embodiments, container120may include a groove240. Groove240may traverse along an inner surface of body208and engage a portion of one or more of the plurality of battery cells116. For instance, without limitation, bottom battery cell116nmay have a complementary surface, such as a rib244, that may be disposed within groove240of container120and traverse along groove240to allow battery cells116to easily slide within container120. In one or more embodiments, groove240may also be used to distribute heat that may be generated by battery cells116.

According to embodiments, container120may include end cap204, which is configured to encapsulate at least a portion of container120and enclose at least a portion of battery cells116within container120. End cap204may provide structural support for container120. In other embodiments, end cap204may hold battery cells116in a fixed position relative to container120once battery cells116have been inserted into body208of container120. End cap204may have a protruding boss on a first end that mates up with and snaps into a receiving feature on a first end of body208. End cap204may include a second protruding boss on a second end that mates up with and snaps into a receiving feature on sense board212. Sense board212may be consistent with the sense board disclosed in U.S. patent application Ser. No. 16/948,140 entitled, “SYSTEM AND METHOD FOR HIGH ENERGY DENSITY BATTERY MODULE,” which is incorporated herein by reference in its entirety. Additionally, second end cap204may have a protruding boss on a first end that mates up with and snaps into a receiving feature on a second end of body208. Second end cap204may also include a second protruding boss on a second end that mates up with and snaps into a receiving feature on sense board212. In one or more embodiments, end cap204may include a non-electrically conductive component.

Body208of container120may include opposing side panels that may encapsulate two sides of battery cells116. The side panels may include opposite and opposing inner faces made from a metal or composite material. Container120may provide structural support for battery cells116and provide a barrier to separate battery cells116from exterior components within a system of use, such as a vehicle.

In one or more embodiments, container120may include a sense board212configured to detect a temperature of a battery cell116a-nof at least a portion of the plurality of battery cells116. Container120may further include a thermal sensor248communicatively and electrically connected to sense board212that is configured to detect thermal energy or the temperature of one or more battery cells116a-nof the plurality of battery cells116and translate the detected information to sense board212. In one or more embodiments, container120includes various other types of sensors. Such as, without limitation, container120includes a sensor configured to detect when each of the plurality of battery cells116are engaged with the fastener of end cap204.

End cap204may include a nonconductive component configured to align sense board212and battery cells116and hold their position. End cap204may form an end of and encapsulate a portion of a first end of power source104and the second opposite and opposing end cap216may form a second end and encapsulate a portion of a second end of power source104. As previously mentioned in this disclosure, end cap204may have a snap attachment mechanism having a protruding boss224which is configured to be captured, at least in part by receptacle232of a corresponding size disposed in body208. In one or more embodiments, end cap204may employ a similar or same method for connecting itself to sense board212, which may have a similar or the same receptacle. One of ordinary skill in the art would appreciate that the embodiments of a quick attach/detach mechanism end cap is only an example and any number of mechanisms and methods may be used for this purpose. It should also be noted that other mechanical connecting mechanisms may be used that are not necessarily designed for quick removal. Such mechanical connecting may include, as non-limiting examples, rigid connecting (e.g., beam connecting), bellows connecting, bushed pin connecting, constant velocity, split-muff connecting, diaphragm connecting, disc connecting, donut connecting, elastic connecting, flexible connecting, fluid connecting, gear connecting, grid connecting, hirth joints, hydrodynamic connecting, jaw connecting, magnetic connecting, Oldham connecting, sleeve connecting, tapered shaft lock, twin spring connecting, rag joint connecting, universal joints, or any combination thereof. End cap204may include a nonconductive component manufactured from or by a process that renders it incapable or unsuitable for conveying electrical through, on, or over it. Nonconductive materials end cap204may be paper, Teflon, glass, rubber, fiberglass, porcelain, ceramic, quartz, various plastics like HDPE, ABS, among others, alone or in combination.

In one or more embodiments, end cap204may include an electrical bus. The electrical bus, for the purposes of this disclosure and in electrical parlance, is any common connection to which any number of loads, which may be connected in parallel, and share a relatively similar voltage may be electrically coupled. The electrical bus may refer to power busses, audio busses, video busses, computing address busses, and/or data busses. The electrical bus may be responsible for conveying electrical energy stored in power source104to at least a portion of a system of use, such as an eVTOL aircraft. In an exemplary embodiment, the same or a distinct electrical bus may additionally or alternatively be responsible for conveying electrical signals generated by any number of components within power source104to any destination on or offboard an eVTOL aircraft. End cap204may include wiring or conductive surfaces only in portions required to electrically couple the electrical bus to electrical power or necessary circuits to convey that power or signals to their destinations.

With continued reference toFIGS.2C and2D, sense board212may be disposed on end cap204(shown) or body208(not shown). Sense board212may have at least a portion of a circuit board that includes one or more sensors configured to, for example, measure the temperature of battery cells116disposed within power source104. In one or more embodiments, sense board212may include one or more openings disposed in rows and column on a surface of sense board212. In embodiments, each hole may correspond to a battery cell116a-ndisposed within, encapsulated, at least in part, by container120. For example, the location of each hole may correspond to the location of each battery cell116a-ndisposed within container120.

