WO2024167781A1

WO2024167781A1 - Battery pack including battery modules and methods of making the battery pack and repurposing the battery modules

Info

Publication number: WO2024167781A1
Application number: PCT/US2024/014181
Authority: WO
Inventors: Guillermo Garcia; Arvind Kumar PEEHAL
Original assignee: Samsar Resources, Llc
Priority date: 2023-02-06
Filing date: 2024-02-02
Publication date: 2024-08-15

Abstract

A battery pack includes a battery pack housing and a plurality of interlocked battery modules located in the battery pack housing. Each of the plurality of interlocked battery modules includes a battery module housing, a plurality of battery cells located in the battery module housing, and a battery management system (BMS) unit electrically coupled to the plurality of battery cells.

Description

BATTERY PACK INCLUDING BATTERY MODULES AND METHODS OF

MAKING THE BATTERY PACK AND REPURPOSING THE BATTERY MODULES

FIELD

[0001] The present invention relates to a battery pack including battery modules, and to methods of making thereof and to methods of repurposing the battery modules.

BACKGROUND

[0002] A battery module may include a plurality of a battery cells. The battery cells may include, for example, a secondary battery cell (e.g., rechargeable battery cell) such as a lithium-ion battery cell, a sodium-ion battery cell, a nickel cadmium battery cell, a nickel metal hydride battery cell, etc. The battery cells may commonly be configured, for example, as a pouch cell, a cylindrical cell or a prismatic cell.

[0003] The battery cells in the battery module may be electrically coupled in series or in parallel, depending on the application. For example, in an application requiring a high voltage, the battery cells may be coupled in series. In an application requiring a high capacity, the battery cells may be coupled in parallel.

[0004] A battery pack may include a plurality of the battery modules. The battery modules in the battery pack may also be electrically coupled in series or in parallel, depending on the application. The battery pack may be used to power electrical devices and electrical systems that require a high voltage and/or high capacity. For example, an electric vehicle may be powered by a battery pack with a voltage from about 400V to 900V or more.

SUMMARY

[0005] According to an aspect of the present disclosure, a battery pack includes a battery pack housing and a plurality of interlocked battery modules located in the battery pack housing. Each of the plurality of interlocked battery modules includes a battery module housing, a plurality of battery cells located in the battery module housing; and a battery management system (BMS) unit electrically coupled to the plurality of battery cells.

[0006] According to another aspect of the present disclosure, a method includes removing at least a first battery module of the plurality of interlocked battery modules from the above described battery pack housing; placing the first battery module in a first repurposed battery pack; and using the BMS unit in the first battery module to at least one of reconfigure a series/parallel connection in the first battery module, or adjust a maximum amount of at least one of voltage or current that can be drawn from the first battery module.

[0007] According to another aspect of the present disclosure, a method of making a battery pack comprises providing a plurality of battery modules, each comprising a battery module housing, a battery management system (BMS) unit electrically coupled to the plurality of battery cells, a plurality of male terminals and a plurality of female terminals; interlocking the plurality of battery modules by inserting the plurality of male terminals of a first battery module of the plurality of battery modules into the plurality of female terminals of a second battery module of the plurality of battery modules to form a battery module stack; and connecting the battery module stack to a plurality of battery pack terminals located on the battery pack housing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a better understanding of the various described embodiments, reference should be made to the Detailed Description below, in conjunction with the following drawings in which like reference numerals refer to corresponding parts throughout the Figures.

[0009] FIG. 1 A is a vertical cross-sectional view of a battery module according to one or more embodiments.

[0010] FIG. IB is a vertical cross-sectional view of a battery module stack including the battery module stacked on a battery module.

[0011] FIG. 2 is a schematic view of the battery management system (BMS) unit according to one or more embodiments.

[0012] FIG. 3 is a vertical cross-sectional view of a battery pack according to one or more embodiments.

[0013] FIG. 4 is a flow chart illustrating a method of making the battery pack according to one or more embodiments.

[0014] FIG. 5 is a schematic illustration of a first repurposed battery pack and a second repurposed battery pack according to one or more embodiments.

[0015] FIG. 6 is a flow chart illustrating a method of repurposing the battery modules of a battery pack according to one or more embodiments. DETAILED DESCRIPTION

[0016] As discussed above, the embodiments of the present disclosure are directed to a battery module, particularly to a battery module including male and female terminals, and a battery pack including a plurality of the battery modules, the various aspects of which are discussed herein in detail. The drawings are not necessarily drawn to scale. Multiple instances of an element may be duplicated where a single instance of the element is illustrated, unless absence of duplication of elements is expressly described or clearly indicated otherwise. Ordinals such as “first,” “second,” and “third” are employed merely to identify similar elements, and different ordinals may be employed across the specification and the claims of the instant disclosure. The same reference numerals refer to the same element or similar element. Unless otherwise indicated, elements having the same reference numerals are presumed to have the same composition. As used herein, a first element located “on” a second element can be located on the exterior side of a surface of the second element or on the interior side of the second element. As used herein, a first element is located “directly on” a second element if there exist a physical contact between a surface of the first element and a surface of the second element. As used herein, a “layer” refers to a continuous portion of at least one material including a region having a thickness. A layer may consist of a single material portion having a homogeneous composition, or may include multiple material portions having different compositions.

