TW202239049A - Battery module and battery rack with enhanced fire safety features, and applications thereof - Google Patents

Abstract

Provided is a battery module and battery rack having enhanced fire safety features. The battery module includes a swelling/pressure sensor that detects swelling of a battery cell. An output signal of the sensor is used to halt operation of a battery rack/battery system containing the battery module and prevent charging and discharging of the battery module. In an embodiment, the battery module uses an AC-to-AC power supply to provide AC frequency power for balancing battery cells of the battery module. In an embodiment, the battery rack includes an internal water fire suppression system that provides battery cooling in the event of a battery cell fire to prevent the spread and/or reigniting of the fire.

Description

Battery modules and racks with enhanced fire safety features and applications thereof

The present invention relates to battery energy storage systems.

Battery energy storage systems use large numbers of batteries, which can present a fire hazard if not managed properly. Conventional battery management systems usually only monitor battery cell voltage and temperature. It does not monitor or indicate the internal state of the battery cell. Battery cell voltage and cell temperature are not by themselves good indicators of changing conditions/stress inside a cell that could lead to a battery fire.

Embodiments featured herein help to address or alleviate the above-mentioned problems and additional disadvantages associated with battery storage systems.

In certain contexts, an embodiment of the invention includes a battery module having a sensor that detects expansion of a battery cell. An output signal of the sensor is used to suspend the operation of the battery rack/system containing the battery modules and thereby suspend the charging and discharging of the battery cells until the battery module containing the battery cells can be replaced and the battery rack/system is Tested to verify its safe operation.

In one embodiment, high frequency AC power is used as one of the power sources for balancing the battery modules. The use of high frequency AC power allows the use of isolation transformers as part of the cell balancing circuit.

In one embodiment, a battery module according to the invention includes a top cover that collects water and directs this water to the plates of the battery module to cool the batteries.

In one embodiment, a battery rack according to the present invention includes a water fire suppression system with a cascade of water flow between battery modules that provides cooling in the event of a battery cell fire and thereby controls and prevents the spread of a battery cell fire to adjacent units and racks.

In one embodiment, the battery rack according to the invention comprises a row for removing gas and/or heat and directing these gases and/or heat to the outside of the room, container, building, etc. housing the battery rack. trachea.

Further features and advantages of the present invention, as well as the structure and operation of various embodiments, are described in detail below with reference to the accompanying drawings. It should be noted that the present invention is not limited to the specific embodiments described herein. These examples are presented herein for illustration only. Additional embodiments will be apparent to those skilled in the relevant art based on the teachings contained herein.

Cross References to Related Applications This application asserts U.S. Patent Application 17/531,378 filed November 19, 2021, U.S. Provisional Patent Application 63/211,732 filed June 17, 2021, and U.S. Provisional Patent Application filed April 5, 2021 63/170,600 and to the benefit of U.S. Provisional Patent Application 63/164,502 filed March 22, 2021, each of which is incorporated herein by reference as if reproduced in full below.

Embodiments will be described in more detail below with reference to the accompanying drawings. The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatus and/or systems described herein and modifications thereof. Accordingly, various modifications and equivalents of the methods, apparatus, and/or systems described herein will be apparent to those of ordinary skill. Descriptions of well-known functions and constructions may be omitted for increased clarity and conciseness.

FIG. 1 illustrates an exemplary battery module 100 according to an embodiment of the present invention. As shown more clearly in FIG. 3A, battery module 100 includes several features that enhance fire safety and can prevent a battery fire.

Over time, a battery cell within a battery module can become damaged and begin to swell. This is a very good indicator of a change in internal pressure of the expansion system unit and a very good indicator that the unit may catch fire if not replaced. Swelling can be caused, for example, by the formation of flammable and explosive gases inside the cell due to changes in the electrolyte and other active materials inside the cell. Cell expansion occurs before a cell vents and/or catches fire.

As described herein, a new expansion/pressure sensor was designed and installed on battery modules according to embodiments of the present invention, which can detect and quantify the amount of expansion/pressure in the battery cells. When changes in expansion/pressure beyond normal cycles are detected using firmware/software and data from the sensors, an alarm/warning is generated by the firmware/software so that action can be taken whereby the unit can be replaced before the unit is vented. Abnormal expansion/stress of the battery cells may progress to the point where a fire may occur. Alarms/warnings can also be used to automatically disconnect, for example, a battery rack containing battery cells with abnormal expansion/pressure so that the battery cells are not further charged or discharged and thus further damaged, which can lead to battery cell venting and/or a Battery unit fire.

In one embodiment, as will be described in more detail below, one expansion/pressure sensor can be used to monitor several cells simultaneously by attaching the sensor to the board of a battery assembly or battery module. In another embodiment, the expansion/pressure sensor(s) are attached directly to the battery cell(s). As described herein, detecting abnormal expansion/pressure in a battery cell can be used to shut down the battery system and make it safe until a cell with a problem is replaced and the system tested to ensure it is safe to operate again.

FIG. 2A shows a front cover 200 of the battery module 100 . The front cover 200 includes a handle 201 for lifting and carrying the battery module 100 .

FIG. 2B shows the battery module 100 with the front cover 200 removed. As shown in FIG. 2B , the battery module 100 includes battery cells 202a and 202b. The battery cells have a predetermined amount of pressure applied to them using side plates 203 , side bars 204 a and 204 b and a spring 206 . Applying a predetermined amount of pressure to the battery cell 202 can increase the cycle life of the battery cell 202 . By applying this pressure using spring 206 , side plate 203 is still free to move due to expansion/expansion of battery cells 202 . As will be described in more detail below, sensors may be used in accordance with embodiments of the present invention to monitor and measure movement of side plates 203 .

FIG. 3A shows an exploded view of the battery module 100 . As shown in FIG. 3A, the battery module 100 includes a front cover 200, a rear cover 300, battery cells 202 (eg, 202a, 202b), side panels 203 (eg, 203a, 203b, 203c), side bars 204 (eg, 204a, 204b) ), a base plate 302, a center plate 304, a top tray 306 and a cover 308. The battery module 100 also includes battery module controller circuit boards 310 a and 310 b , bus bars 312 , sensors 314 and connectors 316 .

In one embodiment, the battery module 100 includes eight battery cells 202 . However, the battery module 100 may contain fewer or more battery cells, such as 2, 4, 6, 10, 12, 14, 16 and so on. The battery unit 202 is used for storing electric energy. Eight battery cells 202 are connected in series using bus bar 312 . A predetermined amount of pressure is applied to the battery cell 202 using the side plates 203 , the center plate 304 and the side bars 204 . Side plates 203 and center plate 304 also provide cooling for battery cells 202 . Top tray 306 fits on top of battery unit 202 and provides several functions including providing a protected space for sensor 314 and battery module controller circuit boards 310a and 310b. Other functions of the top tray 306 will be described below. A cover 308 fits on top of the top tray 306 . The front cover 200 and the rear cover 300 are used, for example, to lift and carry the battery module 100 . Front cover 200 includes connectors 316 that allow several battery modules 100 to be easily wired together to form a larger battery system. As will be described in more detail below, the battery module controller circuit board provides battery management functions of the battery module 100 such as, for example, monitoring the voltage, temperature and pressure of the battery cells 202 .

FIG. 3B illustrates the battery module 100 with handle straps 318a and 318b installed therein. As shown in FIG. 3B , handle straps 318 a and 318 b connect the tops of front cover 200 and rear cover 300 together for added support when lifting and carrying battery module 100 .

FIG. 4A shows the battery module 100 with the top cover 308 and the battery module controller circuit boards 310a and 310b removed. Accordingly, top tray 306, bus bar 312, and sensors 314a-314d are more clearly visible in FIG. 4A. As can be seen in Figure 4A, the top tray 306 includes holes 400a, 400b, and 400c. Holes 400a and 400c are located on the sides of top tray 306 . The hole 400b is located in the center of the top tray 306 . The holes 400 allow air to flow over the side plates and through the center plate of the battery module 100 to cool the battery cells. As will be described in more detail below, the holes 400 also allow water collected in the top tray 306 delivered from a water suppression system to flow over the side panels and through the center panel of the battery module 100 . Water flow can be affected by the slope of the bottom of the top tray 306 .

FIG. 4B shows an example of the expansion/pressure sensor 314 of the battery module 100 . Other expansion/pressure sensors will be described below and can be used with battery modules according to embodiments of the present invention. Figure 4B also shows the hole 400 of the top tray 306 in more detail.

FIG. 5 shows a rear view of the battery module 100 with the cover 308 removed. Many features of the battery module 100 described herein can be seen in FIG. 5 .

FIG. 6 illustrates the principle of operation of an example expansion/pressure sensor 314 that may be used in accordance with embodiments of the present invention. As shown in FIG. 6, in one embodiment, a sensor 314 according to the present invention has a ring 600, which may be metal or plastic or any other suitable material. Ring 600 includes two attachment points 602a and 602b where a force can be applied. When a force is applied at attachment point 602, ring 600 experiences tension and compression at locations 604a-604d, as shown in FIG. In an embodiment, one or more strain gauges are attached to the ring 600 at one or more of these locations and are used to measure tension and/or compression at these locations. How this is done is explained in more detail below.

7A-7B further illustrate an example expansion/pressure sensor 314 that may be used in accordance with embodiments of the present invention. As shown in Figure 7A, the sensor 314 includes a metal ring 700 and two plastic attachments 702a and 702b. Metal ring 700 is held securely on attachments 702a-702b by plastic caps 704a and 704. In one embodiment, plastic caps 704a and 704b are coupled to attachments 702a and 702b to hold ferrule 700 securely in place. This coupling can be achieved using an adhesive or glue. FIG. 7B shows an assembled sensor 314 . One or more strain gauges (not shown) are attached to ferrule 700 as described herein.

8A-8B illustrate an example expansion/pressure sensor 800 that may be used in accordance with embodiments of the present invention. As shown in FIG. 8A, sensor 800 includes a metal ring 802 and plastic attachments 804a and 804b. In one embodiment, after the metal ring 802 is inserted into the grooves in the plastic attachments 804a-804b, a small amount of glue or adhesive can be applied to firmly fix the metal ring 802 to the plastic attachments 804a-804b. FIG. 8B shows an assembled sensor 800 . One or more strain gauges (not shown) are attached to ferrule 802 as described herein.