Sense board212may include a battery management system, which may monitor battery cells116in a plurality of ways including temperature and voltage as discussed further in this disclosure. A battery management system may be consistent with disclosure of battery management system in U.S. patent application Ser. No. 17/111,002 and titled “SYSTEMS AND METHODS FOR A BATTERY MANAGEMENT SYSTEM INTEGRATED IN A BATTERY PACK CONFIGURED FOR USE IN ELECTRIC AIRCRAFT”, which is incorporated herein by reference in its entirety. In one or more embodiments, sense board212may include one or more circuits and/or circuit elements, including and without limitation, a printed circuit board component, aligned with a first side of battery cells116. Sense board212may include, without limitation, a control circuit configured to perform and/or direct any actions performed by sense board212and/or any other component and/or element described in this disclosure. Control circuit may include any analog or digital control circuit, including without limitation a combinational and/or synchronous logic circuit, a processor, microprocessor, microcontroller, or the like.

Sense board212may include one or more sensors248. In embodiments, sensor248may be a humidity sensor. Humidity, as used in this disclosure, is the property of a gaseous medium (almost always air) to hold water in the form of vapor. An amount of water vapor contained within a parcel of air can vary significantly. Water vapor is generally invisible to the human eye and may be damaging to electrical components. There are three primary measurements of humidity, absolute, relative, specific humidity. “Absolute humidity,” for the purposes of this disclosure, describes the water content of air and is expressed in either grams per cubic meters or grams per kilogram. “Relative humidity”, for the purposes of this disclosure, is expressed as a percentage, indicating a present stat of absolute humidity relative to a maximum humidity given the same temperature. “Specific humidity”, for the purposes of this disclosure, is the ratio of water vapor mass to total moist air parcel mass, where parcel is a given portion of a gaseous medium. Humidity sensor may be psychrometer. Humidity sensor may be a hygrometer. Humidity sensor may be configured to act as or include a humidistat. A “humidistat”, for the purposes of this disclosure, is a humidity-triggered switch, often used to control another electronic device. Humidity sensor may use capacitance to measure relative humidity and include in itself, or as an external component, include a device to convert relative humidity measurements to absolute humidity measurements. “Capacitance”, for the purposes of this disclosure, is the ability of a system to store an electric charge, in this case the system is a parcel of air which may be near, adjacent to, or above a battery cell.

Still referring toFIGS.2C and2D, sense board212may further include battery management system, where the battery management system may monitor the plurality of battery cells116a-nin numerous ways. Sense board212may include one or more sensors248, for example, a sensor configured to measure a temperature, and as a whole is further configured to detect failure within each battery cell of the plurality of battery cells116a-n. Battery cell failure may be characterized by a spike in temperature, wherein sense board212may be configured to detect the increase in temperature. Sense board212may be further configured to comprise sensors configured to measure a voltage and as a whole is further configured to detect a failure within, for example, first battery cell116aand/or any other battery cell116b-n. Cell failure may be further characterized by a spike and/or depletion in voltage, wherein sense board212may be configured to detect the increase and/or decrease in voltage. Sense board212may be further configured to generate signals to, as non-limiting examples, notify users, support personnel, safety personnel, maintainers, operators, emergency personnel, aircraft computers, or any combination thereof. Sense board212may be configured to comprise thermocouples, thermistors, thermometers, passive infrared sensors, resistance temperature sensors (RTD's), semiconductor based integrated circuits (IC), a combination thereof or another undisclosed sensor type, alone or in combination.

Temperature, for the purposes of this disclosure, and as would be appreciated by someone of ordinary skill in the art, is a measure of the heat energy of a system. Heat energy is, at its core, the measure of kinetic energy of any or all matter present within a system. Temperature, as read by any number or combinations of sensors present on sense board212, may be measured in Fahrenheit (° F.), Celsius (° C.), Kelvin (° K), or another scale alone or in combination. The temperature measured by sensors may comprise electrical signals which are transmitted to appropriate destination wirelessly or through a wired connection. Outputs from sensors or any other component present within system may be analog or digital. Onboard or remotely located processors can convert those output signals from a sensor suite to a usable form by the destination of those signals. The usable form of output signals from sensors, through processor may be either digital, analog, a combination thereof or an otherwise unstated form. Processing may be configured to trim, offset, or otherwise compensate the outputs of the at least a sensor. Based on sensor output, the processor can determine the output to send to downstream component. Processor can include signal amplification, operational amplifier (OpAmp), filter, digital/analog conversion, linearization circuit, current-voltage change circuits, resistance change circuits such as Wheatstone Bridge, an error compensator circuit, a combination thereof or otherwise undisclosed components. Persons skilled in the art, upon reviewing the entirety of this disclosure, will be aware of battery management systems that may be used in combination with the sense board consistently with this disclosure.

Still referring toFIGS.2C and2D, sense board212may include sensors configured to measure physical and/or electrical parameters, such as without limitation temperature and/or voltage, of battery cells116. Sense board212and/or a control circuit incorporated therein and/or communicatively connected thereto, may further be configured to detect failure within each battery cell116a-n, for instance and without limitation, as a function of and/or using detected physical and/or electrical parameters. Cell failure may be characterized by a spike in temperature and sense board212may be configured to detect that increase and generate signals, which are discussed further below, to notify users, support personnel, safety personnel, maintainers, operators, emergency personnel, aircraft computers, or a combination thereof. Sense board212may include thermocouples, thermistors, thermometers, passive infrared sensors, resistance temperature sensors (RTD's), semiconductor based integrated circuits (IC), a combination thereof or another undisclosed sensor type, alone or in combination. Temperature, for the purposes of this disclosure, and as would be appreciated by someone of ordinary skill in the art, is a measure of the heat energy of a system. Heat energy is, at its core, the measure of kinetic energy of matter present within a system. Temperature, as measured by any number or combinations of sensors present on sense board212, may be measured in Fahrenheit (° F.), Celsius (° C.), Kelvin (° K), or another scale alone or in combination. The temperature measured by sensors may include electrical signals which are transmitted to their appropriate destination wirelessly or through a wired connection.