[0017] One or more embodiments of the present disclosure may include a battery architecture (e.g., an independent, stackable battery architecture) that may provide simpler repurposing of batteries across multiple applications. At least one embodiment may include, for example, a battery module (e.g., independent battery cell block) with its own battery management system (BMS). The BMS may include, for example, electronic circuitry to control charging and/or discharging and balancing of internal cells. The battery module may also include its own connection terminals, software component, diagnostics and/or environmentally protective/structurally stable enclosure. In particular, the battery module may include software/firmware connections to provide automatic configuration for repurposed packs (e.g., from a flow chart of commands).

[0018] One or more of the battery modules may be joined together to form a battery pack at either higher voltages in a series electrical connection or higher capacities in a parallel electrical connection. The joined battery modules may be joined in series or parallel connection to form the battery pack which may provide environmental protection and structural integrity. [0019] The architecture of the battery module may make it simple to validate the performance of each battery module in the battery pack. This simplicity may allow the battery architecture to greatly simplify the process of repurposing the battery module at the end of the battery's module's first life. In particular, the battery architecture may significantly reduce (e.g., minimize) hardware operations for repurposing of the batteries. For example, the series and parallel connections may be easily removable, allowing the battery pack to be disassembled back into independent battery modules. A repurposing may then be achieved via a software update that limits the maximum amount of current/power that can be drawn from each battery module. The software update may also reconfigure the information on series and parallel connection of the battery modules.

[0020] For example, a 48V electric vehicle battery pack may be built by assembling four 12V battery modules. These dissembled independent battery modules can be repurposed to assemble two separate 24V battery packs that each include two of the 12V battery modules. The two 24V battery packs may be used for an energy storage system (ESS) application along with a software (SW) update that limits the maximum current and/or maximum power that can be withdrawn from each of the 24V battery packs.

[0021] The battery modules may include one or more battery cells connected in series and/or in parallel. At least one embodiment may include, for example, 10 to 500 battery cells connected in series in each battery module. The battery modules may also include an independent battery management system (BMS), a telematics board, a battery module housing (e.g., enclosure), a terminal port for connection with other modules (i.e., independent blocks) in series or parallel configuration, and an input/output port for wired access to the electronics connection. A standard format may be used to provide a variety of battery specifications, including but not limited to voltage ranges between 0.1V to 1,000V, current ranges from 0.1 A to l,000A, a square/rectangular form factor and IP67 environmental protection.

[0022] To simplify interconnection of the battery modules in the battery pack, the series terminals and parallel terminals on the battery modules may include a unique male/female port that may lock battery modules together but also maintain an open connection. Depending on which port is active, the BMS may reconfigure itself to know the voltage/current limits of the battery pack. Over the air continuous monitoring of the battery modules (e.g., via the telematics board) may increase safety protocols for an end user by terminating use of any potentially hazardous battery module. [0023] In the event that a battery module no longer meets the requirements for its existing application, an evaluation of the available capacity may be performed via an assessment (e.g., wired or wireless assessment) by the BMS. Based on its health, the battery module may be repurposed to a new application, in which case it may be removed from a battery pack and combined with one or more other battery modules in another battery pack. The repurposed battery module may then automatically reconfigure itself based on the connection with the other battery modules, creating new voltage/current thresholds. This type of software configuration may provide interactive collaboration that has yet to be seen in battery pack designs.

[0024] The battery module and battery pack including the battery module may include several novel aspects. In particular, at least one embodiment may include individual battery modules with a dedicated BMS and telematics board, wiring, interconnectivity terminals, and a environmentally stable and structurally stable housing. At least one embodiment may provide simplification over existing designs, because a plethora of combination battery packs may be constructed from a small amount of battery module designs.

[0025] The battery module and battery pack may include a modular "interlocking block" type approach that may incorporate intelligent firmware/software design that automatically reconfigures voltage/current limits based on the interconnectivity of dedicated series/parallel terminal ports. Ultimately, this may increase the opportunity for inexpensive streamline repurposing as the logistical evaluation/inspection of each battery module may be based heavily on digital information versus physical parameters. Diagnostic failures may be utilized to isolate battery modules that need servicing and no longer meet specific application criteria. Currently, this is not industry standard and current designs around BMS architecture have not enabled this in larger battery modules. At least one embodiment may incorporate this level of control down to the battery module.

[0026] FIG. 1 A is a vertical cross-sectional view of a battery module 100A according to one or more embodiments. FIG. IB is a vertical cross-sectional view of a battery module stack 200 including the battery module 100A stacked on another battery module 100B.

[0027] As illustrated in FIG. 1A, the battery module 100 A may include a battery module housing 102 and a plurality of battery cells 103 in the battery module housing 102. The battery cells 103 may optionally be arranged in one or more battery cell stacks 104. Each stack 104 may include 2 or more cells. The stacks 104 may be electrically connected in series as shown in FIG. 1 A and/or in parallel. Alternatively, each element number 104 may comprise a single battery cell 103 containing an anode, a cathode and an electrolyte. The battery module 100 A may also include a plurality of male terminals 106 located on a first side 102s 1 of the battery module housing 102 and electrically coupled to the plurality of battery cells 103 (e.g., to the battery cell stacks 104, if present), and a plurality of female terminals 108 located on a second side 102s2 of the battery module housing 102. The plurality of female terminals 108 may be substantially aligned (in the z-direction) with the plurality of male terminals 106, respectively, and electrically coupled to the plurality of battery cells 103 (e.g., to the battery cell stacks 104, if present).

