AU2021106349A4 - Battery Apparatus - Google Patents

Battery Apparatus Download PDF

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Publication number
AU2021106349A4
AU2021106349A4 AU2021106349A AU2021106349A AU2021106349A4 AU 2021106349 A4 AU2021106349 A4 AU 2021106349A4 AU 2021106349 A AU2021106349 A AU 2021106349A AU 2021106349 A AU2021106349 A AU 2021106349A AU 2021106349 A4 AU2021106349 A4 AU 2021106349A4
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AU
Australia
Prior art keywords
enclosure
battery
battery apparatus
interface
electrical
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Application number
AU2021106349A
Inventor
Martin Kime
John Weaver
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3ME Technology Pty Ltd
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3ME Technology Pty Ltd
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Filing date
Publication date
Priority claimed from AU2021902367A external-priority patent/AU2021902367A0/en
Application filed by 3ME Technology Pty Ltd filed Critical 3ME Technology Pty Ltd
Application granted granted Critical
Publication of AU2021106349A4 publication Critical patent/AU2021106349A4/en
Priority to AU2022322266A priority Critical patent/AU2022322266A1/en
Priority to PCT/AU2022/050808 priority patent/WO2023010156A1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
    • G05B19/0423—Input/output
    • G05B19/0425—Safety, monitoring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/0241—Structural association of a fuse and another component or apparatus
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/05—Component parts thereof
    • H01H85/055—Fusible members
    • H01H85/12—Two or more separate fusible members in parallel
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H9/00—Details of switching devices, not covered by groups H01H1/00 - H01H7/00
    • H01H9/10—Adaptation for built-in fuses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/64—Heating or cooling; Temperature control characterised by the shape of the cells
    • H01M10/647—Prismatic or flat cells, e.g. pouch cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6556—Solid parts with flow channel passages or pipes for heat exchange
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/14—Primary casings; Jackets or wrappings for protecting against damage caused by external factors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0029—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with safety or protection devices or circuits
    • H02J7/00309—Overheat or overtemperature protection
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H05K5/0217—Mechanical details of casings
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H05K5/0247—Electrical details of casings, e.g. terminals, passages for cables or wiring
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/06—Hermetically-sealed casings
    • H05K5/067—Hermetically-sealed casings containing a dielectric fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/03—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for supply of electrical power to vehicle subsystems or for
    • B60R16/033—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for supply of electrical power to vehicle subsystems or for characterised by the use of electrical cells or batteries
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/04—Arrangement of batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/0241—Structural association of a fuse and another component or apparatus
    • H01H2085/0275—Structural association with a printed circuit board
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/147—Lids or covers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/271—Lids or covers for the racks or secondary casings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
    • H04L12/00—Data switching networks
    • H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
    • H04L12/40—Bus networks
    • H04L2012/40208—Bus networks characterized by the use of a particular bus standard
    • H04L2012/40215—Controller Area Network CAN
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H05K5/03—Covers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Secondary Cells (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

A battery apparatus (10) including a first or inner enclosure (12) in which one or more battery cells (14) are located, a second or outer enclosure (16) adapted to receive and substantially conceal the first enclosure (12) therein, and a third or interface enclosure (18) adjacent the first enclosure (12) in which one or more electrical interface components (20) are located, the one or more electrical interface components (20) being in electrical communication with the one or more battery cells (14). 16 1/9 [0 2F0 Figure 1

Description

1/9
[0
2F0
Figure 1
Battery Apparatus
Technical Field
[001] The invention relates to a battery apparatus. In particular, the invention relates to a battery apparatus including an enclosure for battery cells.
Background
[002] Battery cells such as lithium-ion battery cells may be secured in use within a housing that contains a bank of battery cells. Such housings may include a housing body adapted to generally isolate the battery cells from the external environment and connection points on the housing body that allow electrical connection to the internal battery cells. Within such enclosures, the battery cells may become overheated and as such temperature management features such as temperature sensors and cooling plates may be provided to assist to cool the battery cells to inhibit thermal runaway.
[003] A problem with such housings is that the isolation from the external environment may be insufficient in some circumstances such as a hazardous or gaseous environment. Another problem with such housings relates to the ability of the housing to contain thermal runaway and a possible resulting explosive event.
[004] The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative.