Alternatively or additionally, sense board212may detect voltage and direct the charging of individual battery cells according to charge level. Detection may be performed using any suitable component, set of components, and/or mechanism for direct or indirect measurement and/or detection of voltage levels, including without limitation comparators, analog to digital converters, any form of voltmeter, or the like.

In one or more embodiments, sense board212and/or a control circuit incorporated therein and/or communicatively connected thereto may be configured to adjust charge to battery cells116as a function of a charge level and/or a detected parameter. For instance, and without limitation, sense board212may be configured to determine that a charge level of a battery cell is high based on a detected voltage level of that battery cell. Sense board212may alternatively or additionally detect a charge reduction event, defined for purposes of this disclosure as any temporary or permanent state of a battery cell requiring reduction or cessation of charging. A charge reduction event may include a cell being fully charged and/or a cell undergoing a physical and/or electrical process that makes continued charging at a current voltage and/or current level inadvisable due to a risk that the cell will be damaged, will overheat, or the like. Detection of a charge reduction event may include detection of a temperature, of the cell above a threshold level, detection of a voltage and/or resistance level above or below a threshold, or the like.

Sense board212and/or a control circuit incorporated therein and/or communicatively connected thereto may be configured to adjust charge to at least one battery cell of the plurality of battery cells as a function of the detected parameter (this may include adjustment in charge as a function of detection of a charge reduction event). Alternatively or additionally, sense board212and/or a control circuit incorporated therein and/or communicatively connected thereto may be configured to increase charge to a cell upon detection that a charge reduction event has ceased. For instance, sense board212and/or a control circuit incorporated therein and/or communicatively connected thereto may detect that a temperature of a subject battery cell has dropped below a threshold, and may increase charge again. Charge may be regulated using any suitable means for regulation of voltage and/or current, including without limitation use of a voltage and/or current regulating component, including one that may be electrically controlled such as a transistor; transistors may include without limitation bipolar junction transistors (BJTs), field effect transistors (FETs), metal oxide field semiconductor field effect transistors (MOSFETs), and/or any other suitable transistor or similar semiconductor element. Voltage and/or current to one or more cells may alternatively or additionally be controlled by thermistor in parallel with a cell that reduces its resistance when a temperature of the cell increases, causing voltage across the cell to drop, and/or by a current shunt or other device that dissipates electrical power, for instance through a resistor.

Still referring toFIGS.2C and2D, sense board212may include a high current busbar and integral electrical connections. Sense board212, and further battery management system of power source104may charge individual battery cells116a-ndepending on battery cell charge levels. Charging may be balanced throughout the plurality of battery cells116by directing energy through balance resistors by dissipating current through resistors as heat. In this manner, battery cells may be charged evenly, for example, cells with a lower amount of electrical energy will charge more than battery cells with a greater amount of energy. Cell charge balancing may be controlled via any means described above for regulation of charge levels, including without limitation metal oxide silicon field effect transistor or a metal oxide semiconductor field effect transistor (MOSFET).

Outputs from sensors or any other component present within system may be analog or digital. Onboard or remotely located processors can convert those output signals from sensor suite to a usable form by the destination of those signals. The usable form of output signals from sensors, through processor may be either digital, analog, a combination thereof, or an otherwise unstated form. Processing may be configured to trim, offset, or otherwise compensate the outputs of sensor suite. Based on sensor output, the processor can determine the output to send to downstream component. Processor can include signal amplification, operational amplifier (OpAmp), filter, digital/analog conversion, linearization circuit, current-voltage change circuits, resistance change circuits such as Wheatstone Bridge, an error compensator circuit, a combination thereof or otherwise undisclosed components.

With reference toFIG.3, an exemplary embodiment of a battery pack324that includes a plurality of power sources104is illustrated. As previously discussed, power source104may be configured to store electrical energy in the form of a plurality of battery cells or battery modules, which themselves include of a plurality of electrochemical cells. These cells may utilize electrochemical cells, galvanic cells, electrolytic cells, fuel cells, flow cells, and/or voltaic cells. In general, an electrochemical cell is a device capable of generating electrical energy from chemical reactions or using electrical energy to cause chemical reactions. Voltaic or galvanic cells are electrochemical cells that generate electric current from chemical reactions, while electrolytic cells generate chemical reactions via electrolysis. In general, the term “battery” is used as a collection of cells connected in series or parallel to each other. A battery cell may when used in conjunction with other cells, be electrically connected in series, in parallel or a combination of series and parallel. Series connection includes wiring a first terminal of a first cell to a second terminal of a second cell and further configured to include a single conductive path for electricity to flow while maintaining the same current (measured in Amperes) through any component in the circuit. A battery cell may use the term “wired”, but one of ordinary skill in the art would appreciate that this term is synonymous with “electrically connected”, and that there are many ways to couple electrical elements like battery cells together. An example of a connector that does not include wires may be prefabricated terminals of a first gender that mate with a second terminal with a second gender. Battery cells may be wired in parallel. A parallel connection includes wiring a first and a second terminal of a first battery cell to a first and second terminal of a second battery cell and further configured to include more than one conductive path for electricity to flow while maintaining the same voltage (measured in Volts) across any component in the circuit. Battery cells may be wired in a series-parallel circuit which combines characteristics of the constituent circuit types to this combination circuit. Battery cells may be electrically connected in a virtually unlimited arrangement which may confer onto the system the electrical advantages associated with that arrangement such as high-voltage applications, high-current applications, or the like.