[0028] In an alternative embodiment, the first side 102s 1 may include both male and female terminals and the second side 102s2 may also include both male and female terminals. In this alternative embodiment, the male terminal of the first side is aligned in the z-direction with a respective female terminal on the second side of the same battery module housing 102. [0029] The battery module housing 102 may include, for example, a substantially hollow cuboid shape having six sidewalls. The six sidewalls may include the first sidewall 102sl, the second sidewall 102s2. The six sidewalls may also include a third sidewall 102s3 and a fourth sidewall 102s4 opposite the third sidewall 102s3, that connect the first sidewall 102sl to the second sidewall 102s2. The six sidewalls may also include a fifth sidewall (in front of the plane of FIG. 1 A, not shown) and a sixth side wall (behind the plane of FIG. 1 A, not shown) opposite the fifth sidewall. The fifth sidewall and sixth sidewall may connect the first sidewall 102sl to the second sidewall 102s2 and connect the third sidewall 102s3 to the fourth sidewall 102s4. Other shapes of the battery module housing 102 are within the contemplated scope of disclosure.

[0030] The battery module housing 102 may be divided into two separate sections to allow access to an interior of the battery module housing 102. The two sections may include, for example, an upper section including the first side wall 102sl and a lower section including the second sidewall 102s2. In at least one embodiment, the two separate sections may be connected by a connecting structure (not shown), such as a hinge. In at least one embodiment, the battery module housing 102 may include a box-shaped case body (lower section) having a lid (upper section) that opens upward.

[0031] The six sidewalls of the battery module housing 102 may be formed, for example, of a rigid material such as a metal, ceramic or polymer material. Other materials are within the contemplated scope of disclosure. The battery module housing 102 may be formed, for example, by mold forming, milling, casting, etc.

[0032] The plurality of battery cells 103 in the battery module 100A may include any type of energy storage device that may store chemical energy and convert it to electrical energy. The battery cells 103 may include a secondary (e.g., rechargeable) battery cell. In at least one embodiment, the battery cells 103 may include lithium-ion battery cells, sodium-ion battery cells, nickel cadmium battery cells, and/or a nickel metal hydride battery cells. The battery cells 103 may commonly be configured, for example, as a pouch cell, a cylindrical cell or a prismatic cell. Other types of battery cells 103 and other configurations of the battery cell stacks 104 are within the contemplated scope of disclosure. For example, instead of cells having ion insertion (i.e., intercalation) type anode and cathode electrodes, the cells may comprise hybrid cell stacks having one intercalation electrode (e.g., cathode) and one non-ion insertion type (e.g., double layer capacitor type) electrode (e.g., anode).

Alternatively, the cells may have two non-ion insertion electrodes (e.g., supercapacitor type cell stacks).

[0033] The battery cell stacks 104 may include a positive end 104p having a positive battery cell terminal (not shown) and a negative end 104n having a negative battery cell terminal (not shown). The battery cell stacks 104 may be arranged in the battery module housing 102 such that the positive ends 104p and the negative ends 104n alternate.

[0034] As illustrated in FIG. 1A, the battery cells 103 in each stack 104 may be connected together in a series and the battery cell stacks 104 may be connected together in a series. In at least one embodiment, the battery cell stacks 104 may be connected together in parallel or may include a combination of series connections and parallel connections. The battery module 100A may also include battery cell stack 104 interconnects 110 for electrically coupling the ends of the battery cell stacks 104. The interconnects 110 may be press fit or soldered to the stack 104 terminals.

[0035] As shown in FIG. IB, the battery module 100A may have a design that allows it to be securely stacked in an interlocking manner with another battery module 100B having substantially the same design as the battery module 100A, to form a battery module stack 200. For example, the modules 100A and 100B may be stacked one over the other. In particular, the male terminals 106 and female terminals 108 may include series terminals that allow the battery module 100 A to be connected in series with the battery module 100B. The male terminals 106 and female terminals 108 may also include parallel terminals that allow the battery module 100 A to be connected in parallel with the battery module 100B.

[0036] As illustrated in FIG. 1 A, the male terminals 106 may include a positive parallel male terminal 106p-P, a negative parallel male terminal 106p-N and a positive series male terminal 106s-P. The female terminals 108 may include a positive parallel female terminal 108p-P, a negative parallel female terminal 108p-N and a negative series female terminal 108s-N. Alternatively, the negative series terminal may be a male terminal and the positive series terminal may be a female terminal. In order to facilitate an interlocked connection between the battery module 100A and the battery module 100B, the positive parallel male terminal 106p-P may be substantially aligned in the z-direction with the positive parallel female terminal 108p-P. The negative parallel male terminal 106p-N may also be substantially aligned in the z-direction with the negative parallel female terminal 108p-N. The positive series male terminal 106s-P may also be substantially aligned in the z-direction with the negative series female terminal 108s-N. Although the battery module 100A is illustrated with three male terminals 106 and three female terminals 108, any number of male terminals 106 and female terminals 108 may be included in the battery module 100 A. The male terminals 106 may have the same shape or different shapes from each other. The female terminals 108 may have the same shape or different shapes from each other.