9A-9B illustrate an example expansion/pressure sensor 900 that may be used in accordance with embodiments of the present invention. As shown in FIG. 9A , sensor 900 includes two half-metal rings 902a and 902b and two plastic attachments 904a and 904b. In one embodiment, after the metal half-rings 902 are inserted into the grooves in the plastic attachments 904a-904b, a small amount of adhesive or glue can be applied to firmly fix the metal half-rings 902a-902b to the plastic attachments 904a-904b. FIG. 9B shows an assembled sensor 900 . One or more strain gauges (not shown) are attached to metal half-ring 902 as described herein.

Figure 10 illustrates an exemplary expansion/pressure sensor 1000 that may be used in accordance with embodiments of the present invention. The sensor 1000 comprises two metal half rings 1001a and 1001b and a plastic appendage 1002 with a flexible central piece 1004 (which may be plastic or any other suitable material). Flexible centerpiece 1004 may facilitate assembly of sensor 1000 . One or more strain gauges (not shown in the figures) are attached to metal half-rings 1001a and 1001b as described herein.

FIG. 11A illustrates an exemplary expansion/pressure sensor 1100 that may be used in accordance with embodiments of the present invention. As shown in FIG. 11A , sensor 1100 includes two oval half-metal rings 1102a and 1102b and two plastic attachments 1104a and 1104b. In one embodiment, after the oval metal half-rings 1102 are inserted into the grooves in the plastic attachments 1104a and 1104b, a small amount of adhesive or glue can be applied to firmly fix the metal half-rings 1102a-1102b to the plastic attachments 1104a-1104b. As shown in FIG. 11A , one or more strain gauges 1106 are attached to the elliptical metal half-ring 1102 as described herein.

FIG. 11B illustrates an example expansion/pressure sensor 1110 that may be used in accordance with embodiments of the present invention. As shown in FIG. 11B , the sensor 1110 includes a single component 1111 and one or more strain gauges 1112 attached to the plastic component 1111 . The unitary part 1111 may be made entirely of plastic or any suitable material. Sensor 1110 may be less expensive to manufacture and assemble than other sensors according to the invention described herein.

11C-11H illustrate an exemplary top tray 1130 with integrated expansion/pressure sensors 1132a-1132d according to one embodiment of the invention. 11C is a top view of an example top tray 1130 in which four integrated expansion/pressure sensors 1132a-1132d are visible. These sensors are similar to sensor 1110 in FIG. 11B. FIG. 11D is a bottom view of the top tray 1130 . In FIG. 11D we can see holes 400a-400c for directing water to the side and center plates of a battery module according to the present invention to cool the cells in the event of a cell fire. 11E is a cross-sectional view of the top tray 1130 showing sensors 1132a and 1132b. FIG. 11F shows the top tray 1130 installed on a battery module 100 according to the present invention. In FIG. 11F , one can see the installed battery module controller circuit boards 310 a - 310 b mounted on the battery module and see how the top tray 1130 protects the circuit boards. FIG. 11G further illustrates the top tray 1130 and one of its integrated sensors 1132c. FIG. 11H further illustrates a cross-sectional view of the top tray 1130 with its integrated sensor 1132c mounted on a battery module 100 .

In other embodiments of the invention, other sensors according to the invention are integrated into a top tray of a battery module. For example, in embodiments, sensors similar to those shown in FIGS. 7A-7B , 8A-8B , 9A-9B , 10 and 11A may be integrated into a top tray , as shown in Figures 11C-11H. Integrating a sensor according to the present invention into a top tray can, for example, reduce manufacturing costs, tooling costs, labor costs, and the like. Additionally, although the ring(s) of the sensors shown in Figures 7A-7B, 8A-8B, 9A-9B, 10, and 1 IA are described as metal, any suitable material may be used. Similarly, although the attachment(s) and cap(s) of the sensors shown in FIGS. Use any suitable material.

Figure 12A illustrates a circuit 1200 that may be used with an expansion/pressure sensor according to an embodiment of the invention. Circuit 1200 is a Wheatstone bridge circuit. As shown in FIG. 12A , circuit 1200 includes a voltage source 1202 , three fixed resistance values 1204 a - 1204 c , and a variable resistance value 1206 . In an embodiment of the present invention, variable resistor 1206 is an expansion/pressure sensor as described herein. In operation, a voltage is applied to the Wheatstone bridge circuit and a strain forming part of an expansion/pressure sensor is due to expansion of a battery cell forming part of a battery module Any change in the resistance of the gauge is detected as a change in the output voltage shown in Figure 12A. One or more strain gauges may be coupled to (eg, wired to) one or more battery module controller circuit boards.

Figure 12B illustrates a circuit 1210 that may be used with an expansion/pressure sensor according to an embodiment of the invention. Circuit 1210 is a Wheatstone bridge circuit with one of four variable resistors 1212a to 1212d. In an embodiment, each of the four variable resistors 1212 is one of the expansion/pressure sensors described herein. One selection circuit of the multiplexer circuit 1214 is used to select which variable resistor or sensor is used when measuring or determining the output voltage using the battery module controller circuit boards 310a to 310b. In one embodiment, the voltage source 1202 is a 12 V voltage source and each variable resistor 1212 is a 350 Ohm strain gauge forming part of an expansion/pressure sensor according to an embodiment of the invention. In another embodiment, each variable resistor 1212 comprises two 350 Ohm strain gauges connected in series forming part of an expansion/pressure sensor according to an embodiment of the invention. These two strain gauges are attached, for example, at locations 604a and 604c, as shown in FIG. 6 .

FIG. 13 illustrates an exemplary battery module 100 in accordance with an embodiment of the invention with the top 308 removed. As shown in FIG. 13 , in this embodiment, the battery module 100 has four expansion/pressure sensors 1500 . The sensor 1500 will be described in more detail below.

FIG. 14 shows an exploded view of the battery module 100 shown in FIG. 13 . As shown in FIG. 14, the battery module 100 includes a front cover 200, a rear cover 300, battery cells 202 (such as 202a, 202b), side panels 203 (such as 203a, 203b, 203c), side bars 204 (such as 204a, 204b) ), springs 206 (one at each end of the battery module 100), a bottom plate 302, center plate 304, top tray 306, and a cover 308 (as shown in FIG. 13 ). The battery module 100 also includes battery module controller circuit boards 310 a and 310 b , bus bars 312 and four sensors 1500 .

In one embodiment, the battery module 100 includes eight battery cells 202 . The battery unit 202 is used for storing electric energy. Eight battery cells 202 are connected in series using bus bar 312 . A predetermined amount of pressure is applied to the battery cell 202 using the side plates 203 , the center plate 304 , the springs 206 and the side bars 204 . Side plates 203 and center plate 304 also provide cooling for battery cells 202 . Top tray 306 fits on top of battery unit 202 and provides several functions including providing a protected space for sensor 1500 and battery module controller circuit boards 310a and 310b. Other functions of the top tray 306 will be described below. A cover 308 (as shown in FIG. 13 ) fits on top of the top tray 306 . The front cover 200 and the rear cover 300 are used, for example, to lift and carry the battery module 100 . Front cover 200 includes connectors 316 that allow several battery modules 100 to be easily wired together to form a larger battery system. As will be described in more detail below, the battery module controller circuit board provides battery management functions of the battery module 100 such as, for example, monitoring the voltage, temperature and pressure of the battery cells 202 .

FIG. 15 illustrates an exemplary all-plastic expansion/pressure sensor 1500 for a battery module according to an embodiment of the present invention. As shown in FIG. 15 , sensor 1500 includes a plastic part 1502 and a strain gauge 1504 attached to part 1502 . When a force is applied to the end of member 1502, strain gauge 1504 expands or compresses thereby changing the resistance of the strain gauge. For example, this resistance change can be detected using the circuit 1210 described above. In other embodiments, expansion/pressure sensor 1500 may be made of any other suitable material.

FIG. 16 further illustrates how an exemplary expansion/pressure sensor, such as sensor 1500 , may be manufactured and used. As shown in FIG. 16 , in an embodiment, one or more strain gauges 1602 are attached to the top of a plastic part 1604 . The strain gauges can be attached using an adhesive. A thin section may be formed in member 1604 directly below strain gauge(s) 1602 to facilitate, for example, expansion of this section when a force is applied to the end of member 1604 . In embodiments, the ends of member 1604 are attached to side or pressure plates of a battery module, such as the battery modules described herein.

FIG. 17 illustrates how a region of high local strain and stress develops in part 1604 when a force is applied to the end of part 1604 .

FIG. 18 illustrates an exemplary battery module 1800 according to an embodiment of the present invention. As shown in FIG. 18 , a battery module 1800 has four battery cell assemblies 1802 . Each battery cell assembly 1802 has two battery cells 202a and 202b, a middle plate 304 and two side plates 203a and 203b, which can act as heat sinks. The middle board 304 is coupled to a bottom board 302 of the battery module 1800 . In one embodiment, the battery unit 202 is attached to the middle plate 304 and the side plate 203 by, for example, an adhesive or double-sided tape. Various commercially available adhesives and tapes can be used depending on desired set time, cure time, strength and thermal conductivity.

In one embodiment, as shown in FIG. 18 , each battery cell assembly 1802 has its own expansion/pressure sensor, such as, for example, sensor 1500 . The sensor 1500 is attached to the two side plates 203 . When one or both of the battery cells 202 expands, the side plate 203 moves, and this movement is detected/measured by the sensor 1500 . In one embodiment, this sensor may be made of a plastic tape with strain gauge(s) attached to the plastic tape, as described above. The thickness of the plastic tape can be varied to allow more stretching of the plastic tape in the area where the strain gauge(s) are attached. Those skilled in the relevant art will appreciate that in other embodiments, sensors other than 1500 are used.

FIG. 19 further illustrates an exemplary battery module 1800 according to an embodiment of the present invention. As shown in Figure 19, the battery module 1800 includes three side bars 204a-204c for applying pressure to the battery cells. The three side bars 204 are connected together using a strip 1900 and bolts. A spring 1902 controls the amount of pressure exerted by the side bars 204 on the battery cells.

20A-20B further illustrate an exemplary battery assembly 1802 according to an embodiment of the present invention. As shown in FIG. 20B , in an embodiment, the bottom plate 302 has a hole 2000 positioned at the location where the center plate 304 is attached to the bottom plate 302 . The holes 400 allow air and water to flow through the center plate 304 without being blocked by the bottom plate 302 .