With continued reference toFIG.3, power source104may include a plurality of battery cells. The battery cells may be wired together in series and in parallel. Power source104may include a center sheet which may include a thin barrier. Barrier may include a fuse connecting battery cells on either side of the center sheet. Fuse may be disposed in or on the center sheet and configured to connect to an electric circuit comprising a first battery module and therefore battery unit and cells. In general, and for the purposes of this disclosure, a fuse is an electrical safety device that operate to provide overcurrent protection of an electrical circuit. As a sacrificial device, its essential component is metal wire or strip that melts when too much current flows through it, thereby interrupting energy flow. The fuse may include a thermal fuse, mechanical fuse, blade fuse, expulsion fuse, spark gap surge arrestor, varistor, or a combination thereof.

Container120may include a side wall that includes a laminate of a plurality of layers configured to thermally insulate the plurality of battery cells from external components of power source104. Side wall layers may include materials that possess characteristics suitable for thermal insulation, as described in the entirety of this disclosure, like fiberglass, air, iron fibers, polystyrene foam, and thin plastic films, to name a few. Side wall may additionally or alternatively electrically insulate battery cells from external components of power source104and the layers of which may include polyvinyl chloride (PVC), glass, asbestos, rigid laminate, varnish, resin, paper, Teflon, rubber, and mechanical lamina. Center sheet may be mechanically coupled to side wall in any manner described in the entirety of this disclosure or otherwise undisclosed methods, alone or in combination.

With continued reference toFIG.3, battery pack324and/or power source104may include an end panel including a plurality of electrical connectors and further configured to fix battery cells in alignment with at least side wall. End panel may include a plurality of electrical connectors of a first gender configured to electrically and mechanically couple to electrical connectors of a second gender. The end panel may be configured to convey electrical energy from battery cells to at least a portion of, for example, an eVTOL aircraft. Electrical energy may be configured to power at least a portion of an aircraft or include signals to notify aircraft computers, personnel, users, pilots, and any others of information regarding battery health, emergencies, and/or electrical characteristics. The plurality of electrical connectors may include blind mate connectors, plug and socket connectors, screw terminals, ring and spade connectors, blade connectors, and/or an undisclosed type alone or in combination. The electrical connectors of which end panel includes may be configured for power and communication purposes. End panel may be a separate component or may be end cap204.

With continued reference toFIG.3, any of the disclosed components or systems, namely power source104, sense board212, and/or battery cells may incorporate provisions to dissipate heat energy present due to electrical resistance in integral circuit. Power source104includes one or more battery modules wired in series and/or parallel. The presence of a voltage difference and associated amperage inevitably will increase heat energy present in and around power source104as a whole. The presence of heat energy in a power system is potentially dangerous by introducing energy possibly sufficient to damage mechanical, electrical, and/or other systems connected to or near power source104. Power source104may include mechanical design elements, one of ordinary skill in the art, may thermodynamically dissipate heat energy away from power source104. The mechanical design may include, but is not limited to, slots, fins, heat sinks, perforations, a combination thereof, or another undisclosed element.

Heat dissipation may include material selection beneficial to move heat energy in a suitable manner for operation of power source104. Certain materials with specific atomic structures and therefore specific elemental or alloyed properties and characteristics may be selected in construction of power source104to transfer heat energy out of a vulnerable location or selected to withstand certain levels of heat energy output that may potentially damage an otherwise unprotected component. One of ordinary skill in the art, after reading the entirety of this disclosure would understand that material selection may include titanium, steel alloys, nickel, copper, nickel-copper alloys such as Monel, tantalum and tantalum alloys, tungsten and tungsten alloys such as Inconel, a combination thereof, or another undisclosed material or combination thereof. Heat dissipation may include a combination of mechanical design and material selection. The responsibility of heat dissipation may fall upon the material selection and design as disclosed above in regard to any component disclosed in this paper. Power source104may include similar or identical features and materials ascribed to power source104in order to manage the heat energy produced by these systems and components.

With reference toFIG.4, an exemplary embodiment of power source104is shown. Furthermore, an exemplary embodiment of container120is shown with battery cells116disposed therein after being compressed by compression mechanism108. A plurality of power sources104may be assembled together as discussed previously to provide battery pack324ofFIG.3.

FIG.5shows a block diagram of an embodiment of a battery management and monitoring system. A sensor suite552may be disposed in or on a portion of power source104near battery cells116. Battery pack324or power source104may include a battery management system head unit304. For example, battery management system head unit304may be disposed on end cap204or second end cap216of power source104or on end panel of battery pack324(shown inFIG.3). In one or more exemplary embodiments, and without limitation, battery management system head unit304may be configured to communicate with a flight controller of an aircraft using a controller area network (CAN). Controller area network includes bus. Bus may include an electrical bus. “Bus”, for the purposes of this disclosure and in electrical parlance, is any common connection to which any number of loads, which may be connected in parallel, and share a relatively similar voltage may be electrically coupled. Bus may refer to power busses, audio busses, video busses, computing address busses, and/or data busses. Bus may be responsible for conveying electrical energy stored in power source104to at least a portion of a system, such as an electric aircraft. Battery management system head unit548may comprise wiring or conductive surfaces only in portions required to electrically couple bus to electrical power or necessary circuits to convey that power or signals to their destinations.