[0037] The male terminals 106 may include one or more layers of conductive material. The male terminals 106 may have a cylindrical shape, such as a circular cylindrical shape, square cylindrical shape, etc. The male terminals 106 may be connected to the battery module housing 102. The female terminals 108 may include, for example, one or more layers of conductive material lining a recessed portion of the battery module housing 102. The female terminals 108 may also have a cylindrical shape, such as a circular cylindrical shape, square cylindrical shape, etc. The female terminals 108 have a size and shape that are substantially the same as a size and shape of the male terminals 106, respectively.

[0038] The battery module 100 A may be designed so that the male terminals 106 of battery module 100B (see FIG. IB) may be inserted into the female terminals 108 of battery module 100A. The male terminals 106 may be designed to have a snug fit in the female terminals 108.

An upper surface of the male terminals 106 may contact an upper surface of the female terminals 108. A side surface of the male terminals 106 may also be in sliding contact with a side surface of the female terminals 108. In at least one embodiment, substantially an entirety of the upper surface and side surface of the male terminals 106 may contact substantially an entirety of the upper surface and side surface of the female terminals 108, respectively.

[0039] A size and shape of the male terminals 106 and the female terminals 108 may be sufficient to provide rigidity and stability to the battery module stack 200, as shown in FIG. IB. A size of the male terminals 106 and female terminals 108 may be determined by a size of the battery module housing 102. In at least one embodiment a total width (in the x- direction) of the male terminals 106 may be greater than 5% of the width of the battery module housing 102. A total width (in the x-direction) of the female terminals 108 may also be greater than 5% of the width of the battery module housing 102. In at least one embodiment a height (in the z -direction) of each of the male terminals 106 and the female terminals 108 may be greater than 10% of the height of the battery module 100A.

[0040] Further, the first surface 102s 1 of the battery module 100 A may have a shape that is substantially similar to the shape of the second surface 102s2. This may allow the second surface 102s2 of the battery module housing 102 of battery module 100 A to be mated together with the first surface 102sl of the battery module housing 102 of battery module 100B at the time of inserting the male terminals 106 into the female terminals 108.

[0041] The male terminals 106 and female terminals 108 may include the same materials. The male terminals 106 and female terminals 108 may include one or more layers of metal or metal alloy. In at least one embodiment, the male terminals 106 and female terminals 108 may include copper, lead, or alloys of copper or lead. Other materials may be within the contemplated scope of disclosure.

[0042] The battery module 100 A may also include a positive wiring line 112p connecting the positive end 104p of the series connected battery cell stacks 104 to the positive series male terminal 106s-P, the positive parallel male terminal 106p-P and the positive parallel female terminal 108p-P. The battery module 100 A may also include negative wiring line 112n connecting the negative end 104n of the series connected battery cell stacks 104 the plurality of battery cells 104 to the negative parallel male terminal 106p-N, the negative parallel female terminal 108p-N and the negative series female terminal 108s-N. The positive wiring line 112p and the negative wiring line 112n may be formed, for example, of an insulated wire, such as an insulated copper wire. Other materials may be within the contemplated scope of disclosure.

[0043] The battery module 100A may also include a battery management system (BMS) unit 120 electrically coupled to the battery cell stacks 104. The BMS unit 120 may keep the battery module 100A from operating outside of its safety margins. The BMS unit 120 may monitor each of the battery cells 103 and/or battery cell stacks 104 and calculate how much current can safely go in (charge) and come out (discharge) without damaging the battery module 100A. The BMS unit 120 may thereby prevent a source (e.g., a battery charger) and load (such as an inverter) from overdrawing or overcharging the battery. The BMS unit 120 may monitor the remaining charge in the battery, continually tracking the amount of energy (e.g., power) entering and exiting the battery cells and/or stacks and monitoring voltages and/or currents of the battery cells 103 and/or battery cell stacks 104. The BMS unit 120 may collect and store data indicating that the battery module 100A is drained and shut the battery module 100A down. The BMS unit 120 may also monitor a temperature inside the battery module 100A and control a temperature control system (e.g., cooling fans) (not shown) of the battery module 100A to help maintain the temperature within an operating range. The BMS unit 120 may also detect a problem (e.g., a short) in the electrical circuitry of the battery module 100A.

[0044] In at least one embodiment, the BMS unit 120 may monitor the state of charge (SOC) of the battery cells 103 and/or battery cell stacks 104 and thereby help to identify a bad battery cell 103 and/or a battery cell stack 104 in the battery module 100A. The BMS unit 120 may also reconfigure the battery module 100A to allow for repurposing of the battery module 100 A from one application to another application.

[0045] The battery module 100A may also include a telematics unit 130 (e.g., telematics board) electrically coupled to the BMS unit 120. The telematics unit 130 may allow the battery module 100A to receive/store and transmit information (e.g., by wireless or wired connection) to and from an external device. In at least one embodiment, the telematics unit 130 may include a wireless transceiver for wirelessly communicating with a remote device over a wireless network (e.g., cellular, WiFi, bluetooth, etc.). In at least one embodiment, the telematics unit 130 may be communicatively coupled to the BMS unit 120 and may transmit and receive information between the BMS unit 120 and an external device. In at least one embodiment, the BMS unit 120 may include an external communication capability allowing the BMS unit 120 to communication with an external device outside of the battery module 100A. In at least one embodiment, the BMS unit 120 may omit an external communication function in which case the BMS unit 120 may be communicatively coupled to the telematics unit 130 and may transmit information to and receive information from an external device via the telematics unit 130.