Summary
[005] In accordance with a first broad aspect there is provided, a battery apparatus including a first enclosure in which one or more battery cells are located; and a second enclosure adapted to receive and substantially conceal the first enclosure therein. The first and second enclosure may each contain fluid, that may be a dielectric fluid, and the second enclosure includes a fluid expansion means adapted to accommodate expansion and contraction of the dielectric fluid.
[006] In an aspect, an aperture is provided between the first and second enclosures.
[007] In another aspect, the aperture is arranged such as the fluid expansion means functions to maintain the first enclosure substantially filled with the dielectric fluid.
[008] In another aspect, the second enclosure is sealed.
[009] In another aspect, the apparatus includes a third enclosure adjacent the first enclosure and/or second enclosure in which one or more electrical interface components are located, the one or more electrical interface components being in electrical communication with the one or more battery cells.
[0010] In another aspect, the fluid expansion means includes a diaphragm located toward an ordinarily oriented top side of the second enclosure.
[0011] In another aspect, the second enclosure includes a recess, and the diaphragm is provided by a flexible material spanning the recess.
[0012] In another aspect, the second enclosure includes a top wall and the recess is provided at an internally facing side of the top wall.
[0013] In another aspect, the top wall is a removeable lid.
[0014] In another aspect, the first enclosure is shaped to be fittingly received by the second enclosure.
[0015] In another aspect, the first enclosure and the second enclosure are generally rectangular.
[0016] In another aspect, the first enclosure includes a plurality of the battery cell arrangements each including the one or more battery cells.
[0017] In another aspect, each of the plurality of the battery cell arrangements includes a printed circuit board in electrical communication with the one or more battery cells.
[0018] In another aspect, the first enclosure includes a plurality of slots arranged to support each of the plurality of the battery cell arrangements.
[0019] In another aspect, the first enclosure includes a connection board electrically arranged to connect with each of the plurality of the battery cell arrangements.
[0020] In another aspect, the first enclosure includes an interface board adapted to interface with the one or more electrical interface components in the interface enclosure.
[0021] In another aspect, the one or more electrical interface components in the interface enclosure include one or more fuses.
[0022] In another aspect, the interface board of the first enclosure includes further one or more fuses in electrical communication with the one or more fuses of the interface enclosure.
[0023] In another aspect, the interface enclosure includes one or more external contacts arranged to enable electrical connection between the one or more electrical interface components and an external environment.
[0024] In another aspect, the first enclosure includes a first base, first opposing sides, first opposing ends and first a removable lid.
[0025] In another aspect, the second enclosure includes a second base, second opposing sides, second opposing ends and a second a removable lid.
[0026] In another aspect, the first and second enclosure are substantially formed of a metal material.
[0027] In another aspect, the third enclosure is defined between one of the second opposing ends and a removable cover of the third enclosure.
Brief Description of the Figures
[0028] The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which;
[0029] Figure 1 is an exploded isometric view illustrating the battery apparatus;
[0030] Figure 2 is another exploded isometric view illustrating the battery apparatus with surfaces removed to reveal internal features;
[0031] Figure 3 is an isometric view illustrating the battery apparatus;
[0032] Figure 4 is another isometric view illustrating the battery apparatus;
[0033] Figure 5a to 5e are respectively top, side, bottom and opposing end views illustrating the battery apparatus;
[0034] Figure 6 is a hidden detail isometric view illustrating the battery apparatus;
[0035] Figure 7 is a side hidden detail view illustrating the battery apparatus;
[0036] Figure 8 is an end view illustrating the battery apparatus along section A-A as shown in Figure 7;
[0037] Figure 9 is an isometric view illustrating the battery apparatus with a lid removed from a second enclosure;
[0038] Figure 10 is a bottom view illustrating the lid of the second enclosure;
[0039] Figure 11 is a side view illustrating the lid;
[0040] Figure 12 is isometric view illustrating the battery apparatus;
[0041] Figure 13 is isometric view illustrating the battery apparatus with an end covering removed from an interface enclosure;
[0042] Figure 14 is an isometric view illustrating a first enclosure of the battery apparatus removed from the second enclosure;
[0043] Figure 15 is an isometric part cut away view illustrating the first enclosure showing an internal battery arrangement and an interface board;
[0044] Figure 16 an isometric view illustrating the interface board; and
[0045] Figure 17 an isometric view illustrating an example battery arrangement.