FIG. 21 shows an exploded view of the battery module 1800 . In FIG. 21 , the various components forming battery module 1800 can be seen more clearly than in some of the other figures. These components include, for example, battery cells 202 , side plates 203 , side bars 204 , battery module controller circuit boards 310 a and 310 b , and bus bars 312 .

FIG. 22 illustrates another embodiment of an exemplary battery module 1800 according to the present invention with the front cover removed. In this embodiment, the side bars 204a-204c are connected together using a strip 2200, two springs 2202a-2202b and bolts. As shown in FIG. 22 , in this embodiment, the battery module 1800 includes a rear cover 300 , a top tray 306 and a cover 308 .

FIG. 23 illustrates an exemplary battery module 2300 according to an embodiment of the present invention. As shown in FIG. 23 , the battery module 2300 includes battery cells 202 , side plates 203 and a center plate 304 . Pressure is applied to the side plate 203/cell 202 using side bars 204 and two pressure assemblies 2310a-2310b. A pressure assembly 2310 is positioned at both ends of the battery module 2300 as indicated in FIG. 23 .

As shown in FIG. 23 , each pressure assembly 2310 includes a load cell 2312 , a connecting bar 2314 , springs 2316 and bolts 2318 . The pressure applied to the side plates 203 and battery cells 202 is controlled by springs 2316 and can be adjusted using bolts 2318 . In operation, when one or more of the battery cells 202 expands, they cause the side plates 203 to move to apply a force to the load cells 2312 attached to the side plates. This movement is then detected and quantified by battery module controller circuit boards 310a-310b (see, eg, FIG. 26).

24A-24B further illustrate a load cell 2312 that may be used in embodiments of the present invention. As shown in FIG. 24A , the load cell 2312 includes one or more strain gauges 2400 positioned within a central bore of the load cell 2312 . After one or more strain gauges are installed, the center hole is typically filled with epoxy 2402 to protect the strain gauges and associated wires.

Figure 25 illustrates the operation of a load unit 2312 that may be used in embodiments of the present invention. As shown in FIG. 25 , strain gauges are positioned in one or more locations within the central bore of the load cell 2312 to measure the compression and/or tension caused by applying a force to the end of the load cell 2312 . In the embodiment shown in Figure 25, four strain gauges 2400a-2400d are installed. This embodiment may, for example, be used with the circuits that will be shown in Figures 29 and 30 below.

FIG. 26 illustrates an exemplary battery module 2600 with the front and top covers removed, according to an embodiment of the invention. As shown in FIG. 26 , battery module 2600 includes a pressure assembly 2602 that includes a load cell 2604 . The load unit 2604 is wired to one or both of the battery module controller circuit boards 310a-310b. The output of the load cell 2604 is monitored and quantified using the battery module controller circuit boards 310a-310b.

27 and 28 illustrate an example expansion/pressure sensor 2700 that may be used in accordance with embodiments of the present invention. As shown in FIG. 27, sensor 2700 includes two supports 2702a-2702b, two flexures 2704a-2704b (which may be metal or plastic or any other suitable material), and four strain gauges 2706a-2706d . The supports are attached to the side walls of a battery module according to the present invention, and they cause the flexures 2702 to flex when a force is applied to the supports 2702 . This deflection is illustrated in FIG. 28 .

As shown in FIG. 28, when a force is applied to sensor 2700 to cause flexures 2704a-2704b to flex, compressive and tensile forces are applied to strain gauges such as strain gauges 2706a-2706b, as in FIG. shown.

FIG. 29 is a diagram showing how to connect the strain gauges of a sensor in a Wheatstone bridge circuit 2900 according to an embodiment of the present invention. As shown in Figure 29, the circuit 2900 includes a voltage source 2902 and four strain gauges 2904a-2904d. Those skilled in the art will understand that the Wheatstone bridge circuit 2900 compensates for adverse temperature effects of a sensor. In embodiments, the strain gauges may be attached to a load cell or flexure (as described herein) or directly to the pressure plate(s) or battery cell(s).

FIG. 30 is a diagram showing a circuit 3000 for converting the output of a strain gauge into a serial digital signal. The circuit 3001 uses a commercially available HX711 chip 3001 . The sensors described herein are connected to connector 3002 . The serial output of circuit 3000 is connected to battery module controller circuit boards 310 a - 310 b using circuit connector 3004 . In operation, the circuit 3000 provides an input voltage to a sensor strain gage and monitors the output voltage of the strain gage in a manner such as that shown in FIG. 29 . The monitored output voltage is converted to a digital signal by an analog-to-digital converter, and this digital signal is then serially transmitted to another circuit, such as the one included on the battery module controller circuit boards 310a to 310b, as follows The text will be described further.

FIG. 31 shows a battery module 3100 with two side panels 3102 a - 3102 b and eight battery cells 202 . Eight battery cells 202 are compressed by two side plates 3102a-3102b. The pressure applied to the side plates 3102 a - 3102 b is transferred to the eight battery cells 202 . As shown in FIG. 31 , there is space at both ends of the battery module 3100 for attaching a pressure assembly, according to an embodiment of the present invention.

Figure 32 illustrates an expansion/pressure sensor 2700 attached to pressure plates 3102a-3102b of a battery module 3100 according to an embodiment of the present invention. Expansion of a battery cell within the battery module causes movement of the pressure plates or side plates 3102 a - 3102 b , and this movement is detected by the expansion/pressure sensor 2700 .

Figure 33 illustrates two applied pressure assemblies 3302a-3302b attached to two pressure plates 3102a-3102b of a battery module according to an embodiment of the invention. An applied pressure assembly 3302a is attached to the front of the battery module. A second applied pressure assembly 3302b is attached to the rear of the battery module. These two applied pressure assemblies 3202a-3202b include integrated sensors for determining/measuring the applied force and detecting changes in force/movement of the pressure plates 3102a-3102b of the battery module.

34 and 35 are diagrams depicting two embodiments of an applied pressure assembly with an integrated sensor of a battery module according to the present invention. FIG. 34 shows an applied pressure assembly 3400 including an integrated sensor 3402 with a leaf spring 3404 . FIG. 35 shows an applied pressure assembly 3500 including an integrated sensor 3502 with a die spring 3504 . The external pressure assembly is used to apply a predetermined force to the battery cells constituting the battery module. Integrated sensors are used to determine/measure applied force and detect changes in force/movement of the pressure plates 3406a-3406b of the battery module, eg, due to expansion of one of the battery cells within the battery module.

FIG. 34 shows an applied pressure assembly 3400 including an integrated sensor 3402 with a leaf spring 3404 . As shown in FIG. 34 , the applied pressure assembly 3400 includes a leaf spring 3404 , a bolt 3408 , a washer 3410 and a nut 3412 . A metal bracket 3416 attaches the leaf spring 3404 to a first pressure plate 3406b. A second metal bracket 3414 attaches a second pressure plate 3406a to the washer 3410/nut 3412. Force is applied to the two pressure plates 3406a-3406b by turning the nuts 3412 and/or the bolts 3408. The bolt 3408 is in contact with the leaf spring 3404 . The applied force is determined by the leaf spring 3404 and transferred to the pressure plates 3406a-3406b by two metal brackets 3414 and 3416. When the desired force is applied, the nut 3412 can be, for example, spot welded to the bolt 3408 to ensure that the bolt 3408 does not loosen over time.

In one embodiment, a strain gauge 3420 is attached to the leaf spring 3404 as shown in FIG. 34 . In one embodiment, four strain gauges 3420 are used. The strain gauges 3420 are connected in a Wheatstone bridge configuration. Strain gauge 3420 is wired to an electronic circuit that converts the output of strain gauge 3420 into a digital signal, as described herein.

FIG. 35 shows an applied force assembly 3500 with an integrated sensor 3502 having a die spring 3504 . As shown in FIG. 35 , the applied pressure assembly 3500 includes a die spring 3504 , a bolt 3506 , a washer 3508 and a nut 3510 . A metal bracket 3512 attaches the gasket 3508 to a first pressure plate 3406a. A second metal bracket 3514 attaches a second pressure plate 3406b to the nut 3510 . For example, force is applied to the two pressure plates 3406a-3406b by turning the bolt 3506 in contact with the die spring 3504. The applied force is determined by die spring 3504 and transferred to pressure plates 3406a-3406b by two metal brackets 3512 and 3514. When the desired force is applied, nut 3510 may be spot welded to bolt 3506 to ensure that bolt 3506 does not loosen over time. The nut 3510 can also be spot welded to the second metal bracket 3514 so that it does not rotate when the bolt 3506 is turned.

FIG. 36 illustrates characteristics of an exemplary center plate 3600 and bottom plate 3602 of a battery module according to an embodiment of the invention. As shown in Figure 36, the bottom plate 3602 has one or more holes 3604 that allow air and/or water to flow through the center plate 3600, as described herein. In an embodiment, center plate 3600 is welded to bottom plate 3602 . The battery cells 202 are then attached to the center plate 3600, eg, using a thermally conductive adhesive or tape.

FIG. 37 shows a battery module side plate 3700 according to an embodiment of the present invention. As shown in Figure 37, the side plate 3700 has a heat sink 3702 attached thereto to facilitate cooling. In an embodiment, heat sink 3702 is attached, for example, by welding or screws.

FIG. 38 illustrates an exemplary battery module controller 3800 according to an embodiment of the present invention. The battery module controller 3800 includes an AC to AC power supply 3802 and isolation transformer 3804 and a battery module controller circuit board 3806 attached to the top of a battery module, as described herein. The battery module controller circuit board 3806 includes a power supply 3808 , a CPU 3810 , voltage sensors 3812 , temperature sensors 3814 , a cell balancing circuit 3816 and communication circuit(s) 3818 . It also includes a cell pressure monitor 3820 that interfaces with the expansion/pressure sensor described herein, which is a feature of battery modules according to the present invention.

In operation, the AC-AC power supply 3802 draws power from an electrical grid and converts this power to a higher frequency AC power. The higher frequency AC power output by the power supply 3802 is supplied to the power supply 3808 and the cell balancing circuit 3816 on the battery module controller circuit board 3806 . The power supply 3808 generates the DC power required to operate the various components of the battery module controller circuit board 3806 . CPU 3810 runs firmware and software that control the operation and function of battery module controller circuit board 3806 . These functions include monitoring the voltage, temperature and pressure of the battery cells making up the battery modules controlled by the battery module controller 3800 . Functions also include balancing the battery cells of the battery module and communicating data about the battery module and battery cells to a higher level controller such as, for example, a battery rack controller as described below. Cell voltage monitor(s) 3812, cell temperature monitor(s) 3814 and cell pressure monitor(s) 3820 are the hardware sensors and circuitry required to monitor battery cell voltage, temperature and pressure. Cell balancing circuit 3816 is the hardware required to provide balanced current/power to individual battery cells of a battery module controlled by battery module controller 3800 . More details on these functions and associated hardware are provided below.