[0046] The battery module 100 A may also include an input/output (I/O) port 140 located on the battery module housing 102. In at least one embodiment, the I/O port 140 may be located on the third sidewall 102s3 of the battery module housing 102. The I/O port 140 may include any type of data transfer port, such as an RJ45 port. The I/O port 140 may be electrically coupled to the telematics unit 130, and data may be transmitted to and from the telematics unit 130 through the I/O port 140. The telematics unit 130 may also transmit information between the BMS unit 120 and an external device via the I/O port 140. [0047] FIG. 2 is a schematic view of the BMS unit 120 according to one or more embodiments. As illustrated in FIG. 2, the BMS unit 120 may coupled between the battery cells 103 or cell stacks 104 and the positive wiring line 112p. The BMS unit 120 may include, for example, a management unit 122, a current sensor 123, a voltage sensor 125, and equalizing circuitry 126. The BMS unit 120 is one example of a management system for an energy storage device that may be used to manage an operation of the battery module 100A. Other management systems may be within the contemplated scope of disclosure.

[0048] The management unit 122 may operate with electric power supplied from the battery cells 103. The management unit 122 may include a central processing unit (CPU) 122a (e.g., microprocessor), a memory device 122b (e.g., read-only memory (ROM), random access memory (RAM), etc.), a communication unit 122c, and the like. The memory device 122b may include ROM for storing various control programs and data indicating postdischarge open-circuit voltage (OCV) and state-of-charge (SOC) characteristics. The CPU 122a may control each part of the battery module 100 A by executing a control program stored in the ROM.

[0049] The communication unit 122c may communicate (e.g., by wire or wirelessly) with an external controller (e.g., external device) that is outside the battery module 100A. In at least one embodiment, the communication unit 122c may be connected by a communication line 129 to the external controller. In at least one embodiment, the communication line 129 may be connected to the telematics unit 130 which may be connected (e.g., by wire or wireless) to the external controller. In that case, the communication unit 122c may be omitted and the communication line 129 may connect the CPU 122a to the telematics unit 130, so that an external communication function of the BMS unit 120 may be performed by the telematics unit 130.

[0050] In at least one embodiment, the battery module 100 A may be included in a vehicle (e.g., an electric vehicle, hybrid vehicle, etc.). In that case, the communication unit 122c may transmit data signals to and receive data signals from an electrical control unit (ECU) of the vehicle over the communication line 129. Data signals received by the management unit 122 from the ECU may include an ignition-on signal transmitted when an ignition switch of the vehicle is at an ignition-on position, an engine start signal transmitted when the ignition switch is at an engine start position, an accessory signal transmitted when the ignition switch is at an accessory position, a lock signal transmitted when the ignition switch is at a lock position, and the like. [0051] The current sensor 123 may be provided in a current path in series with the battery cells 103 or stacks 104. If the battery module 100A is included in a vehicle, for example, the current sensor 123 may measure a current value of a charge current flowing from the alternator to the battery cells during charge, and a current value of a discharge current flowing from the battery cells to the electric load during discharge. The current sensor 123 may then output the measured current value to the CPU 122a of the management unit 122.

[0052] The voltage sensor 125 may be connected to both ends of each battery cells 103 or stacks 104 of the battery module 100A. The voltage sensor 125 may measure a voltage value which is a terminal voltage of the battery cell or stack and output the measured voltage value to the CPU 122a of the management unit 122.

[0053] The equalizing circuitry 126 may include equalizing circuits 126a in parallel connection with each of the battery cells 103 or stacks 104. Each equalizing circuit 126a may include, for example, a switch element and a discharge resistor. When the switch element is turned on, electric power of the battery cell or stack in parallel connection with the equalizing circuit 126a may be discharged by the discharge resistor.

[0054] When the battery cells are brought into a pause state, the management unit 122 may measure the OCV with the voltage sensor 125 and estimate the SOC of the battery cells by specifying the SOC corresponding to the measured OCV from the postdischarge OCV-SOC characteristics stored in the memory device 122b. In at least one embodiment, the management unit 122 may estimate the SOC of the battery cells 103 (e.g., execute an SOC estimation process) by first causing the equalizing circuit 126 to discharge the battery cells 103 for a predetermined time. The management unit 122 may then measure the OCV with the voltage sensor 125. The management unit 122 may then estimate the SOC of the battery cells 103 by specifying the SOC corresponding to the OCV measured from the post-discharge OCV-SOC characteristics.

[0055] The BMS unit 120 may also help allow for convenient repurposing of the battery module 100A. In particular, the memory device 122 may store repurposing software that may be executed by the CPU 122a to adjust the voltage and/or current of the battery module 100A (e.g., the maximum amount of voltage and/or current that can be drawn from the battery module 100 A). Thus, for example, if the battery module 100A is repurposed from a higher voltage application to a lower voltage application, the repurposing software may be executed by the CPU 122a to reduce the voltage of the battery module 100A.