Detailed Description
[0046] Referring initially to Figures 1 to 5e, there is shown a battery apparatus 10 including a first or inner enclosure 12 in which one or more battery cells 14 are located, a second or outer enclosure 16 adapted to receive and substantially conceal the first or inner enclosure 12 therein, and a third or interface enclosure 18 adjacent the first enclosure 12 in which one or more electrical interface components 20 are located, the one or more electrical interface components 20 being in electrical communication with the one or more battery cells 14.
[0047] The first and second enclosures 12, 16 each contain fluid such as, but not limited to, a dielectric fluid or single-phase liquid immersion fluid, and the second enclosure includes a fluid expansion means 11, in this example a diaphragm 22 (shown in Figure ), adapted to accommodate expansion and contraction of the fluid. The function of the dielectric fluid is to manage any heat generated during the normal operation of the battery and to manage any heat generated during abnormal conditions that may arise. There is an aperture or breather 15 between the first and second enclosures 12, 16 to allow fluid from the first enclosure 12 to breathe into and communicate with fluid of the second enclosure 16, and the diaphragm 22 functions to keep the first enclosure 16 always full.
[0048] The first enclosure 12 generally functions to hold and contain the one or more battery cells 14 and other electronic components, the second or outer enclosure 16 generally functions as a blast or energy containment enclosure and the third or interface enclosure 18 functions to provide an interface ultimately between the one or more battery cells 14 and an external environment to enable connection of the battery apparatus 10 to a load or other system such as a vehicle or the like.
[0049] As shown in Figure 2, the first enclosure 12 includes a top or lid 24, bottom 26, opposing sides 28 and opposing ends 30 to provide a generally sealed internal environment capable of holding the dielectric fluid. Preferably, the fill level of the dielectric fluid is such that the first enclosure 12 is entirely filled without any air gaps. The aperture or breather 15 may be in the top or lid 24 or at one of the opposing sides 28 and opposing ends 30. The aperture or breather 15 may be at a centre line of the top or lid 24.
[0050] The first enclosure 12 has a generally rectangular shape. The top 24 may be removeable to reveal the internal components such as battery arrangements 30 that include the or more battery cells 14, slots 34 to support the battery arrangements 32, a connection board 36 and battery interface arrangement 38. The battery interface arrangement 38 includes a first set of internal fuses 39.
[0051] As shown in Figures 3 and 4, the second enclosure 16 includes a top or lid 40, a bottom 42, opposing sides 44 and opposing ends 46 to provide a generally sealed internal environment capable of holding the dielectric fluid. The second enclosure 16 has a generally rectangular shape with internal dimension shaped to fittingly receive the first enclosure 12 with the first enclosure 12 nested within the second enclosure 16.
[0052] The top or lid 40 may be removeable to reveal and access the first enclosure 12. One of the opposing sides 40, or other suitable surface, may be adapted to promote heat transfer or include integral cooling means such as a circulating cooling fluid. The second enclosure 16 also contains the dielectric fluid which resides between the first and second enclosures 12, 16. Preferably, the fill level of the dielectric fluid is such that the second enclosure 16 is entirely filled without any air gaps. The second enclosure 16 enclosure does not house any switching or electronic parts which is essentially an avoidance technique, and the construction of the second enclosure 16 enclosure utilises the principles of the containment technique thus achieving the desired multiple explosion protection techniques.
[0053] Accordingly, it may be appreciated that the first and second enclosures 12, 16 provide a box within a box type structure being generally double walled, with closely spaced or adjacent walls. The material of the first and second enclosures 12, 16 may generally be a metal such as steel or aluminium. A welded construction may be used such that the only joins are for the respective tops or lids.
[0054] The third enclosure 18 is defined between one of the opposing ends 46 of the second enclosure 16, a removable end 48 thereof, an opposing top and bottom 50, and opposing sides 52. These surface or walls may be shared with the second enclosure 16 or separate depending on the configuration. 14. The one or more electrical interface components 20 in the third enclosure 18 include a second set of fuses 54 that are, of course, external to the first enclosure 16, and include internal and external ports 55, 56 to enable sealed electrical communication via terminals 57 ultimately between the battery arrangements 30 within the first enclosure 12 and the external environment via the third enclosure 18. The sealing of the third enclosure 18 is such that the third enclosure 18 is a flame proof enclosure. The third enclosure is preferably not filled with the dielectric fluid.