FIG. 39 shows more details of an example battery module controller 3900 according to an embodiment of the invention. As described herein, the battery module controller 3900 monitors the voltage, temperature and pressure of the battery cells by the battery module controller 3900 . The battery module controller 3900 also balances the cells of the battery module and communicates data about the battery modules and cells to a higher level controller such as, for example, a battery rack controller described herein.

FIG. 40 illustrates an example battery module controller 4000 according to an embodiment of the invention. In an embodiment, the battery module controller provides a constant balancing current to each battery cell controlled by the battery module controller 4000 . In an embodiment, the constant balancing current is, for example, 1 amp or 2 amps. In one embodiment 4010, the battery module controller provides balancing current to individual battery cells selected to receive balancing current using a star configuration. In another embodiment 4020, the balancing current is provided through a loop that charges cells selected for balancing and bypasses cells not selected for receiving balancing current, as shown in FIG. 40 .

FIG. 41 illustrates an example battery module controller 4100 according to an embodiment of the invention. In these embodiments, high frequency AC current is supplied to individual battery cells via an isolation transformer 4102, as shown in FIG. 41 . The AC current is then rectified by a rectifier circuit 4104 and used to charge/balance the battery cells. In one embodiment, the transformer 4106 used to supply cell balancing current may also be used to supply power to other battery module controller components, as shown in FIG. 41 .

FIG. 42 illustrates an exemplary battery module power supply 4200 according to an embodiment of the invention that may be used to generate the high frequency AC required to provide balanced power to battery cells.

FIG. 43 illustrates an exemplary cell charging/balancing circuit 4300 that may be used in embodiments of the invention to rectify an AC current and provide DC current for balancing battery cells.

FIG. 44 illustrates another exemplary cell charging/balancing circuit 4400 that may be used to balance battery cells in one embodiment of the invention.

FIG. 45 illustrates an exemplary cell charging/balancing circuit 4500 that may be used to charge/balance battery cells in one embodiment of the invention.

Those skilled in the relevant art will understand the operation of the charging/balancing circuit described above in view of the circuit diagrams in the figures and the description herein.

FIG. 46 illustrates an exemplary battery module controller 4610 according to an embodiment of the present invention. As shown in FIG. 46 , battery module controller 4610 includes two battery module controller circuit boards 310 a and 310 b connected together by ribbon cable 4602 . In one embodiment, the battery module controller circuit board 310 a includes a power supply 4612 and a control and monitoring circuit 4614 . The battery module controller circuit board 310 b includes a monitoring circuit 4616 . The battery module controller circuit boards 310a to 310b are shown mounted on a battery module 4600 according to an embodiment of the present invention.

FIG. 47 further illustrates an example battery module controller 4610 . As shown in FIG. 47, in addition to the power supply 4612, the battery module controller 4610 also includes a microcontroller unit (MCU) 4620, a cell voltage monitor 4622, a cell temperature monitor 4624, and a cell pressure monitor 4626. , a unit balance controller 4630 , a balance transformer 4632 and a balance rectifier 4634 . In one embodiment, the MCU 4620 communicates with a higher-level controller using a CANBus communication circuit 4628 . The CANBus communication circuit uses a connector 4640 to connect to the higher level controller. In one embodiment, the higher level controller is one of the rack controllers described herein.

In operation, the power supply 4612 draws power from an electrical grid and converts this power to the higher frequency AC power and DC voltage required to operate the components of the battery module controller 4610 . The higher frequency AC power output by the power supply 4612 is supplied to a cell balancing transformer 4632 and a balancing rectifier 4634 for a balancing unit 4636 . The power supply 4612 generates the power required to operate the various components of the battery module controller 4610 such as, for example, the MCU 4620, the cell voltage monitor 4622, the cell temperature monitor 4624, the cell pressure monitor 4626, and the cell balance controller 4630. DC power. The MCU 4620 runs firmware and software that control the operation and functions of the battery module controller 4610 . These functions include monitoring the voltage, temperature and pressure of the battery cells making up the battery modules controlled by the battery module controller 4610 . Functions also include balancing the battery cells of the battery module and communicating data about the battery module and battery cells to a higher level controller such as, for example, a battery rack controller as described below. Cell voltage monitor(s) 4622, cell temperature monitor(s) 4624 and cell pressure monitor(s) 4626 are the hardware sensors and circuitry required to monitor battery cell voltage, temperature and pressure. The cell balancing controller 4630 is the hardware required to provide balanced current/power to the individual battery cells 4636 of the battery modules controlled by the battery module controller 4610 . More details on these functions and associated hardware are provided below.

FIG. 48 is a detailed circuit diagram of a battery module controller 4610 according to an embodiment of the present invention. As shown in Figure 48, in one embodiment, two converters each drive a transformer each producing four isolated outputs. These eight outputs are used with a constant current circuit to charge one or more battery module cells. Monitor the temperature of each battery cell. The circuit is controlled by a microprocessor and communicates with a higher level controller using CANBus communication. The microprocessor also measures the voltage across each cell. The controller also includes circuitry to measure the expansion/pressure of the battery cells.

FIG. 49 illustrates an exemplary power supply 4900 that may be used with a battery module controller in accordance with an embodiment of the present invention. As shown in FIG. 49, power supply 4900 includes an electromagnetic interference (EMI) filter 4902, a rectifier 4904, a quasi-resonant power processor 4906, isolation transformers 4908 and 4910, a regulated 5 V power circuit 4912, a regulated 12 V power circuit 4914 and one or more DC to DC 6 V power converter circuits 4916 for cell balancing. In an embodiment, isolation transformers 4908 and 4910 may be multiple windings on the same transformer core. The power supply 4900 is connected to the grid using a connector 4918 . In one embodiment, quasi-resonant power processor 4906 is implemented using an Infineon Technologies 5QR1680AG integrated circuit chip.

FIG. 50 is a detailed circuit diagram of a power supply 4900 according to an embodiment of the present invention. As shown in Figure 50, the power supply 4900 includes a universal 100 V to 240 V, 50 Hz/60 Hz input and circuitry to limit EMI and inrush current. It also includes an offline quasi-resonant switching power supply. AC power is supplied to a connector and passes through a fuse and EMI filter. The input voltage is then rectified and stored on a capacitor. The power supply controller causes energy to be stored as flux in the transformer, where the flux is intermittently removed by two isolated output diodes. In one embodiment, the power supply circuit generates +5 V and +12 V that are dielectrically isolated from each other and the input. An optocoupler is used to sense and regulate the output voltage.

Figure 51 further illustrates one embodiment of the cell pressure monitor(s) 4626 according to one embodiment of the invention. As shown in FIG. 51, the cell pressure monitor 4626 uses a load cell 2312 with a Wheatstone bridge circuit 5100 including four strain gauges 5102a-5102d. The operation of this load cell and Wheatstone bridge circuit is described above with reference to FIGS. 23 to 26 .

FIG. 52 illustrates an exemplary battery rack controller 5200 according to an embodiment of the invention. As shown in Figure 52, the battery rack controller 5200 includes four DC power connectors 5202a-5202d, two AC power connectors 5204a-5204b, two system level communication connectors 5206a-5206b, two battery module communication Connectors 5208a-5208b, a status indicator 5210, and a power switch 5212. The battery rack controller 5200 can control a plurality of battery modules, such as the battery module 100, as shown in FIGS. 55 and 57A-57C below.

The DC power connectors 5202a to 5202d are used to connect the battery modules of the battery rack to the DC bus bars of a battery energy storage system. In one embodiment, DC power connectors 5202a and 5202c connect battery rack controller 5200 to the energy storage system DC bus bars. Power connectors 5202b and 5202d connect the rack controller 5200 to the battery modules that make up the rack. AC grid power is provided to the rack controller 5200 using the AC power connector 5204a. This power is then provided to the battery module using the AC power connector 5204b.

System-level communication connectors 5206a-5206b are used to communicate with a higher-level energy storage system controller. In one embodiment, such communications occur using TCP/IP communications. The battery module communication connectors 5208a to 5208b are used to communicate with the battery modules of the battery rack. In one embodiment, such communications occur using CANBus communications. In one embodiment, CANopen communication is used.

In an embodiment of the battery shelf controller 5200, when powered on, the status indicator 5210 displays, for example, a green light indicating that everything is operating normally or a yellow or red light indicating that the battery shelf has a minor or major operational problem. Lights to show the status of the battery holder. The power switch 5212 is used to switch on and off the power of the battery rack controller 5200 .

FIG. 53 further illustrates a battery rack controller 5200 according to one embodiment of the present invention. As shown in FIG. 53, the battery rack controller 5200 includes a battery rack controller circuit board 5300, an ammeter 5302, two voltmeters 5304a-5304b, three contactors 5306a-5306c, a power resistor 5308, and two fuses 5310a to 5310b. The battery rack controller circuit board 5300 includes a microcontroller unit running firmware and/or software that implements the functions of the battery rack controller 5200 . These functions include using the battery module controller and battery energy storage system controller to measure battery rack current, battery rack voltage and communication data. In operation, the rack controller circuit board 5300 opens and closes the contactor 5306 to connect the battery modules to the battery system DC bus bars. Contactor 5306a and power resistor 5308 are used to pre-charge the battery rack and match the voltage of the battery rack to the DC system bus bars before closing contactor 5306b. If an abnormal current or voltage is detected by the ammeter 5302 or one of the two voltmeters 5304a-5304b during operation, the battery rack controller circuit board 5300 opens the contactor 5306 to isolate the battery rack from the DC system bus Wait until the abnormal condition is corrected. Fuses 5310a-5310b are included in case of a short circuit or other overcurrent problem. In an embodiment, fuse 5310 is a very fast acting fuse.

As shown in FIG. 53 , the battery rack controller 5200 includes a power supply 5312 for powering the components of the battery rack controller 5200 . The power of this power supply is grid power. A relay 5314 controlled by the rack controller circuit board 5300 controls the battery modules that supply grid power to the rack. In one embodiment, opening and closing relay 5314 may be used as needed to reset the battery module controllers of the battery modules making up the battery rack.