Outputs from sensors or any other component present within system may be analog or digital. Onboard or remotely located processors can convert those output signals from sensor suite552to a usable form by the destination of those signals. The usable form of output signals from sensors, through processor may be either digital, analog, a combination thereof or an otherwise unstated form. Processing may be configured to trim, offset, or otherwise compensate the outputs of sensor suite. Based on sensor output, the processor can determine the output to send to downstream component. Processor can include signal amplification, operational amplifier (OpAmp), filter, digital/analog conversion, linearization circuit, current-voltage change circuits, resistance change circuits such as Wheatstone Bridge, an error compensator circuit, a combination thereof or otherwise undisclosed components.

According to embodiments, the circuitry disposed within or on power source104may be shielded from electromagnetic interference. The battery elements and associated circuitry may be shielded by material such as mylar, aluminum, copper a combination thereof, or another suitable material. Power source104and associated circuitry may include one or more of the aforementioned materials in their inherent construction or additionally added after manufacture for the express purpose of shielding a vulnerable component. Power source104and associated circuitry may alternatively or additionally be shielded by location. Electrochemical interference shielding by location includes a design configured to separate a potentially vulnerable component from energy that may compromise the function of said component. The location of vulnerable component may be a physical uninterrupted distance away from an interfering energy source, or location configured to include a shielding element between energy source and target component. The shielding may include an aforementioned material in this section, a mechanical design configured to dissipate the interfering energy, and/or a combination thereof. The shielding comprising material, location and additional shielding elements may defend a vulnerable component from one or more types of energy at a single time and instance or include separate shielding for individual potentially interfering energies.

Still referring toFIG.5, battery management and monitoring system500is disposed on at least a portion of battery pack324or power source104. Battery management and monitoring system500may include more than one electrically isolated systems performing at least a portion of the same functions. Battery management and monitoring system500may include more than one electrically isolated systems performing redundant functions. Battery management and monitoring system500may include more than one electrically isolated systems performing entirely different functions. Battery management and monitoring system500may include more than one electrically isolated systems performing entirely separate and distinct functions. Battery management and monitoring system500may include one or more physically separated systems disposed on at least a distinct portion of battery pack324or any subcomponents thereof. Battery management and monitoring system500may include one or more physically isolated systems that perform at least a portion of the same functions. Battery management and monitoring system500may include more than one physically isolated systems performing the redundant functions. Battery management and monitoring system500may include more than one physically isolated systems performing entirely different functions. Battery management and monitoring system500may include more than one physically isolated systems performing entirely separate and distinct functions. In one or more embodiments, at least a portion of battery management and monitoring system500may be disposed on sense board212, or another integrated circuit board component known in the art.

With continued reference toFIG.5, battery management and monitoring system500includes a sensor suite552. Sensor suite552may include any sensor suite described above consistent with the disclosure. Sensor suite552is configured to measure a plurality of battery pack data. Plurality battery pack data may include any plurality of power source data504described in this disclosure. Sensor suite552may include any of the sensors, grouping of sensors, or prefabricated sensor packages as described above with reference toFIGS.1and2. Sensor suite552may include an accelerometer. Sensor suite552may include a vibrometer, vibration sensor, load cell, pressure sensor, force gauge, a combination thereof, among other sensors configured to measure physical parameters like acceleration, force, vibration, pressure, and the like. Sensor suite552may include a voltmeter. Additionally, sensor suite552may include a multimeter, configured to measure electrical current, potential difference (voltage), resistance, impedance, capacitance, or other electrical parameters alone or in combination. Sensor suite552may include an ohmmeter, ammeter, or other separate electrical sensors. Sensor suite552may include a thermocouple. Additionally or alternatively, sensor suite552may include a thermometer, RTD, or other sensor configured to measure temperature or heat energy of a system.

With continued reference toFIG.5, battery management and monitoring system500includes a battery monitoring component508. Battery monitoring component508is configured to detect, as a function of plurality of power source data504, first fault512in power source104. Battery monitoring component508may be disposed on at least a portion of an integrated circuit board on or in power source104or battery pack324. Integrated circuit board may be disposed in power source104proximate to battery cells or disposed on end cap of power source104. First fault512may include an over-voltage condition of at least a portion of power source104, for example, a single electrochemical battery cell over-voltage, or a portion thereof. First fault512may include an under-voltage condition of at least a portion of power source104. First fault512may be characterized by a comparison, by battery monitoring component508, of a voltage measurement from sensor suite552, to a voltage threshold which has been predetermined or calculated by at least a user or additional system, or alternatively, input by a user. First fault512may include a temperature rise rate. There may be a threshold temperature rise rate or threshold temperature to which a temperature measurement by sensor suite552is compared by battery monitoring component508. First fault512may include a detection of a resistance. This resistance may be measured by sensor suite552and compared to a range or threshold resistance input by a user, calculated by at least a portion of an alternate system, or a combination thereof.

With continued reference toFIG.5, battery monitoring component508produces a first fault detection response516upon detection of first fault512. First fault detection response516may be generated in response to any of the described variations of first fault512. This is a non-exhaustive list of possible faults that may be detected as first fault512, one of ordinary skill in the art would understand the greater number and variation of physical, electrical, or other faults that may be detected by a sensor suite configured to measure characteristics of power source or battery pack. First fault detection response516includes notification of a user of the first fault512in power source104. Battery monitoring component508communicates first fault detection response516to be displayed on graphical user interface (GUI)520. In an exemplary embodiment, graphical user interface520may include a flight display known in the art to be disposed in at least a portion of a cockpit of an electric aircraft. GUI520may be disposed on a user device located remotely from the electric aircraft. GUI520may be disposed on a computer device located remotely or onboard the electric aircraft. GUI520may be disposed on a smartphone located remotely or onboard the electric aircraft. First fault detection response516may include a textual display. The textual display may include a warning message to a user, which may include a pilot, whether onboard or remotely located. The textual display may include a message describing the fault. Additionally, or alternatively, the textual display may include a generic message that a fault was detected. The textual display may include where the fault was located within power source104or battery pack324. The textual display may include a suggestion for pilot or user intervention or suggested maintenance procedures. First fault detection response516may include an image display. The image display included in first fault detection response516may include a depiction of power source104. The image display may include a depiction of a portion of power source104. The image display may include a depiction of the portion of power source104first fault512was detected in. The image display may include a depiction of suggested user operations or suggested maintenance. It should be noted that battery monitoring component508is only capable of notifying a user of first fault512by first fault detection response516.