[0055] Referring additionally to Figures 6 to 11, as best shown in Figures 10 and 11 in this example the diaphragm 22 is located toward the ordinarily oriented top 40 of the second enclosure 16. More specifically, in this example, the diaphragm 22 is provided by a recess 60 that is located on an internally facing side 59 of the lid 40 and a flexible membrane 62 that spans over the recess 60. The recess 60 may include air or other gas and allow for the membrane 62 to move to accommodate expansion and contraction of the dielectric fluid. The diaphragm 22 therefore functions to maintain the fluid levels of the first and second enclosures 12 and 16.
[0056] Turning now to Figures 12 to 17, disassembly of the battery apparatus 10 is shown with the first enclosure 12 fully removed as shown in Figure 14 and its internal configuration revealed in Figure 15 showing an example battery arrangement 32 fitted in the slots 34, the connection board 36, and the battery interface arrangement 38 with the internal fuses 39. The connection board 36 provides a plug-in connection for the battery arrangements 32 and the battery interface arrangement 38. The design of the backplane connection board 36 is such that it may be impossible to insert the battery arrangements 32 and hence create a reverse polarity. A layer of Nomex sheet (not shown) 0.5mm thick provides a layer of insulation between the connection board 36 and the metallic material of the first enclosure 12.
[0057] It is noted that only one battery arrangement 32 is shown, however in use a plurality of removable battery arrangements 32 may be installed to provide a battery bank. It may be appreciated that the first enclosure 12 houses all the main components, other than interconnecting cables.
[0058] The battery interface arrangement 38 is best shown in Figure 16 and further includes interlock relays 64, isolation contactors 66, a communication connector 68 and power connectors 70 in addition to the fuses 39 supported by printed circuit board 71. The control connector 68 is used to communicate between the battery interface arrangement 38 and each of the battery arrangements 32.
[0059] The isolation contactors 66 function to trip the power from the battery both for operational and safety reasons. A high methane detection received from a gas sensor (external to the apparatus 10) may trip the safety contactors 66. The fuses 39 (should this be fuses 54) are provided to detect and clear short circuit faults that may occur in the field connection enclosure and provide a graded backup protection to the fuses 39 located within the field connection enclosure. The battery interface arrangement 38 includes SIL2 safety interlocks (not shown) and an IS circuit for methane interlock (not shown).
[0060] Part of an overall battery management system resides in the battery interface arrangement 38 and the battery interface arrangement 38 may include a central processor (not shown) adapted to communicate with the individual battery arrangements 32 via a dedicated controller area network. The central processor may receive, and store information received to calculate the differential voltage across the battery interface arrangement 38 or each battery arrangement 32, whether a particular cell 14 needs balancing or whether the voltage of a particular cell 14 is reaching the limit of its operational voltage or temperature range. It also monitors the pack voltage and total load current to ensure that the battery system operates within its design parameters.
[0061] Referring to Figure 17, each of the plurality of the battery cell arrangements 32 includes a printed circuit board 80 in electrical communication with the one or more battery cells 14. The battery cells 14 in this example may be, but not limited to, lithium ion battery cells or pouches. The circuit board 80 carries all or most of the electronic components and cells 14 that make up the battery cell arrangements 32.
[0062] In this example, there are two lithium-ion cells 14 mounted to the circuit board 80. The cells 14 are arranged to form a series circuit between the two cells 14 giving an output to the connection board 36 of the two cells. Each cell may be, but not limited to, an NMC Lithium-Ion pouch type cell having a 75AmpHour capacity. The cell tabs are clamped via clamps 82 to the power connections on the board 80 by copper busbars.
[0063] A further Part of the battery management system is located on the battery arrangement 32. The battery management system comprises a central processing unit (not shown) and the necessary hardware to operate the system. The battery management system monitors the cell temperature, cell voltage and also the pressure exerted by the cells upon the board 80. The power supply for the electronics is derived from the cells themselves meaning that each battery arrangement 32 is essentially self-sufficient. Each battery arrangement 32 communicates its status to the battery interface arrangement 38 by the controller area network.