[0056] In particular, the repurposing software may be executed (e.g., automatically executed) by the CPU 122a to reconfigure the series/parallel connection of the battery module 100A. Thus, for example, if the battery module 100A is repurposed from an application requiring a series connection to an application requiring a parallel application, the repurposing software may be executed by the CPU 122a to switch the battery module from series mode in which the battery module 100A delivers power via the series terminals (e.g., 106s-P, 108s-N) to a parallel mode in which the battery module 100A delivers power via the parallel terminals (e.g., 106p-P, 106p-N). In at least one embodiment, a parallel switch may be included in the positive wiring line 112p between the battery cells 104 and the positive parallel male terminal 106p-P, and a series switch may be included in the positive wiring line 112b between the battery cells 104 and the positive series male terminal 106s-P. To switch the battery module 100A from series mode to parallel mode, the CPU 122a may open the series switch and close the parallel switch. To switch the battery module 100A from parallel mode to series mode, the CPU 122a may open the parallel switch and close the series switch. [0057] FIG. 3 is a vertical cross-sectional view of a battery pack 300 according to one or more embodiments. As illustrated in FIG. 3, the battery pack 300 may include a battery module stack 400 including the battery module 100A and the battery module 100B stacked together with a battery module 100C and a battery module 100D. Battery module 100C and battery module 100D may also have the same configuration as battery module 100A as illustrated in FIG. 1A and described above. In at least one embodiment, the battery modules 100A, 100B, 100C, 100D may include 12V battery modules connected in series, so that the battery pack 300 may include a 48 V battery pack that may be used to power an electric vehicle.

[0058] As illustrated in FIG. 3, the battery modules 100A, 100B, 100C and 100D of the battery module stack 400 may be stacked together in an interlocking manner as described above with respect to FIG. IB. The battery pack 300 may include a battery pack housing 302 that houses the battery module stack 400. The battery pack housing 302 may have a construction similar to the construction of the battery module 100 A described above. In particular, the battery pack housing 302 may have a substantially cuboid shape including a box-shaped case body (lower section) with a lid (upper or side section) that opens upward or sideways. The battery pack housing 302 may include sidewalls formed, for example, of a rigid material such as a metal, ceramic or polymer material.

[0059] The battery pack 300 may include a temperature control system (not shown) for controlling a temperature of the battery module stack 400. The temperature control system may include, for example a heater (e.g., resistance heater) 350 in the battery pack housing 302. [0060] The battery pack 300 may further include a plurality of battery pack terminals 360 located on the battery pack housing 302 and electrically coupled to the battery module stack 400. The battery pack terminals 360 may be similar in construction to the male terminals 106 of the battery module 100 A described above. The battery pack terminals 360 may be connected to an electrical system of a device (e.g., machine, tool, vehicle, aircraft, watercraft, etc.) in order to power the device.

[0061] The battery pack terminals 360 may include a positive parallel battery pack terminal 360p-P and a negative parallel battery pack terminal 360p-N located on a first sidewall 302s 1 of the battery pack housing 302. The positive parallel battery pack terminal 360p-P may be electrically connected toto the positive parallel male terminal 106p-P of the battery module 100A, and the negative parallel battery pack terminal 360p-N may be electrically connected to the negative parallel male terminal 106p-N of the battery module 100A.

[0062] The battery pack terminals 360 may further include a positive series battery pack terminal 360s-P located on the first sidewall 302s 1 of the battery pack housing 302, and a negative series battery pack terminal 360s-N located on a second sidewall 302s2 of the battery pack housing 302 opposite the first side wall 302s 1. The positive series battery pack terminal 360s-P may be electrically connected to o the positive series male terminal 106s-P of the battery module 100A, and the negative series battery pack terminal 360s-N may be electrically connected to the negative series female terminal 108s-N of the battery module 100D.

[0063] The battery pack 360 may further include a battery pack controller (BPC) 320 configured to monitor and control an operation of the battery pack 300 including an operation of the battery module stack 400. The BPC 320 may mounted on or in the battery pack housing 302. The BPC 320 may include a plurality of input/output (I/O) connectors 340 (e.g., RJ45 connectors) connected to the I/O ports 140 of the battery modules 100A, 100B, 100C 100D. The BPC 320 may be communicatively coupled to the I/O connectors 340 via battery pack wiring line 345 (e.g., copper wiring, Cat 6 cable, coaxial cable, fiber optic cable, etc.). The BPC 320 may also an external I/O port 320a connected to an external communication line 329. In that case, the BPC may transmit data signals to and receive data signals from an external device (e.g., outside the battery pack 300) via the external communication line 329. In particular, where the battery pack 300 is included in an electric vehicle, the BPC may communicate with the ECU of the vehicle via the external communication line 329. [0064] The BPC 320 may have a configuration and function similar to the configuration and function of the BPC 120 (e.g., see FIG. 2). The BPC 320 may keep the battery pack 300 from operating outside of its safety margins. The BPC 320 may monitor each of the battery modules 100A, 100B, 100C, 100D and calculate how much current can safely go in (charge) and come out (discharge) without damaging the battery pack 300. The BPC 320 may thereby prevent a source (e.g., a battery charger) and load (such as an inverter) from overdrawing or overcharging the battery pack 300. The BPC 320 may monitor the remaining charge in the battery pack 300, continually tracking the amount of energy (e.g., power) entering and exiting the battery modules 100A, 100B, 100C, 100D and monitoring voltages of the battery modules 100A, 100B, 100C, 100D. The BPC 320 may collect and store data indicating that the battery pack 300 is drained and shut the battery pack 300 down. The BPC 320 may also monitor a temperature inside the battery pack 300 and control a temperature control system (e.g., cooling fans) (not shown) of the battery pack 300 to help maintain the temperature within an operating range. The BPC 320 may also detect a problem (e.g., a short) in the electrical circuitry of the battery pack 300.