With continued reference toFIG.5, battery management and monitoring system500includes battery management component524. Battery management component may be consistent with the description of the battery management components hereinabove, namely first and second battery management components. Battery management component524is configured to detect, as a function of plurality of power source data504, second fault528in power source104. Second fault528may be characterized exactly like first fault512. For example, second fault528may include an over-voltage condition or temperature rise rate. Second fault528may not be characterized like first fault512. For example, second fault528may be an over-voltage condition and first fault512may be an undervoltage condition. First fault512and second fault528may be detected separately from each other, at least partially together, or at the same instant. One of ordinary skill in the art would understand first fault512and second fault528to have near limitless combinations and/or iterations thereof. First fault512does not necessarily need to be detected before second fault528chronologically, and largely depends on the active component at the time, which will be described in detail herein. Battery management component524is configured to produce a second fault detection response532upon receiving detection of second fault528. Second fault detection response532is configured to mitigate second fault528in power source104. “Mitigate”, for the purposes of this disclosure, describes operations, procedures, actions, or reconfigurations with the intent to resolve an operational fault in a component of a system. In a non-limiting embodiment, battery management component524may control electrical contacts outside of power source104or battery pack324, during, for example, testing and/or charging, such that second fault detection response532may disconnect and/or connect electrical contacts when a fault is detected. “Electrical contacts”, for the purposes of this disclosure, refer to electronic elements that connect or complete a circuit when contacted. In non-limiting embodiments, electrical contacts may connect power source104to external electrical circuits, battery management/monitoring component/system to external electrical circuits, or any two or more circuits or components together. Interlock component536may include geometry provisions so as to make it impossible for any fault response to control contacts when power source104is installed in aircraft. Alternatively, or additionally, there could be contacts that are connected, and therefore electrical circuits using such contacts made, only when power source104is installed in aircraft, only when power source104is uninstalled from aircraft, only when power source104is being tested, only when aircraft is in flight, or another undisclosed function or state. Contacts could be used to enable one or more of the first fault detection response516, second fault detection response532. One of ordinary skill in the art, upon reviewing the entirety of this disclosure, would appreciate the vast number of scenarios, assemblies, configurations, and embodiments using circuits, contacts, and interlocks consistent with this disclosure, and this disclosure does not preclude any configuration thereof. Geometry provisions may include structures that block electrical connections when installed in aircraft that are exposed when uninstalled in aircraft. Battery management component524may display that second fault528was detected on a web-based tool in addition to second fault detection response532. In a non-limiting example, battery management component524may redirect current around at least a portion of power source104if second fault528is detected in at least a portion of power source104. The mitigation would be to bypass the malfunctioning area of the battery pack or automatedly disconnect contacts outside of aircraft, in this non-limiting example. Second fault detection response532may additionally include a prioritization of current to a portion of power source104that is experiencing a lack of charging to that portion, thus mitigating the charging difference within power source104. Battery management component524may include a contactor control circuit. “Contactor control circuit”, for the purposes of this disclosure, describes an electrically controlled switch used for switching an electrical power circuit. The contacts referenced in “contactor control circuit” may be consistent with any contacts consistent with this disclosure. Typically, a contactor control circuit is controlled by a circuit which has a lower power level than the switched circuit. One of ordinary skill in the art would understand that there are a plurality of methods and systems capable of switching circuits electromechanically, like relays, and that a plurality may be used herein substituted for contactor control circuit.