54A-54B illustrate an exemplary battery holder 5400 according to an embodiment of the present invention. As shown in FIG. 54A , battery rack 5400 includes a base 5402 , doors 5404 a - 5404 b , a cover 5406 , a water suppression system 5408 , and exhaust duct 5410 . The base 5402 can be used to move and position the battery rack 5400, eg, using a stack of tall trucks. Doors 5404a-5404b allow access to the battery modules and battery module controllers housed inside the battery rack enclosure. The shroud 5406 provides space at the top of the battery rack for the fire suppression system sprinkler head(s). The exhaust pipe 5410 is used to draw air through the battery rack and cool the battery module. It is also used, for example, to direct heat and any gases to the outside of the container or chamber in which the battery rack is located when a battery cell is vented. In an embodiment, the fan(s) used to move air through the battery rack are located in the exhaust duct 5410, which makes replacing a fan easier than having many small fans included as part of, for example, a battery module One of the better designs inside the enclosure.

As shown in FIG. 54B , one or more water spray heads 5420 are positioned inside the battery rack 5400 . In the event of a fire, the sprinkler heads are activated and spray water directly inside the battery rack 5400. This water is collected by the top tray of the battery module and the water is then directed to flow down through the center plate of the battery module and past the side plates of the battery module to extinguish the fire and cool the surrounding battery modules so the fire does not spread to other Modules and thus problematic modules do not catch fire a second time. If a battery were to vent and potentially catch fire, the heat and gases would be removed from the battery rack through the exhaust pipe 5410 .

Figure 55 illustrates an exemplary battery holder 5500 according to an embodiment of the present invention. As shown in FIG. 55 , the battery rack 5500 includes a base 5502 , a door 5404 , a cover 5506 , a water suppression system 5508 and exhaust pipes 5510 . The base 5502 can be used to move and position the battery rack 5500, for example, using a stack of tall trucks. The door 5504 allows people to receive the battery module 100 and the battery module controller 5200 housed inside the enclosure of the battery rack. The shroud 5506 provides space at the top of the battery rack for the fire suppression system sprinkler head(s). The exhaust pipe 5510 is used to draw air through the battery rack and cool the battery module. It is also used, for example, to direct heat and any gases to the outside of the container or chamber in which the battery rack is located when a battery cell is vented. In an embodiment, the fan(s) used to move air through the battery rack are located in the exhaust duct 5510, which makes replacing a fan easier than having many small fans as part of, for example, the battery module 100 One of the better designs contained within the enclosure.

The battery rack 5500 and other battery racks described herein allow water from a commercial sprinkler system (see, e.g., FIG. Flow down through the battery module 100 to provide cooling and fire suppression. Water flows down the top of the battery module where it is collected/collected by a plastic top with a berm positioned on the top of the battery module. This water flows down through the middle plate and over the side plates or heat sinks of each of the battery module or battery cell assembly and cools the battery cells. As the water leaves the middle plate, it is collected/collected by the battery module below and can then flow through the middle plate of this battery module and past the side plates, as described herein.

56A-56B illustrate an exemplary battery holder 5600 according to an embodiment of the present invention. As shown in FIG. 56A , battery rack 5600 includes a base 5602 , a door 5604 , a cover 5606 , a water suppression system 5608 and exhaust pipe 5610 . The base 5602 can be used to move and position the battery rack 5600, eg, using a stack of tall trucks. Door 5604 allows access to battery modules 100 housed inside the battery rack enclosure. The shroud 5606 provides space at the top of the battery rack for the fire suppression system sprinkler head(s). The exhaust pipe 5610 is used to draw air through the battery rack and cool the battery module. It is also used, for example, to direct heat and any gases to the outside of the container or chamber in which the battery rack is located when a battery cell is vented. In an embodiment, fan(s) for moving air through the battery rack are located in the exhaust duct 5610 .

FIG. 56B is a more detailed diagram of one of the battery holders 5600 . In FIG. 56B, one can see the battery module 100 more clearly, and the bus bars 5630a-5630c and the cables 5640a-5640b are used to connect the battery modules 100 together to form a battery rack.

57A-57C illustrate exemplary battery rack products or units according to embodiments of the present invention. Figure 57A shows a battery rack 5500 that can be used as part of a battery energy storage system. In an embodiment, the battery rack contains 15 battery modules 100 according to the present invention and forms a nominal 440 V battery energy storage system. Figure 57B shows a battery rack product including a battery rack 5500 and a battery rack 5600 that can be used as part of a battery energy storage system. In an embodiment, the battery rack product includes 33 battery modules 100 according to the present invention and forms a nominally 1000 V battery energy storage system. Figure 57C shows a battery rack product including one battery rack 5500 and two battery racks 5600 that can be used as part of a battery energy storage system. In an embodiment, the battery rack product includes 51 battery modules 100 according to the present invention and forms a nominally 1500 V battery energy storage system. In fact, battery energy storage systems can be very large and formed by operating many of these rack products together in parallel.

FIG. 58 further illustrates an exemplary fire suppression system for a battery rack according to an embodiment of the present invention. As shown in FIG. 58, a battery rack 5800 has a water fire suppression system including a sprinkler head 5802 that allows water from a commercial sprinkler system to flow down in a cascading waterfall through the interior of the battery rack enclosure. The battery module 100 provides cooling and fire suppression. Water flows down the top of the battery module 100 where the water is collected/collected by a plastic top with a berm located on the top of the battery module. This water flows down through the middle plate and over the side plates or heat sinks of each of the battery module or battery cell assembly and cools the battery cells. As the water leaves the middle plate, it is collected/collected by another battery module 100 below and can then flow through the middle plate of this battery module and past the side plates, as described herein.

59A to 59B illustrate a fire extinguishing system 5900 of a battery rack according to an embodiment of the present invention. As shown in FIGS. 59A-59B , fire suppression system 5900 includes one or more water distribution mains 5902 that direct water to battery modules 5901 housed in a battery rack. The water distribution main 5902 sprays water directly onto the battery modules 5901, as shown in Figure 59A. In the event of a fire, the water extinguishes the fire and cools the surrounding battery modules so the fire does not spread to other modules and thus the module in question does not catch fire again.

FIG. 60 illustrates an exemplary battery module 6000 according to an embodiment of the present invention. FIG. 60 is an exploded view of the battery module 6000 such that the components of the battery module 6000 can be seen. As shown in FIG. 60 , the battery module 6000 includes battery cells 202 , side panels 203 , side bars 204 , a bottom panel 302 , center panel 304 , top tray 306 and a cover 6002 . The battery module 6000 also includes battery module controller circuit boards 310 a and 310 b , bus bars 312 and sensors 314 .

In one embodiment, the battery module 6000 includes eight battery cells 202 . The battery unit 202 is used for storing electric energy. Eight battery cells 202 are connected in series using bus bar 312 . A predetermined amount of pressure is applied to the battery cell 202 using the side plates 203 , center plate 304 , side bars 204 and springs 206 . Side plates 203 and center plate 304 also provide cooling for battery cells 202 . Top tray 306 fits on top of battery unit 202 and provides several functions including providing a protected space for sensor 314 and battery module controller circuit boards 310a and 310b. Other functions of the top tray 306 are described herein. Cover 6002 fits on top of top tray 306 . As described in more detail above, the battery module controller circuit board provides battery management functions of the battery module 6000 such as, for example, monitoring the voltage, temperature and pressure of the battery cells 202 .

FIG. 61 illustrates an exemplary battery rack 6100 according to an embodiment of the present invention that houses a battery module 6000 . As shown, the battery module 6000 includes a cover 6002 for facilitating air flow to a cooling air collection system. The battery rack further included a water distribution system attached to the back of the battery rack depicted between the battery modules and the cooling air collection system, as shown in Figures 62A-62B.

62A-62B further illustrate an exemplary battery holder 6100 according to one embodiment of the invention. As shown in FIGS. 62A-62B , battery rack 6100 includes a fire suppression system 6202 and exhaust duct 6204 . The fire suppression system 6202 includes a water distribution main that directs water to the battery modules 6000 housed in the battery racks. The water distribution main pipe sprays water directly onto the battery module 6000. In the event of a fire, the water extinguishes the fire and cools the surrounding battery modules so the fire does not spread to other modules and thus the module in question does not catch fire again. The exhaust duct 6204 is used to draw air through the battery rack and cool the battery module. It is also used, for example, to direct heat and any gases to the outside of the container or chamber in which the battery rack is located when a battery cell is vented. In an embodiment, fan(s) for moving air through the rack are located in the exhaust duct 6204 .

63A-63B illustrate an exemplary battery rack 6300 for housing, for example, a battery module 1800 according to an embodiment of the invention. The battery rack 6300 allows air to enter the bottom of the rack and rise to the top of the rack to provide cooling air during operation of the battery. A fan 6302 is positioned at the top of the battery rack.

FIG. 64 further illustrates an exemplary battery holder 6300 according to an embodiment of the invention.

FIG. 65 illustrates an exemplary container system 6500 for housing battery racks according to the present invention to form a battery energy storage system. The container system houses a plurality of battery racks and protects the battery racks from the environment. In an embodiment, container system 6500 includes an HVAC unit 6502 .

Figure 66 shows a plurality of containers 6602 forming a battery energy storage system 6600 housing battery racks according to the present invention. In addition to the container 6602, the battery energy storage system 6600 also includes a plurality of bidirectional power converters 6604 for charging and discharging the battery racks housed in the container 6602.

Figure 67 shows a building 6700 housing battery racks according to the invention forming a battery energy storage system.

In one embodiment, a battery module may include: a plurality of battery cells, each of which is in contact with one of the plurality of side plates; and a sensor coupled to at least one of the plurality of side plates, wherein the A sensor is configured to detect expansion of at least one of the plurality of battery cells.

In some further embodiments, the sensor includes a first flexible section having a circular or oval shape, and wherein a first strain gauge is attached to the first flexible section.

In some further embodiments, the first flexible section includes at least one of metal or plastic.

In some further embodiments, the sensor includes a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge and the second strain gauge electrically connected in series.

In some further embodiments, the battery module can include a tray in contact with the battery module configured to collect water and direct the water toward at least one of the plurality of side panels.