[0065] The structure and configuration of the battery modules 100A, 100B, 100C and 100D may allow them to be conveniently repurposed. In particular, a method of repurposing the battery modules 100A, 100B, 100C and 100D may include opening the battery pack housing 302 and disconnecting the battery pack terminals 360 from the battery module stack 400. The I/O connectors 340 may also be disconnected from the I/O ports 140 of the battery modules 100A, 100B, 100C and 100D. The battery modules 100A, 100B, 100C and 100D may then be disconnected and repurposed (e.g., individually repurposed).

[0066] FIG. 4 is a flow chart illustrating a method of making the battery pack 300 according to one or more embodiments. Step 410 may include providing a plurality of battery modules including a plurality of male terminals and a plurality of female terminals. Step 420 may include interlocking the plurality of battery modules by inserting the plurality of male terminals of a battery module of the plurality of battery modules into the plurality of female terminals of another battery module of the plurality of battery modules to form a battery module stack. The battery modules may be stacked into a battery module stack in a battery pack housing. Alternatively, the battery modules may be stacked into the battery module stack outside the battery pack housing, followed by placing the battery module stack into the battery pack housing. Step 430 may include connecting the battery module stack to a plurality of battery pack terminals located on the battery pack housing. [0067] FIG. 5 is a schematic illustration of a first repurposed battery pack 500 and a second repurposed battery pack 700 according to one or more embodiments. Each of the first repurposed battery pack 500 and the second repurposed battery pack 700 may have a structure and function similar to the structure and function of battery pack 300 described above. Each of the first repurposed battery pack 500 and the second repurposed battery pack 700 may include two 12V battery modules (100A, 100B) and (100C, 100D) connected in series. Each of the first repurposed battery pack 500 and the second repurposed battery pack 700 may, therefore, include a 24V battery pack.

[0068] As illustrated in FIG. 5, the first repurposed battery pack 500 may include a battery module stack 600 including the battery module 100 A and the battery module 100B that have been repurposed from the battery pack 300 (e.g., a 48V battery pack). The second repurposed battery pack 700 may include a battery module stack 800 including the battery module 100C and the battery module 100D that have been repurposed from the battery pack 300.

[0069] After the battery module stack 600 has been repurposed into the first repurposed battery pack 500 and the battery module stack 800 has been repurposed into the second repurposed battery pack 700, each of the battery modules 100A, 100B, 100C and 100D may be reconfigured (e.g., automatically reconfigured) by executing the repurposing software included in each of the battery modules 100A, 100B, 100C and 100D. In particular, the repurposing software that may be executed by the CPU 122a in each BMS unit 120 of each of the battery modules 100A, 100B, 100C and 100D to adjust the voltage/current of the battery modules 100A, 100B, 100C and 100D. The repurposing software may also be automatically executed by the CPU 122a to reconfigure the series/parallel connection of each of the battery modules 100A, 100B, 100C and 100D.

[0070] Thus, for example, in each of the battery modules 100A, 100B, 100C and 100D, a parallel switch may be included in the positive wiring line 112p between the battery cells 103 or stacks 104 and the positive parallel male terminal 106p-P, and a series switch may be included in the positive wiring line 112p between the battery cells 103 or stacks 104 and the positive series male terminal 106s-P. The CPU 122a may execute (e.g., automatically execute) the repurposing software to reconfigure (e.g., automatically reconfigure) one or more of the battery modules 100 A, 100B, 100C, 100D from series mode to parallel mode, by opening the series switch and closing the parallel switch. The CPU 122a may alternatively reconfigure one or more of the battery modules 100 A, 100B, 100C, 100D from parallel mode to series mode, by closing the series switch and opening the parallel switch. [0071] FIG. 6 is a flow chart illustrating a method of repurposing the battery modules of a battery pack according to one or more embodiments. Step 610 may include removing at least one battery module (e.g., just a first module or a module stack) from the battery pack.

The at least one battery module may be removed by removing a plurality of male terminals of the second battery module from a plurality of female terminals of the first battery module or vise- versa. Step 620 may include placing the first battery module in a first repurposed battery pack and optionally placing the second battery module in a second repurposed battery pack. Step 630 may include executing software in the BMS of the first battery module and optionally in the BMS of the second battery module to at least one of reconfigure the series/parallel connection in the first battery module and optionally in the second battery module, and/or adjust maximum amount of voltage and/or current that can be drawn from the first battery module and optionally from the second battery module.

[0072] The preceding description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the following claims and the principles and novel features disclosed herein.

