Modular battery pack apparatus, systems, and methods

Abstract

Modular sealed battery packs configured to provide enhanced performance and safety features, along with associated apparatus, systems, and methods for monitoring and controlling operation and use of such battery packs and associated coupled devices and systems are disclosed.

We claim: 
     
         1 . A battery enclosure, comprising:
 an outer casing assembly;   a thermally conductive structural housing element configured to house a battery assembly in an interior volume, the thermally conductive structural housing element including an opening for placement of the battery assembly within the inner volume;   a lid element configured to cover the opening in the thermally conductive structural housing element and mechanically reinforce the thermally conductive structural housing element, the lid element including a circuit element for electrically coupling the battery cell to a battery-powered device; and   a vent assembly configured to allow exchange of gases to and from the interior volume and restrict entry of water into the interior volume.   
     
     
         2 . The battery enclosure of  claim 1 , wherein the thermally conductive structural housing element comprises a metal. 
     
     
         3 . The battery enclosure of  claim 1 , wherein the thermally conductive structural housing element comprises a flame retardant plastic material. 
     
     
         4 . The battery enclosure of  claim 1 , wherein the thermally conductive structural housing element includes one or more apertures configured to allow light transmission from the interior volume. 
     
     
         5 . The battery enclosure of  claim 1 , further comprising a sealing element disposed between the thermally conductive structural housing element and the lid element to provide a waterproof seal of the interior volume. 
     
     
         6 . The battery enclosure of  claim 1 , wherein the lid element comprises a printed circuit board (PCB) assembly. 
     
     
         7 . The battery enclosure of  claim 6 , wherein the lid element comprises a PCB exterior layer and a metallic interior layer. 
     
     
         8 . The battery enclosure of  claim 7 , wherein the PCB exterior layer comprises a flame retardant material. 
     
     
         9 . The battery enclosure of  claim 6 , wherein the PCB includes a surface mount connector for coupling the battery assembly to the circuit assembly. 
     
     
         10 . The battery enclosure of  claim 6 , wherein the PCB includes one or more contact assemblies for electrically coupling the battery assembly to the battery-powered device, wherein the one or more contact assemblies are configured to provide a wiping action during a connection with the battery-powered device. 
     
     
         11 . The battery enclosure of  claim 10 , wherein the one or more contact assemblies comprise a plurality of contact assemblies and wherein a first subset of the plurality of contact assemblies is configured to provide an electrical power connection between the battery assembly and the battery-powered device and a second subset of the plurality of contact assemblies is configured to provide a data connection between the battery assembly and the battery-powered device. 
     
     
         12 . The battery enclosure of  claim 6 , wherein the PCB includes a battery control element comprising an electronic circuit configured to provide information on a battery assembly state and/or operating condition. 
     
     
         13 . The battery enclosure of  claim 12 , wherein the battery assembly state is a battery element charge state. 
     
     
         14 . The battery enclosure of  claim 12 , further comprising a switch element coupled to the battery control element, wherein the information on a battery condition is provided responsive to an actuation of the switch. 
     
     
         15 . The battery enclosure of  claim 12 , wherein the battery control element includes an electronic circuit configured to control an operating function of the battery assembly. 
     
     
         16 . The battery enclosure of  claim 1 , further including a communication element configured to send or receive data or signals associated with a battery assembly state and/or operating condition. 
     
     
         17 . The battery enclosure of  claim 16 , wherein the data or signals are associated with a battery element charge condition. 
     
     
         18 . The battery enclosure of  claim 18 , further includes a clock device. 
     
     
         19 . The battery enclosure of  claim 18 , further including a non-volatile memory element for storing battery condition or state information and time information provided from the clock device. 
     
     
         20 . The battery enclosure of  claim 19 , wherein the battery condition or state information includes battery usage information. 
     
     
         21 . The battery enclosure of  claim 19 , wherein the battery condition of state information includes charge and/or discharge cycle information. 
     
     
         22 . The battery enclosure of  claim 19 , wherein the battery condition or state information includes battery load information. 
     
     
         23 . The battery enclosure of  claim 1 , further including a non-volatile memory element for storing information on a battery condition. 
     
     
         24 . The battery enclosure of  claim 1 , further including a status indicator element configured to provide a visual indication of a condition or state of the battery assembly. 
     
     
         25 . The battery enclosure of  claim 24 , wherein the status indicator element comprises a light emitting diode (LED). 
     
     
         26 . The battery enclosure of  claim 24 , wherein the condition or state of the battery assembly is a state of charge. 
     
     
         27 . The battery enclosure of  claim 1 , wherein the vent assembly is disposed on or within the lid element or the thermally conductive structural housing element. 
     
     
         28 . The battery enclosure of  claim 27 , wherein the vent assembly comprises a plurality of holes covered by a hydrophobic gas-permeable membrane. 
     
     
         29 . The battery enclosure of  claim 1 , wherein the outer casing comprises a capture shell assembly and a bottom case shell assembly connected to the capture shell assembly to enclose the thermally conductive structural housing element and the lid element. 
     
     
         30 . The battery enclosure of  claim 1 , wherein the outer casing includes a sliding contact seal disposed to form a seal with a receiver module. 
     
     
         31 . The battery enclosure of  claim 1 , wherein the outer casing includes a release latch element configured to facilitate mechanical release of the battery enclosure from a receiver module. 
     
     
         32 . The battery enclosure of  claim 31 , wherein the release latch element is further configured to actuate a switch element. 
     
     
         33 . The battery enclosure of  claim 32 , wherein the switch element is coupled to an electronic circuit element configured to determine a battery condition responsive to switch actuation. 
     
     
         34 . The battery enclosure of  claim 33 , wherein the battery condition is a charge state. 
     
     
         35 . The battery enclosure of  claim 33 , wherein the electronic circuit element is further configured to provide an indication of the battery condition responsive to switch actuation. 
     
     
         36 . The battery enclosure of  claim 1 , further comprising one or more light pipes configured to transmit light through the outer casing assembly. 
     
     
         37 . The battery enclosure of  claim 10 , further comprising a face sealing element configured to provide a seal between the one or more contacts and the outer casing assembly. 
     
     
         38 . The sealed battery enclosure of  claim 1 , further including a sealing element disposed between the lid element and thermally conductive structural housing element. 
     
     
         39 . The battery enclosure of  claim 25 , wherein the LED is controlled by a pulse-width modulation (PWM) circuit. 
     
     
         40 . The battery enclosure of  claim 25 , wherein the PWM circuit controls the LED output as a function of remaining battery charge. 
     
     
         41 . The battery enclosure of  claim 24 , wherein the status indicator element comprises a first LED of a first color and a second LED of a second color different than the first color. 
     
     
         42 . The battery enclosure of  claim 41 , wherein the first LED is a green LED and the second LED is a red LED. 
     
     
         43 . The battery enclosure of  claim 42 , wherein the remaining battery charge is displayed using a combination display of the red LED and the green LED. 
     
     
         44 . The battery enclosure of  claim 40 , wherein the LED output is a varying frequency function of the remaining charge. 
     
     
         45 . The battery enclosure of  claim 1 , further including a memory and a processing element configured to transfer code stored in the memory to a coupled device. 
     
     
         46 . The battery enclosure of  claim 1 , further including a memory and a processing element configured to transfer data stored in the memory to a coupled device.