[0064] Each battery arrangement 32 has four power connectors 84 and one control connector 86. Two of the connectors are used for the positive connection and two are used for the negative connection. Each connector may be rated at 60 amps. There may be a total of twelve battery arrangement 32 giving a total capacity of 720 Amps. The control connector 86 is used to communicate between the battery arrangements 32 and the battery interface arrangement 38.
[0065] Further features including outputs of the battery apparatus 10 and example uses are now described. Firstly, there is an intrinsically safe circuit provided by the sealed relays 64 of the battery interface arrangement 38 for the purpose of interfacing with the vehicle safety circuits. The circuit is Ex ia and SIL2. It is noted that Ex ia and SIL are both the same circuit but are different features of the circuit. A circuit may be intrinsically safe Ex ia without being SIL2 compliant and vice versa. The Ex ia is its feature to not ignite a hazardous atmosphere and the SIL2 is the safety function in is the integrity of the circuit to operate as designed.
[0066] It is intended to connect all safety devices that may be exposed in a hazardous area into the circuit relays 64 such as Methane Trip Circuits, Vehicle DCB door interlocks, Emergency Stop systems, Whole Current Isolator Auxiliary Contacts as well as an interlock on the Field Interface Enclosure cover.
[0067] The control supply for the vehicle, or other load, is derived from a DCDC converter (not shown) having a 24VDC output housed on the battery interface arrangement 38 in the first enclosure 12. Contacts 66 from the safety interlock circuit are connected into the 24VDC control circuit so that the supply to the vehicle is not present unless the interlock circuit is healthy. The contact arrangement is designed and verified as a SIL2 safety circuit. The 24VDC control circuit is also used to trip the main power contactors in case of a fault or abnormal situation that arises. The contactors 66 will also open if required to do so by the battery management system.
[0068] The output contacts from the interlock circuit are connected into the coil circuit of the battery safety contactors. There are two contactors in the positive leg and two in the negative leg giving a total of four individual breaks per battery. This arrangement provides a SIL2 isolation and tripping circuit.
[0069] The main form of communications between the battery and the vehicle is by a controller area network. The controller area network is not intrinsically safe and contacts from the interlock circuit are connected to prevent the controller area network exiting the battery until the interlocks are healthy. The circuit is arranged as a SIL2 safety circuit. In order for a circuit to be SIL2 the circuit needs to be designed according to IEC 61508 suite of standards. This includes the selection, design, assembly, testing and maintenance of equipment for the SIL2 circuit. The intent of a safety circuit is to remain safe during the life cycle of the product.
[0070] There is the provision for safety interlocks within a vehicle control system (not shown), e.g.. Ground Fault Monitoring. The contacts for this interlock, including the fuses 54, are located in the third enclosure 18 and is designed to break the safety contactors on the when an abnormal situation arises within the vehicle.
[0071] In use, the battery apparatus 10 may be fitted to a vehicle (not shown) as an electrical power source. Although each application may vary the operating principle will be similar. An example of a vehicle start-up is provided below.
[0072] With the vehicle in a parked state, a methane system (not shown) will be asleep as the methane system may time out and shut down if it is not being used. In order for the system to become healthy, the methane system must be reset, the methane system will then provide power to the CH4 sensors that will close the contacts for the SIL2 circuit when they are healthy.
[0073] Provided that the methane monitoring system is healthy, and all door interlocks are closed, the SIL2 circuit is ready. A selector switch in the dash must first be turned to OFF, then to START and finally to RUN. In this position relays SRI and SR3 will be energised and SR2 will be de energised thus closing the contacts in the 24VDC control circuit and enabling the control supply to the Vehicle. The 24VDC control supply energises the ground fault monitor and vehicle control unit. When all is healthy the hard-wired safety interlocks will be closed and the vehicle control unit. will initiate the safety contactors on the battery interrace arrangement to close. The main battery contactors will close and provide power to the on-board machine DCB. This all reads right to me.
[0074] Advantageously, the battery apparatus combines hazardous area techniques such as exclusion, energy limitation, containment. The battery apparatus is designed to maintain the temperature of the battery cells within their operating range. The design is such that a catastrophic thermal runaway is inhibited as the temperature generated in the early stages of such an event will be absorbed by the dielectric fluid. Therefore, the battery apparatus may maintain its explosion protected properties under all known failure modes. Most advantageously, the battery apparatus includes a generally dual walled structure in which both enclosures contain the dielectric fluid with the outer one of the enclosures having a diaphragm to maintain fluid levels and adapt to thermal expansion and contraction. Furthermore, advantageously, the battery apparatus includes two sets of fuses, one set inside the first enclosure and one outside the first enclosure in the third enclosure, and the battery apparatus includes interlocks including methane and safety interlocks.