In some further embodiments, the battery module can include an inner panel in contact with one of the plurality of battery cells and extending at least partially into the battery module, wherein the tray is configured to direct water to The inner plate is used to cool the battery module.

In some further embodiments, the battery module may include a controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal from the sensor, wherein the The control signal is configured to cause the battery module to suspend charging and discharging of the at least one of the plurality of battery cells of the battery module.

In some further embodiments, the battery module may include a controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal from the sensor, wherein the The control signal is configured to cause the battery module to be electrically disconnected from an electrical busbar.

In some further embodiments, the controller includes a power supply configured to generate an electrical output having an AC frequency greater than 40,000 Hz and less than 280,000 Hz, and wherein the electrical output from the power supply is passed through Provided to a balancing circuit configured to balance electrical inputs of at least two battery cells of the plurality of battery cells.

In some further embodiments, the power supply is coupled to the plurality of battery cells using at least one isolation transformer.

In another embodiment, the battery module includes a plurality of battery assemblies, wherein each battery assembly includes: a first battery unit and a second battery unit; an inner plate, which is located between the first battery unit and the Between the second battery unit; a first side plate, which is in contact with the first battery unit; a second side plate, which is in contact with the second battery unit; and a sensor, which is coupled to the first side plate or the At least one of the second side panels, wherein the sensor is configured to detect movement of at least one of the first side panel or the second side panel, wherein the movement is attributable to the first battery unit or the second side panel At least one of the two battery cells expands.

In some further embodiments, the sensor includes a first flexible section having a circular or oval shape, and wherein a first strain gauge is attached to the first flexible section.

In some further embodiments, the first flexible section includes metal or plastic.

In some further embodiments, the sensor includes a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge and the second strain gauge electrically connected in series.

In some further embodiments, the battery module can include a tray in contact with the battery module configured to collect water and direct the water to the first side panel and the second side panel.

In some further embodiments, the battery module can include a tray in contact with the battery module configured to collect water and direct the water to the inner panel.

In some further embodiments, the battery module may include a controller configured to receive at least one output signal from the sensor and generate a control signal in response to the at least one output signal, wherein the control signal is passed configured to cause the battery module to suspend charging and discharging of at least one of the plurality of battery cells of the battery module.

In some further embodiments, the battery module may include a controller configured to receive at least one output signal from the sensor and generate a control signal in response to the at least one output signal, wherein the control signal is passed configured to cause the battery module to be electrically disconnected from an electrical busbar.

In some further embodiments, the controller includes a power supply configured to generate an electrical output having an AC frequency greater than 40,000 hertz and less than 280,000 hertz, and wherein the electrical output from the power supply is passed through Provided to a balancing circuit configured to balance electrical inputs of at least two battery cells of the plurality of battery cells of the plurality of battery assemblies.

In some further embodiments, the power supply is coupled to the battery cells of the battery assembly using at least one isolation transformer.

In one embodiment, a battery rack includes: a plurality of battery modules, wherein each battery module includes: a plurality of battery cells, each battery cell is in contact with a side plate; a sensor is coupled to the side plate and assembled state to detect movement of the side plate due to expansion of a battery cell; and a battery module controller configured to receive an output signal from the sensor and generate a a control signal, wherein the control signal is configured to cause the battery module to suspend charging and discharging of the plurality of battery cells of the battery module; and a battery rack controller having a contactor, wherein the battery rack controller receiving the control signal and opening the contactor sufficiently to suspend charging and discharging of the battery module with the battery module controller generating the control signal.

In some further embodiments, the battery rack or any of the battery modules may further include a tray in contact with the battery module configured to collect water and direct the water to the battery module the side panels.

In some further embodiments, the sensor includes a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section.

In some further embodiments, the flexible section includes at least one of metal or plastic.

In some further embodiments, the battery module controller includes a power supply configured to generate an electrical output, and wherein the electrical output from the power supply is provided to a balancing circuit, the balancing circuit is Configured to balance electrical inputs of at least two of the battery cells of the battery module.

In some further embodiments, the power supply is coupled to the battery cells of the battery module using at least one isolation transformer.

In some further embodiments, the battery rack can include a water spray system configured to spray water on the battery modules.

In some further embodiments, the sprinkler system is configured to be connected to a fire protection system of a building.

In some further embodiments, the water spray system is configured to connect to a pipe configured to allow water to be pumped into the battery rack.

In some further embodiments, the battery rack can include a shroud connected to an exhaust duct configured to remove gases released by a battery cell of the battery rack.

In some further embodiments, the battery rack may further include: a first housing including the battery rack controller and the first plurality of battery modules; and a second housing coupled to the first housing including The second plurality of battery modules.

In some further embodiments, the battery rack can include a third housing coupled to the first housing that includes a third plurality of battery modules.

In another embodiment, a battery rack may include: a plurality of battery modules, wherein each battery module includes: a plurality of battery cells, each battery cell is in contact with a side plate; a sensor is coupled to the side plate and configured to detect movement of the side plate due to expansion of a battery cell; a tray, in contact with the battery module, configured to collect water and direct the water to the side of the battery module the side plates; and a battery module controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal, wherein the control signal is configured to cause the battery module group suspending charging and discharging of the battery module; a battery rack controller including a contactor, wherein the battery rack controller receives the control signal and sufficiently disconnects the contactor to suspend the battery module having the control signal a set of controllers for charging and discharging the battery modules; and a water spray system configured to spray water on the battery modules.

In some further embodiments, the sprinkler system is configured to be connected to a fire protection system of a building.

In some further embodiments, the water spray system is configured to connect to a pipe configured to allow water to be pumped into the battery rack.

In some further embodiments, the battery rack further includes a shroud connected to an exhaust duct, wherein the exhaust duct is configured to remove gases released by a battery cell of the battery rack.

In some further embodiments, the sensor includes a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section.

In some further embodiments, the flexible section includes at least one of metal or plastic.

In some further embodiments, the battery module controller includes a power supply configured to generate an electrical output, and wherein the electrical output from the power supply is provided to a balancing circuit, the balancing circuit is Configured to balance electrical inputs of at least two of the battery cells of the battery module.

In some further embodiments, the power supply is coupled to the battery cells of the battery module using at least one isolation transformer.

In one embodiment, a battery module may include a sensor configured to detect expansion of a battery cell.

In some further embodiments, an output of the sensor is configured to suspend operation of a battery system including the battery module.

In some further embodiments, an output of the sensor is configured to suspend charging and discharging of the battery module.

In some further embodiments, the battery module may include a cell balancing circuit that uses an AC-to-AC power supply to provide audio power for balancing the battery cells of the battery module.

In some further embodiments, the AC-to-AC power supply provides an electrical output with an AC frequency greater than 5,000 Hz.

In some further embodiments, the AC-to-AC power supply provides electrical power with an AC frequency greater than 5,000 Hz but less than 20,000 Hz.

In some further embodiments, the battery module can include an applied pressure sensing assembly for detecting the expansion of a battery cell of the battery module.

In some further embodiments, the battery module is further configured to allow water to flow through a conduit configured to direct the water to a predetermined location within the battery rack.

In some further embodiments, the fire suppression system is configured to be connected to a fire protection system of a building.

In some further embodiments, the battery module or the fire suppression system is further configured to connect to a pipe configured to allow water to be pumped into the battery rack.

In some further embodiments, the sensor can be further configured to detect movement of a plate in contact with the battery module.

In some further embodiments, the sensor may comprise a metal strip and at least one strain gauge attached to the metal strip.

In some further embodiments, the sensor may be made of plastic and have at least one strain gauge attached to the plastic.

In some further embodiments, the sensor may comprise a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section.

In some further embodiments, the battery module can further include a tray in contact with the battery module configured to direct water to a plate of the battery module.

In one embodiment, a battery module may include a sensor configured to detect movement of a plate in contact with the battery module, wherein the movement is caused by expansion of a battery cell within the battery module .

In some further embodiments, the sensor may comprise a load cell.

In some further embodiments, the sensor may comprise a metal strip and at least one strain gauge attached to the metal strip.

In some further embodiments, the sensor may be made of plastic and have at least one strain gauge attached to the plastic.

In some further embodiments, the sensor may comprise a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section.

In another embodiment, an external force assembly for a battery module may include: a spring for applying a force; a bolt in contact with the spring; a nut coupled to the bolt; and a metal bracket that transfers force from the spring to a pressure plate of a battery module.

In some further embodiments, the spring is one of a leaf spring and a die spring.

In some further embodiments, the applied pressure assembly may include a sensor for detecting expansion of a battery cell of the battery module.

In one embodiment, a battery rack can be configured to house a battery module and allow water to be sprayed from a fire suppression system onto the battery cells of the battery module.

Those skilled in the related art should readily understand that various adaptations and modifications of the above-mentioned exemplary embodiments can be made without departing from the scope and spirit of the present invention. It is therefore to be understood that within the scope of the appended claims the teachings of the invention may be practiced otherwise than as specifically described herein.