With continued reference toFIG.5, battery management and monitoring system500includes an interlock component536. Interlock component536includes a first mode540and a second mode544. Interlock component536is configured to enable battery monitoring component508and disable battery management component524when in first mode540. Interlock component is configured to enable battery management component524and disable battery monitoring component508when in second mode544. One of ordinary skill in the art would understand that first mode and second mode do not refer to order of operations or chronology, but to more than one distinct mode the interlock component536can reconfigure itself into. One of ordinary skill in the art would appreciate from the present disclosure that battery management component524and battery monitoring component508are enabled and disabled separately. In other words, the enabling of one component does not disable the other automatedly, for example. Interlock component536may include a mechanical component. For example, a mechanical interlock component536may include a lever, button, switch that is physically interacted with by a user, subsystem, or a combination thereof. Interlock component536may include an electrical component. For example, an electrical interlock component536may include a circuit that is completed when a certain component is to be enabled. Interlock component536may enable battery monitoring component508when power source104is installed in electric aircraft. In this non-limiting example, a mechanical and/or electrical interlock component disposed in or on power source104may be actuated when power source104is installed in electric aircraft. Interlock component536may include a logic circuit, combinatorial circuit, sequential circuit, finite state machine, analog circuit, or any processor as described in the entirety of this disclosure. Additionally or alternatively, when installed in electric aircraft, interlock component536may enter first mode540, enabling battery monitoring component508and disabling battery management component524. In another non-limiting example, interlock component536enters second mode544and thus enables battery management component524when the battery is uninstalled from the electric aircraft. Interlock component536may enter second mode544, enabling battery management component524during charging of power source104. Interlock component536may enter second mode544, enabling battery management component524during testing of power source104. In a non-limiting embodiment, battery monitoring component508is enabled by interlock component536when battery pack is installed in electric aircraft, and thus when electric aircraft is in flight mode. It would follow to one of ordinary skill in the art, upon reviewing the entirety of this disclosure, that when battery pack324is uninstalled from electric aircraft, battery management component524is enabled when battery pack is offboard of electric aircraft. Interlock component536may include circuitry, components, processors, or the like that may detect which mode interlock component is in. For example, interlock component536may detect electrical phenomena consistent with battery charging, discharging, or switching when battery management component524is engaged; sensing may be performed, for instance, by comparison of one or more voltages or other parameters to threshold levels using a comparator, a transistor, or other element connected to a control interface such as a gate, base, and/or input pin of interlock component536. Interlock component536may include provisions such as sensors and/or circuitry to receive a signal, for instance from a flight controller of an aircraft, a manual switch activated by a user, or the like, when electric aircraft is in flight mode and therefore battery monitoring component508is engaged. Interlock component536may detect when electric aircraft is in certain flight modes like hover, takeoff, landing, vertical takeoff, vertical landing, banks, turns, rolls, climbs, dives, and the like. When interlock component536engages battery monitoring component508and disengages battery management component524, sensor suite552detects plurality of power source data504for first fault512within power source104. Sensor suite552transmits first fault512to battery monitoring component508, which in tum transmits first fault detection response516to graphical user interface520, which may be a screen in the cockpit for a pilot to be notified or a client device to which a remotely located user may be notified of first fault512. When interlock component536engages battery management component524and disengages battery monitoring component508, sensor suite552detects second fault528based on plurality of power source data504within power source104. Sensor suite552transmits second fault528to battery management component524. In tum, battery management component transmits second fault detection response532to mitigate second fault528. In other words, faults detected in flight can be detected and displayed to a user, wherein the discretion of the user is used to mitigate faults, as opposed to offboard electric aircraft when battery management system can mitigate risks without user intervention, in a non-limiting example.

With continued reference toFIG.5, battery management and monitoring system includes battery management system head unit (BMSHU)548configured to electronically communicate with a controller. BMSHU548may be consistent with any communicatively coupled electronic component described in this disclosure. The controller may be any circuit, computing device, or combination of electronics and power electronics consistent with this disclosure.

FIG.6shows a flow chart illustrating the power source assembly method600in accordance with one or more embodiments of the present disclosure. As shown in block605, method600includes applying compressive force112on plurality of battery cells116using compression mechanism108of the power source assembly system100as described in this disclosure.

As shown in block610, method600includes the step of inserting at least a portion of the compressed plurality of battery cells116into container120. For example, battery cells116may be moved perpendicular to compression force112to be inserted into opening144of container120.

As shown in block615, method600includes the step of engaging each of battery cells116a-nof plurality of battery cells116with end cap204of container120. In one or more embodiments, end cap204is configured to maintain the predetermined arrangement of plurality of battery cells116.

As shown in block620, method600includes the step of releasing compressive force112from at least a portion of plurality of battery cells116. In one or more embodiments, plurality of battery cells116disposed within container120creates power source assembly system100. Power source104may be used to supply energy to various types of systems. For example, power source104may provide energy to a vehicle, as discussed in this disclosure. In one or more embodiments, the method of600may further include connecting container120to an electrical system of a vehicle; and providing power to at least a portion of the vehicle. In an exemplary embodiment, the vehicle may be an electric aircraft. For example, the vehicle may be an eVOTL aircraft, as discussed in this disclosure.

It is to be noted that any one or more of the aspects and embodiments described in this disclosure may be conveniently implemented using one or more machines (e.g., one or more computing devices that are utilized as a user computing device for an electronic document, one or more server devices, such as a document server, etc.) programmed according to the teachings of the present specification, as will be apparent to those of ordinary skill in the computer art. Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those of ordinary skill in the software art. Aspects and implementations discussed above employing software and/or software modules may also include appropriate hardware for assisting in the implementation of the machine executable instructions of the software and/or software module.

Such software may be a computer program product that employs a machine-readable storage medium. A machine-readable storage medium may be any medium that is capable of storing and/or encoding a sequence of instructions for execution by a machine (e.g., a computing device) and that causes the machine to perform any one of the methodologies and/or embodiments described in this disclosure. Examples of a machine-readable storage medium include, but are not limited to, a magnetic disk, an optical disc (e.g., CD, CD-R, DVD, DVD-R, etc.), a magneto-optical disk, a read-only memory “ROM” device, a random access memory “RAM” device, a magnetic card, an optical card, a solid-state memory device, an EPROM, an EEPROM, and any combinations thereof. A machine-readable medium, as used in this disclosure, is intended to include a single medium as well as a collection of physically separate media, such as, for example, a collection of compact discs or one or more hard disk drives in combination with a computer memory. As used in this disclosure, a machine-readable storage medium does not include transitory forms of signal transmission.

Such software may also include information (e.g., data) carried as a data signal on a data carrier, such as a carrier wave. For example, machine-executable information may be included as a data-carrying signal embodied in a data carrier in which the signal encodes a sequence of instruction, or portion thereof, for execution by a machine (e.g., a computing device) and any related information (e.g., data structures and data) that causes the machine to perform any one of the methodologies and/or embodiments described in this disclosure.