Claims

1. A battery pack, comprising: a battery pack housing; and a plurality of interlocked battery modules located in the battery pack housing, wherein each of the plurality of interlocked battery modules comprises: a battery module housing; a plurality of battery cells located in the battery module housing; and a battery management system (BMS) unit electrically coupled to the plurality of battery cells.

2. The battery pack of claim 1 , wherein each of the plurality of interlocked battery modules further comprises a telematics unit coupled to the BMS unit and configured to transmit information from the BMS unit to an external device and to transmit information from the external device to the BMS unit.

3. The battery pack of claim 2, wherein each of the plurality of interlocked battery modules further comprises an input/output (I/O) port located on the battery module housing, wherein the telematics unit is configured to transmit the information from the BMS unit to the external device via the I/O port and to transmit the information from the external device to the BMS unit via the I/O port.

4. The battery pack of claim 3, further comprising a battery pack controller located in or on the battery pack housing, connected to the I/O ports of the plurality of interlocked battery modules, and configured to control an operation of the plurality of interlocked battery modules.

5. The battery pack of claim 1, wherein each of the plurality of interlocked battery modules further comprises: a plurality of male terminals located on a first sidewall of the battery module housing and electrically coupled to the plurality of battery cells; and a plurality of female terminals located on a second sidewall of the battery module housing, substantially aligned with the plurality of male terminals, respectively, and electrically coupled to the plurality of battery cells.

6. The battery pack of claim 5, further comprising a plurality of battery pack terminals located on the battery pack housing.

7. The battery pack of claim 6, wherein the plurality of battery pack terminals comprises a positive parallel battery pack terminal and a negative parallel battery pack terminal located on a first sidewall of the battery pack housing.

8. The battery pack of claim 7, wherein the plurality of battery pack terminals further comprises a positive series battery pack terminal located on the first sidewall of the battery pack housing, and a negative series battery pack terminal located on a second sidewall of the battery pack housing opposite the first sidewall of the battery pack housing.

9. The battery pack of claim 5, wherein: the plurality of interlocked battery modules comprises a first battery module and a second battery module; and the first battery module is stacked on the second battery module such that the plurality of male terminals of the second battery module are inserted into the plurality of female terminals of the first battery module.

10. The battery pack of claim 9, wherein: the first battery module comprises a bottom surface and the plurality of female terminals extend into the bottom surface; and the second battery module comprises an upper surface and the plurality of male terminals extend out of the upper surface, and the first battery module is stacked on the second battery module such that the bottom surface of the first battery module is mated to the upper surface of the second battery module.

11. A method, comprising: providing a battery pack comprising a plurality of interlocked battery modules located in a battery pack housing, wherein each of the plurality of interlocked battery modules comprises a battery module housing; a plurality of battery cells located in the battery module housing; and a battery management system (BMS) unit electrically coupled to the plurality of battery cells; removing at least a first battery module of the plurality of interlocked battery modules from the battery pack housing; placing the first battery module in a first repurposed battery pack; and using the BMS unit in the first battery module to at least one of reconfigure a series/parallel connection in the first battery module, or adjust a maximum amount of at least one of voltage or current that can be drawn from the first battery module.

12. The method of claim 1 1 , wherein the using the BMS unit comprises using the BMS unit in the first battery module to reconfigure the series/parallel connection in the first battery module.

13. The method of claim 11, wherein the using the BMS unit comprises using the BMS unit in the first battery module to adjust the maximum amount of at least one of voltage or current that can be drawn from the first battery module.

14. The method of claim 11 , wherein the using the BMS unit comprises using the BMS unit in the first battery module to both reconfigure the series/parallel connection in the first battery module and to adjust the maximum amount of at least one of voltage or current that can be drawn from the first battery module.

15. The method of claim 11 , further comprising: removing a second battery module of the plurality of interlocked battery modules from the battery pack housing; placing the second battery module in a second repurposed battery pack; and using the BMS unit in the second battery module to at least one of reconfigure a series/parallel connection in the second battery module, or adjust a maximum amount of at least one of voltage or current that can be drawn from the second battery module.

16. The method of claim 15, wherein the using the BMS unit comprises using the BMS unit in the second battery module to reconfigure the series/parallel connection in the second battery module.

17. The method of claim 15, wherein the using the BMS unit comprises using the BMS unit in the second battery module to adjust the maximum amount of at least one of voltage or current that can be drawn from the second battery module.

18. The method of claim 15, wherein the using the BMS unit comprises using the BMS unit in the second battery module to both reconfigure the series/parallel connection in the second battery module and to adjust the maximum amount of at least one of voltage or current that can be drawn from the second battery module.

19. A method of making a battery pack, comprising: providing a plurality of battery modules, each comprising a battery module housing, a battery management system (BMS) unit electrically coupled to the plurality of battery cells, a plurality of male terminals and a plurality of female terminals; interlocking the plurality of battery modules by inserting the plurality of male terminals of a first battery module of the plurality of battery modules into the plurality of female terminals of a second battery module of the plurality of battery modules to form a battery module stack; and connecting the battery module stack to a plurality of battery pack terminals located on the battery pack housing.

20. The method of claim 19, wherein each of the plurality of interlocked battery modules further comprises a telematics unit coupled to the BMS unit and configured to transmit information from the BMS unit to an external device and to transmit information from the external device to the BMS unit.