100: battery module 200: front cover 201: handle 202: battery unit 202a: battery unit 202b: battery unit 203: side panel 203a: side panel 203b: side panel 203c: side panel 204: side bar 204a to 204c: side bars 206: spring 300: back cover 302: Bottom plate 304: center plate/middle plate 306:Top tray 308: top cover 310a: Battery module controller circuit board 310b: Battery module controller circuit board 312: bus bar 314: sensor 314a to 314d: sensors 316: Connector 318a: handle strap 318b: handle strap 400: hole 400a to 400c: holes 600: Ring 602: Attachment point 602a: Attachment point 602b: Attachment point 604a to 604d: Location 700: metal ring 702a: Attachments 702b: Attachments 704a: plastic cap 704b: plastic cap 800: Expansion/Pressure Sensor 802: metal ring 804a: Plastic accessories 804b: Plastic accessories 900: Expansion/Pressure Sensor 902a: metal half ring 902b: metal half ring 904a: Plastic accessories 904b: Plastic accessories 1000: expansion/pressure sensor 1001a: metal half ring 1001b: metal half ring 1002: Plastic accessories 1004: Flexible Centerpiece 1100: Expansion/pressure sensor 1102: metal half ring 1102a: metal half ring 1102b: metal half ring 1104a: Plastic accessories 1104b: Plastic accessories 1106: Strain gauge 1110: Expansion/Pressure Sensor 1111: single component 1112: Strain gauge 1130: top tray 1132a to 1132d: expansion/pressure sensors 1200: circuit 1202: Voltage source 1204a to 1204c: fixed resistance value 1206: variable resistance value 1210: circuit 1212:variable resistor 1212a to 1212d: variable resistors 1214: multiplexer circuit 1500: Expansion/Pressure Sensor 1502: Plastic parts 1504: Strain gauge 1602: Strain gauge 1604: Plastic parts 1800: battery module 1802: Battery unit assembly 1900: article 1902: Spring 2000: hole 2200: article 2202a: Spring 2202b: Spring 2300: battery module 2310: pressure assembly 2310a: Pressure Assembly 2310b: Pressure Assembly 2312: load unit 2314: connecting strip 2316: spring 2318: Bolt 2400: strain gauge 2400a to 2400d: Strain gauges 2402: epoxy resin 2600: battery module 2602: pressure assembly 2604: load unit 2700: Expansion/Pressure Sensor 2702a: support 2702b: Support 2704a: Flexure 2704b: Flexure 2706a to 2706d: Strain gauges 2900: Wheatstone bridge circuit 2902: Voltage source 2904a to 2904d: Strain gauges 3000: circuit 3001: circuit 3002: Connector 3004: circuit connector 3100: battery module 3102a: side plate/pressure plate 3102b: Side plate/pressure plate 3302a: Applied pressure assembly 3302b: Applied pressure assembly 3400: Applied pressure assembly 3402: integrated sensor 3404: leaf spring 3406a: Pressure plate 3406b: Pressure plate 3408: Bolt 3410: Gasket 3412: Nut 3414: metal bracket 3416: metal bracket 3420: strain gauge 3500: Applied pressure assembly 3502: integrated sensor 3504: mold spring 3506: Bolt 3508: Gasket 3510: Nut 3512: metal bracket 3514: metal bracket 3600: center board 3602: bottom plate 3604: hole 3700: side panels 3702: Radiator 3800: battery module controller 3802: AC to AC power supply 3804: Isolation Transformer 3806:Battery module controller circuit board 3808: Power supply 3810:CPU 3812: Cell Voltage Monitor 3814: Unit Temperature Monitor 3816: Unit Balancing Circuit 3818: communication circuit 3820: Cell Pressure Monitor 3900: battery module controller 4000: battery module controller 4010: Example 4020: Example 4100: battery module controller 4102: Isolation Transformer 4104: Rectifier circuit 4106:Transformer 4200: battery module power supply 4300: Cell charging/balancing circuit 4400: Cell charging/balancing circuit 4500: Cell charging/balancing circuit 4600: battery module 4602: Ribbon cable 4610: battery module controller 4612: Power Supply 4614: control and monitoring circuit 4616: Monitoring circuit 4620: Microcontroller Unit (MCU) 4622: Cell Voltage Monitor 4624: Unit Temperature Monitor 4626: Unit Pressure Monitor 4628: CANBus communication circuit 4630: Unit Balance Controller 4632: Unit Balancing Transformer 4634: Balanced Rectifier 4636: battery unit 4640: connector 4900: Power supply 4902: Electromagnetic Interference (EMI) Filters 4904: rectifier 4906: Quasi-Resonant Power Processor 4908: Isolation Transformer 4910: Isolation Transformer 4912: Regulated 5 V Power Circuit 4914: Regulated 12 V Power Circuit 4916: DC to DC 6 V Power Converter Circuit 4918: connector 5100: Wheatstone bridge circuit 5102a to 5102d: Strain gauges 5200:Battery Rack Controller 5202a to 5202d: DC Power Connectors 5204a: AC power connector 5204b: AC power connector 5206a: System-level communication connector 5206b: System-level communication connector 5208a: battery module communication connector 5208b: battery module communication connector 5210: status indicator 5212: Power switch 5300:Battery Rack Controller Board 5302: Ammeter 5304a: Voltmeter 5304b: Voltmeter 5306a to 5306c: Contactors 5308: Power Resistor 5310: Fuse 5310a: Fuse 5310b: Fuse 5312: Power supply 5314: Relay 5400: battery holder 5402: base 5404a: door 5404b: door 5406: cover 5408: Water fire extinguishing system 5410: exhaust pipe 5420: sprinkler head 5500: battery holder 5502: base 5504: door 5506: cover 5508: Water fire extinguishing system 5510: exhaust pipe 5600: battery holder 5602: base 5604: door 5606: cover 5608: Water fire extinguishing system 5610: exhaust pipe 5630a to 5630c: bus bars 5640a: cable 5640b: cable 5800: battery holder 5802: sprinkler head 5900: Fire suppression system 5901: battery module 5902: Water distribution main 6000: battery module 6002: cover 6100: battery holder 6202: Fire suppression system 6204: exhaust pipe 6300: battery holder 6302: fan 6500: container system 6502: HVAC units 6600: Battery Energy Storage System 6602: container 6604: Bidirectional Power Converter 6700: Buildings

In addition to describing and illustrating various aspects and/or principles set forth in the present invention, the accompanying drawings, together with the following detailed description, illustrate several exemplary embodiments. The drawings and brief description are provided to enable a person of ordinary skill to practice the various aspects and/or principles set forth in the present invention.

FIG. 1 illustrates an exemplary battery module according to an embodiment of the present invention.

FIG. 2A shows the front cover of the battery module in FIG. 1 .

FIG. 2B illustrates the battery module of FIG. 1 with the front cover removed.

FIG. 3A is an exploded view of the battery module in FIG. 1 .

Figure 3B illustrates the battery module of Figure 1 with the handle strap installed therein.

Figure 4A illustrates the battery module of Figure 1 with the top cover removed.

FIG. 4B shows an example of an expansion/pressure sensor of the battery module in FIG. 1 .

5 illustrates a rear view of the battery module of FIG. 1 with the top cover removed.

Figure 6 illustrates an example expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

7A-7B illustrate an example expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

8A-8B illustrate an example expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

9A-9B illustrate an example expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

Figure 10 illustrates an exemplary expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

FIG. 11A illustrates an example expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

Figure 1 IB illustrates an example expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

11C-11H illustrate an example top tray with integrated expansion/pressure sensors according to embodiments of the invention.

Figure 12A illustrates a circuit that may be used with an expansion/pressure sensor according to an embodiment of the invention.

Figure 12B illustrates a circuit that may be used with an expansion/pressure sensor according to an embodiment of the invention.

FIG. 13 illustrates an exemplary battery module according to an embodiment of the present invention.

FIG. 14 is an exploded view of the battery module in FIG. 13 .

FIG. 15 illustrates an exemplary expansion/pressure sensor of the battery module of FIG. 13 .

FIG. 16 illustrates an exemplary expansion/pressure sensor of the battery module of FIG. 13 .

FIG. 17 illustrates an exemplary expansion/pressure sensor of the battery module of FIG. 13 .

FIG. 18 illustrates an exemplary battery module according to an embodiment of the present invention.

FIG. 19 illustrates an exemplary battery module according to an embodiment of the present invention.

20A-20B illustrate an exemplary battery assembly according to an embodiment of the present invention.

FIG. 21 is an exploded view of the battery module in FIG. 19 .

FIG. 22 illustrates an exemplary battery module with the front cover removed, according to an embodiment of the present invention.

FIG. 23 illustrates an exemplary battery module according to an embodiment of the present invention.

Figures 24A-24B illustrate load cells/meters that may be used in embodiments of the present invention.

Figure 25 illustrates a load cell/gauge that may be used in embodiments of the present invention.

FIG. 26 illustrates an exemplary battery module with the front cover and top cover removed, according to an embodiment of the present invention.

Figure 27 illustrates an example expansion/pressure sensor that may be used in accordance with embodiments of the present invention.

FIG. 28 is a diagram showing how movement of the sensor of FIG. 27 applies stress to the strain gauge.

Fig. 29 is a diagram showing how to connect a strain gauge with a sensor in a Wheatstone bridge configuration.

Figure 30 is a diagram showing a circuit for converting the output of the strain gauges into a serial digital signal.

Figure 31 shows a battery module with two pressure plates and eight battery cells.

Figure 32 depicts an expansion/pressure sensor attached to a pressure plate of a battery module.

Figure 33 depicts two applied pressure assemblies attached to two pressure plates of a battery module.

Figure 34 shows an applied pressure assembly with an integrated sensor with a leaf spring.

Figure 35 shows an applied pressure assembly with an integrated sensor with a die spring.

36 illustrates characteristics of an exemplary center plate and bottom plate of a battery module according to an embodiment of the present invention.

Fig. 37 shows a side plate of a battery module according to an embodiment of the present invention.

FIG. 38 illustrates an exemplary battery module controller according to an embodiment of the present invention.

FIG. 39 illustrates an exemplary battery module controller according to an embodiment of the present invention.

Figure 40 illustrates an exemplary battery module controller according to an embodiment of the present invention.

Figure 41 illustrates an exemplary battery module controller according to an embodiment of the present invention.

FIG. 42 illustrates an exemplary battery module power supply according to an embodiment of the present invention.

Figure 43 illustrates an exemplary cell charging/balancing circuit that may be used in embodiments of the present invention.

Figure 44 illustrates an exemplary cell charging/balancing circuit that may be used in one embodiment of the present invention.

Figure 45 illustrates an exemplary cell charging/balancing circuit that may be used in one embodiment of the present invention.

FIG. 46 illustrates an exemplary battery module controller according to an embodiment of the present invention.

FIG. 47 illustrates an exemplary battery module controller according to an embodiment of the present invention.

FIG. 48 illustrates an exemplary battery module controller according to an embodiment of the present invention.

FIG. 49 illustrates an exemplary power supply of a battery module controller according to an embodiment of the present invention.

FIG. 50 illustrates an exemplary power supply of a battery module controller according to an embodiment of the present invention.

FIG. 51 shows the characteristics of a battery module according to an embodiment of the present invention.

Figure 52 illustrates an exemplary battery rack controller according to an embodiment of the present invention.

Figure 53 illustrates an exemplary battery rack controller according to an embodiment of the present invention.

54A-54B illustrate an exemplary battery holder according to an embodiment of the present invention.

Figure 55 illustrates an exemplary battery holder according to an embodiment of the present invention.

56A-56B illustrate an exemplary battery holder according to an embodiment of the present invention.

57A-57C illustrate an exemplary battery holder according to an embodiment of the invention.

Fig. 58 illustrates a fire extinguishing system of a battery rack according to an embodiment of the present invention.

59A to 59B illustrate a fire extinguishing system of a battery rack according to an embodiment of the present invention.

