Smart battery pack
Systems and methods here may include a modular battery pack including a housing, and within the housing: individual battery cells arranged in rows, a circuit board at one end of the housing configured to manage a thermal condition of the battery pack, heat sensors in communication with the circuit board, an enclosed heat pipe arrangement in a corrugated configuration arranged between each row of battery cells within the housing, and a fan and/or Peltier heat sink configured at one end of the battery pack housing, in communication with the circuit board.
1 . A battery system, comprising:
a battery housing including walls surrounding an array of battery cells arranged in rows;
a set of heat sensors positioned within the battery housing;
a circuit board positioned at a first end of the battery housing;
a heat sink positioned at a second end of the battery housing;
wherein at least two rows of the array of battery cells are arranged between two enclosed corrugated heat pipes within the battery housing, wherein the two heat pipes extend from the first end of the battery housing to the second end of the battery housing and comprise side walls forming a sealed chamber that is configured to contain a liquid and/or a gas to direct heat from the battery cells to the heat sink.
2 . The battery system of claim 1 wherein the two heat pipes are in thermal contact with the circuit board that press connect each of the battery cells in each row within the battery housing.
3 . The battery system of claim 1 further comprising, a second battery system coupled to the battery system by a wall of a multi-battery pack system, the wall of the multi-battery pack system in thermal contact with each of the battery system and the second battery system, and wherein the wall of the multi-battery pack system is configured to remove heat from each of the battery system and the second battery system.
4 . The battery system of claim 1 wherein each of the battery cells are arranged in the walls of the battery housing, such that a polarity for each battery is aligned in a same direction.
5 . The battery system of claim 1 wherein each of the battery cells are arranged in the walls of the battery housing, such that a polarity for each battery is alternating in opposite directions, for each successive battery cell in each row.
6 . The battery system of claim 1 further comprising at least one fuse in the circuit board, the fuse configured to remove a load from the battery cells at a pre-determined voltage.
7 . The battery system of claim 6 wherein the fuse is a double fuse.
8 . The battery system of claim 1 wherein a number of rows of battery cells is five, and wherein a number of battery cells in each row is either 8 or 9.
9 . The battery system of claim 1 further comprising an insulating wrapper configured at one end of the battery cells within the walls of the housing.
10 . The battery system of claim 1 wherein the heat sink is a Peltier heat sink.
11 . The battery system of claim 1 further comprising a third enclosed corrugated heat pipe within the battery housing, arranged between the two rows of battery cells.
12 . The battery system of claim 1 wherein the heat sensors are arranged on corrugated heat sink vapor chambers configured between rows of battery cells within the battery system.
13 . The battery system of claim 1 further comprising, a fan configured at an end of the battery pack housing, wherein the fan is configured to turn on responsive to the logic circuit determining that a thermal data exceeds a predetermined threshold.
14 . The battery system of claim 1 further comprising a thermal grease layer between the two heat pipes and the circuit board.
15 . The battery system of claim 1 wherein the circuit board is configured for load balancing.
16 . The battery system of claim 1 wherein the at least two rows of battery cells comprise a battery pack that is removable.
17 . The battery system of claim 1 wherein the set of heat sensors are configured to send thermal data to the circuit board.
18 . The battery system of claim 16 wherein the circuit board is individualized for the battery pack.
19 . The battery system of claim 18 wherein the battery system is configured to support multiple battery packs and individualized circuit boards.
20 . The battery system of claim 17 wherein the circuit board is configured to activate cooling mechanisms or shut down the battery system if a predefined thermal data is received from the heat sensors.