Examples of a computing device include, but are not limited to, an electronic book reading device, a computer workstation, a terminal computer, a server computer, a handheld device (e.g., a tablet computer, a smartphone, etc.), a web appliance, a network router, a network switch, a network bridge, any machine capable of executing a sequence of instructions that specify an action to be taken by that machine, and any combinations thereof. In one example, a computing device may include and/or be included in a kiosk.

FIG.7shows a diagrammatic representation of one embodiment of a computing device in the exemplary form of a computer system700within which a set of instructions for causing a control system to perform any one or more of the aspects and/or methodologies of the present disclosure may be executed. It is also contemplated that multiple computing devices may be utilized to implement a specially configured set of instructions for causing one or more of the devices to perform any one or more of the aspects and/or methodologies of the present disclosure. Computer system700includes a processor704and a memory708that communicate with each other, and with other components, via a bus712. Bus712may include any of several types of bus structures including, but not limited to, a memory bus, a memory controller, a peripheral bus, a local bus, and any combinations thereof, using any of a variety of bus architectures.

Memory708may include various components (e.g., machine-readable media) including, but not limited to, a random access memory component, a read only component, and any combinations thereof. In one example, a basic input/output system716(BIOS), including basic routines that help to transfer information between elements within computer system700, such as during start-up, may be stored in memory708. Memory708may also include (e.g., stored on one or more machine-readable media) instructions (e.g., software)720embodying any one or more of the aspects and/or methodologies of the present disclosure. In another example, memory708may further include any number of program modules including, but not limited to, an operating system, one or more application programs, other program modules, program data, and any combinations thereof.

Computer system700may also include a storage device724. Examples of a storage device (e.g., storage device724) include, but are not limited to, a hard disk drive, a magnetic disk drive, an optical disc drive in combination with an optical medium, a solid-state memory device, and any combinations thereof. Storage device724may be connected to bus712by an appropriate interface (not shown). Example interfaces include, but are not limited to, SCSI, advanced technology attachment (ATA), serial ATA, universal serial bus (USB), IEEE 1394 (FIREWIRE), and any combinations thereof. In one example, storage device724(or one or more components thereof) may be removably interfaced with computer system700(e.g., via an external port connector (not shown)). Particularly, storage device724and an associated machine-readable medium728may provide nonvolatile and/or volatile storage of machine-readable instructions, data structures, program modules, and/or other data for computer system700. In one example, software720may reside, completely or partially, within machine-readable medium728. In another example, software720may reside, completely or partially, within processor704.

Computer system700may also include an input device732. In one example, a user of computer system700may enter commands and/or other information into computer system700via input device732. Examples of an input device732include, but are not limited to, an alpha-numeric input device (e.g., a keyboard), a pointing device, a joystick, a gamepad, an audio input device (e.g., a microphone, a voice response system, etc.), a cursor control device (e.g., a mouse), a touchpad, an optical scanner, a video capture device (e.g., a still camera, a video camera), a touchscreen, and any combinations thereof. Input device732may be interfaced to bus712via any of a variety of interfaces (not shown) including, but not limited to, a serial interface, a parallel interface, a game port, a USB interface, a FIREWIRE interface, a direct interface to bus712, and any combinations thereof. Input device732may include a touch screen interface that may be a part of or separate from display device736, discussed further below. Input device732may be utilized as a user selection device for selecting one or more graphical representations in a graphical interface as described above.

A user may also input commands and/or other information to computer system700via storage device724(e.g., a removable disk drive, a flash drive, etc.) and/or network interface device740. A network interface device, such as network interface device740, may be utilized for connecting computer system700to one or more of a variety of networks, such as network744, and one or more remote devices748connected thereto. Examples of a network interface device include, but are not limited to, a network interface card (e.g., a mobile network interface card, a LAN card), a modem, and any combination thereof. Examples of a network include, but are not limited to, a wide area network (e.g., the Internet, an enterprise network), a local area network (e.g., a network associated with an office, a building, a campus or other relatively small geographic space), a telephone network, a data network associated with a telephone/voice provider (e.g., a mobile communications provider data and/or voice network), a direct connection between two computing devices, and any combinations thereof. A network, such as network744, may employ a wired and/or a wireless mode of communication. In general, any network topology may be used. Information (e.g., data, software720, etc.) may be communicated to and/or from computer system700via network interface device740.

Computer system700may further include a video display adapter752for communicating a displayable image to a display device, such as display device736. Examples of a display device include, but are not limited to, a liquid crystal display (LCD), a cathode ray tube (CRT), a plasma display, a light emitting diode (LED) display, and any combinations thereof. Display adapter752and display device736may be utilized in combination with processor704to provide graphical representations of aspects of the present disclosure. In addition to a display device, computer system700may include one or more other peripheral output devices including, but not limited to, an audio speaker, a printer, and any combinations thereof. Such peripheral output devices may be connected to bus712via a peripheral interface756. Examples of a peripheral interface include, but are not limited to, a serial port, a USB connection, a FIREWIRE connection, a parallel connection, and any combinations thereof.

The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions can be made without departing from the spirit and scope of this invention. Features of each of the various embodiments described above may be combined with features of other described embodiments as appropriate in order to provide a multiplicity of feature combinations in associated new embodiments. Furthermore, while the foregoing describes a number of separate embodiments, what has been described in this disclosure is merely illustrative of the application of the principles of the present invention. Additionally, although particular methods in this disclosure may be illustrated and/or described as being performed in a specific order, the ordering is highly variable within ordinary skill to achieve methods, systems, and software according to the present disclosure. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.

Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.