FIG. 60 illustrates an exemplary battery module according to an embodiment of the present invention.

Figure 61 illustrates an exemplary battery holder according to an embodiment of the present invention.

62A-62B illustrate an exemplary battery holder according to an embodiment of the present invention.

63A-63B illustrate an exemplary battery holder according to an embodiment of the present invention.

Figure 64 illustrates an exemplary battery holder according to an embodiment of the present invention.

Figure 65 illustrates an exemplary container system for housing battery racks according to the present invention forming a battery energy storage system.

Figure 66 shows a plurality of containers housing battery racks according to the present invention forming a battery energy storage system.

Fig. 67 shows a building housing battery racks according to the present invention forming a battery energy storage system.

100: battery module

200: front cover

202a: battery unit

202b: battery unit

203a: side panel

203b: side panel

203c: side panel

204a: side strip

204b: side strip

300: back cover

302: Bottom plate

304: center plate/middle plate

306:Top tray

308: top cover

310a: Battery module controller circuit board

310b: Battery module controller circuit board

312: bus bar

314: sensor

316: Connector

Claims (60)

A battery module, comprising: a plurality of battery cells, each battery cell in contact with one of the plurality of side panels; and A sensor coupled to at least one of the plurality of side plates, wherein the sensor is configured to detect expansion of at least one of the plurality of battery cells. The battery module of claim 1, wherein the sensor includes a first flexible section having a circular or oval shape, and wherein a first strain gauge is attached to the first flexible section. The battery module according to claim 2, wherein the first flexible section comprises at least one of metal or plastic. The battery module according to claim 2, wherein the sensor includes a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge and the first strain gauge The two strain gauges are electrically connected in series. Such as the battery module of claim 1, which further includes: A tray, in contact with the battery module, is configured to collect water and direct the water toward at least one of the plurality of side panels. As the battery module of claim 5, it further includes: an inner plate in contact with one of the plurality of battery cells and extending at least partially into the battery module, Wherein the tray is configured to guide water to the inner plate to cool the battery module. Such as the battery module of claim 1, which further includes: a controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal from the sensor, wherein the control signal is configured to cause the battery module to pause The at least one of the plurality of battery cells of the battery module is charged and discharged. Such as the battery module of claim 1, which further includes: a controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal from the sensor, wherein the control signal is configured to cause the battery module to communicate with A power busbar power disconnect. The battery module of claim 7, wherein the controller includes a power supply configured to generate an electrical output having an AC frequency greater than 40,000 Hz, and wherein the electrical output from the power supply is provided by to a balancing circuit configured to balance electrical inputs of at least two of the plurality of battery cells. The battery module according to claim 9, wherein the power supply is coupled to the plurality of battery cells using at least one isolation transformer. A battery module, which includes a plurality of battery assemblies, wherein each battery assembly includes: a first battery unit and a second battery unit; an inner plate located between the first battery unit and the second battery unit; a first side plate in contact with the first battery cell; a second side plate in contact with the second battery cell; and a sensor coupled to at least one of the first side plate or the second side plate, wherein the sensor is configured to detect movement of at least one of the first side plate or the second side plate, wherein The movement is due to expansion of at least one of the first battery cell or the second battery cell. The battery module of claim 11, wherein the sensor includes a first flexible section having a circular or oval shape, and wherein a first strain gauge is attached to the first flexible section. The battery module according to claim 12, wherein the first flexible section comprises metal or plastic. The battery module of claim 12, wherein the sensor includes a second flexible section, wherein a second strain gauge is attached to the second flexible section, and wherein the first strain gauge and the first strain gauge The two strain gauges are electrically connected in series. As the battery module of claim 11, it further includes: A tray, in contact with the battery module, is configured to collect water and direct the water to the first side panel and the second side panel. As the battery module of claim 11, it further includes: A tray, in contact with the battery module, is configured to collect water and direct it to the inner panel. As the battery module of claim 11, it further includes: a controller configured to receive at least one output signal from the sensor and generate a control signal in response to the at least one output signal, wherein the control signal is configured to cause the battery module to suspend the battery module At least one of the plurality of battery cells of the set is charged and discharged. As the battery module of claim 11, it further includes: a controller configured to receive at least one output signal from the sensor and generate a control signal in response to the at least one output signal, wherein the control signal is configured to cause the battery module to communicate with an electrical bus Drain disconnected. The battery module of claim 17, wherein the controller includes a power supply configured to generate an electrical output having an AC frequency greater than 40,000 hertz, and wherein the electrical output from the power supply is provided to a balancing circuit configured to balance electrical inputs of at least two battery cells of the plurality of battery cells of the plurality of battery assemblies. The battery module according to claim 19, wherein the power supply is coupled to the battery units of the battery assembly using at least one isolation transformer. A battery rack comprising: A plurality of battery modules, wherein each battery module includes A plurality of battery cells, each battery cell is in contact with one side plate, a sensor coupled to the side plate and configured to detect movement of the side plate due to expansion of a battery cell, and a battery module controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal, wherein the control signal is configured to cause the battery module to suspend the battery module charging and discharging the plurality of battery cells of the group; and a battery rack controller having a contactor, wherein the battery rack controller receives the control signal and opens the contactor sufficiently to suspend charging of the battery module with the battery module controller generating the control signal and discharge. The battery rack according to claim 21, wherein each of the battery modules further comprises: A tray, in contact with the battery module, is configured to collect water and direct water to the side panels of the battery module. The battery rack of claim 21, wherein the sensor includes a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section. The battery holder according to claim 23, wherein the flexible section comprises at least one of metal or plastic. The battery rack of claim 21, wherein the battery module controller includes a power supply configured to generate an electrical output, and wherein the electrical output from the power supply is provided to a balancing circuit, the balancing The circuit is configured to balance the electrical input of at least two of the battery cells of the battery module. The battery rack according to claim 25, wherein the power supply is coupled to the battery cells of the battery module using at least one isolation transformer. As the battery rack of claim 21, it further includes: A water spray system configured to spray water on the battery modules. The battery rack of claim 27, wherein the sprinkler system is configured to connect to a fire protection system of a building. The battery rack of claim 27, wherein the water spray system is configured to connect to a pipe configured to allow water to be pumped into the battery rack. As the battery rack of claim 21, it further includes: A shroud is connected to the exhaust duct, wherein the exhaust duct is configured to remove gas released from a battery cell of the battery rack. As the battery rack of claim 21, it further includes: a first housing including the battery rack controller and the first plurality of battery modules; and A second casing, coupled to the first casing, includes a second plurality of battery modules. As the battery rack of claim 31, it further comprises: A third casing, coupled to the first casing, includes a third plurality of battery modules. A battery rack comprising: A plurality of battery modules, wherein each battery module includes A plurality of battery cells, each battery cell is in contact with one side plate, a sensor coupled to the side plate and configured to detect movement of the side plate due to expansion of a battery cell, a tray in contact with the battery module configured to collect water and direct the water to the side panels of the battery module, and a battery module controller configured to receive an output signal from the sensor and generate a control signal in response to the output signal, wherein the control signal is configured to cause the battery module to suspend the battery module Pack charging and discharging; a battery rack controller including a contactor, wherein the battery rack controller receives the control signal and opens the contactor sufficiently to suspend charging of the battery module with the battery module controller generating the control signal and discharge; and A water spray system configured to spray water on the battery modules. The battery rack of claim 33, wherein the sprinkler system is configured to connect to a fire protection system of a building. The battery rack of claim 33, wherein the water spray system is configured to connect to a pipe configured to allow water to be pumped into the battery rack. As the battery rack of claim 33, it further comprises: A shroud is connected to the exhaust duct, wherein the exhaust duct is configured to remove gas released from a battery cell of the battery rack. The battery rack of claim 33, wherein the sensor includes a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section. The battery holder according to claim 33, wherein the flexible section comprises at least one of metal or plastic. The battery rack of claim 33, wherein the battery module controller includes a power supply configured to generate an electrical output, and wherein the electrical output from the power supply is provided to a balancing circuit, the balancing The circuit is configured to balance the electrical input of at least two of the battery cells of the battery module. The battery rack of claim 39, wherein the power supply is coupled to the battery cells of the battery module using at least one isolation transformer. A battery module includes a sensor configured to detect expansion of a battery cell. The battery module of claim 41, wherein an output of the sensor is configured to suspend operation of a battery system including the battery module. The battery module of claim 41, wherein an output of the sensor is configured to suspend charging and discharging of the battery module. The battery module according to claim 41, further comprising a cell balancing circuit, which uses an AC-to-AC power supply to provide audio power for balancing the battery cells of the battery module. The battery module of claim 44, wherein the AC-to-AC power supply provides an electrical output with an AC frequency greater than 5,000 Hz. The battery module of claim 44, wherein the AC-to-AC power supply provides electric power with an AC frequency greater than 5,000 Hz but less than 20,000 Hz. A battery rack configured to house a battery module and allow water to be sprayed from a fire suppression system onto a plurality of battery cells of the battery module. The battery rack of claim 47, wherein the battery rack is further configured to allow water to flow through a conduit configured to direct the water to a predetermined location within the battery rack. The battery rack of claim 47, wherein the fire suppression system is configured to be connected to a fire protection system of a building. The battery rack of claim 47, wherein the battery module or the fire suppression system is further configured to connect to a pipe configured to allow water to be pumped into the battery rack. A battery module includes a sensor configured to detect movement of a plate in contact with the battery module, wherein the movement is caused by expansion of a battery cell within the battery module. The battery module according to claim 51, wherein the sensor includes a load unit. The battery module of claim 51, wherein the sensor includes a metal strip and at least one strain gauge attached to the metal strip. The battery module of claim 51, wherein the sensor is made of plastic and has at least one strain gauge attached to the plastic. The battery module of claim 51, wherein the sensor includes a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section. The battery module as claimed in claim 41, wherein the sensor is further configured to detect movement of a plate in contact with the battery module. The battery module of claim 56, wherein the sensor comprises a metal strip and at least one strain gauge attached to the metal strip. The battery module of claim 56, wherein the sensor is made of plastic and has at least one strain gauge attached to the plastic. The battery module of claim 56, wherein the sensor includes a flexible section having a circular or oval shape, and wherein a strain gauge is attached to the flexible section. Such as the battery module of claim 41, which further includes: A tray, in contact with the battery module, is configured to direct water to a plate of the battery module.

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