[0075] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
[0076] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.
[0077] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.
[0078] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims (23)

The claims defining the Invention are as follows:
1. A battery apparatus including: a. A first enclosure in which one or more battery cells are located; and b. A second enclosure adapted to receive and substantially conceal the first enclosure therein, Wherein the first and second enclosure each contain dielectric fluid and wherein the second enclosure includes a fluid expansion means adapted to accommodate expansion and contraction of the dielectric fluid.
2. The battery apparatus according to claim 1, wherein an aperture is provided between the first and second enclosures.
3. The battery apparatus according to claim 2, wherein the aperture is arranged such as the fluid expansion means functions to maintain the first enclosure substantially filled with the dielectric fluid.
4. The battery apparatus according to claim 3, wherein the second enclosure is sealed.
5. The battery apparatus according to any one of claims 1 to 4, wherein the apparatus includes a third enclosure adjacent the first enclosure in which one or more electrical interface components are located, the one or more electrical interface components being in electrical communication with the one or more battery cells.
6. The battery apparatus according to any one of claims 1 to 5, wherein the fluid expansion means includes a diaphragm located toward an ordinarily oriented top side of the second enclosure.
7. The battery apparatus according to any one of claims 1 to 6, wherein the second enclosure includes a recess, and the diaphragm is provided by a flexible material spanning the recess.
8. The battery apparatus according to claim 7, wherein the second enclosure includes a top wall and the recess is provided at an internally facing side of the top wall.
9. The battery apparatus according to claim 8, wherein the top wall is a removeable lid.
10. The battery apparatus according to any one of the previous claims, wherein the first enclosure is shaped to be fittingly received by the second enclosure.
11. The battery apparatus according to claim 10, wherein the first enclosure and the second enclosure are generally rectangular.
12. The battery apparatus according to claim 5, wherein the first enclosure includes a plurality of the battery cell arrangements each including the one or more battery cells.
13. The battery apparatus according to claim 12, wherein each of the plurality of the battery cell arrangements includes a printed circuit board in electrical communication with the one or more battery cells.
14. The battery apparatus according to claim 13, wherein the first enclosure includes a plurality of slots arranged to support each of the plurality of the battery cell arrangements.
15. The battery apparatus according to claim 13, wherein the first enclosure includes a connection board electrically arranged to connect with each of the plurality of the battery cell arrangements.
16. The battery apparatus according to claim 15, wherein the first enclosure includes an interface board adapted to interface with the one or more electrical interface components in the interface enclosure.
17. The battery apparatus according to claim 16, wherein the one or more electrical interface components in the interface enclosure include one or more fuses.
18. The battery apparatus according to claim 17, wherein the interface board of the first enclosure includes further one or more fuses in electrical communication with the one or more fuses of the interface enclosure.
19. The battery apparatus according to claim 18, wherein the interface enclosure includes one or more external contacts arranged to enable electrical connection between the one or more electrical interface components and an external environment.
20. The battery apparatus according to claim 5, wherein the first enclosure includes a first base, first opposing sides, first opposing ends and first a removable lid.
21. The battery apparatus according to claim 20, wherein the second enclosure includes a second base, second opposing sides, second opposing ends and a second a removable lid.
22. The battery apparatus according to claim 21, wherein the first and second enclosure are substantially formed of a metal material.
23. The battery apparatus according to claim 21, wherein the third enclosure is defined between one of the second opposing ends and a removable cover of the third enclosure.
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KR101917279B1 (en) * 2017-01-17 2018-11-14 주식회사 피플웍스 Battery Pack with Function of Temperature Control
EP3809519A4 (en) * 2018-06-12 2022-06-22 KMW Inc. Cavity filter and connecting structure included therein
KR102640327B1 (en) * 2018-10-19 2024-02-22 삼성에스디아이 주식회사 Large module of battery
US12080903B2 (en) * 2019-04-15 2024-09-03 Robert Bosch Gmbh Pressure management device for battery pack
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