Structural battery module and battery pack

A battery pack comprising:

• a plurality of battery modules, each battery module including:
• a rectangular housing, the rectangular housing including a top face, a bottom face, a first side face extending between the top face and the bottom face, a second side face extending between the top face and the bottom face, a front open end at a front edge of the rectangular housing and a rear open end at a rear edge of the rectangular housing, the rectangular housing including a plurality of housing bores extending substantially perpendicular through the top face, the bottom face, the first side face and the second side face proximal to the front open end, and a plurality of housing bores extending substantially perpendicularly through the top face, the bottom face, the first side face and the second side face proximal to the rear open end;
• a battery disposed within the rectangular housing;
• a rear plate, the rear plate closing the rear open end of the rectangular housing, the rear plate including a rear plate flanged surface and a plurality of rear plate bores through the rear plate flanged surface in axial alignment with the plurality of housing bores proximal the rear open end of the rectangular housing;
• and
• a front plate, the front plate closing the front open end of the rectangular housing, the front plate including a positive terminal and a negative terminal electrically connected to the battery and the positive and negative terminals each extending outward from the front plate to make an electrical connection, the battery being contained entirely within the rectangular housing, the rear plate, and the front plate, the front plate including a front plate flanged surface that forms a seal with the rectangular housing and including a plurality of front plate bores through the front plate flanged surface in axial alignment with the plurality of housing bores proximal the front open end of the rectangular housing;
• and
• at least two couplers securing together at least a first battery module and a second battery module, at least a first of the couplers being disposed through at least one of the plurality of rear plate bores in axial alignment with at least one of the plurality of housing bores proximal the rear open end of the rectangular housing, and at least a second of the couplers being disposed through at least one of the plurality of front plate bores in axial alignment with at least one of the plurality of housing bores proximal the front open end of the rectangular housing.

A method of constructing a battery pack, the method comprising:

• providing a plurality of battery modules, each battery module including:
• a rectangular housing, the rectangular housing including a top face, a bottom face, a first side face extending between the top face and the bottom face, a second side face extending between the top face and the bottom face, a front open end and a rear open end, the rectangular housing including a plurality of housing bores extending substantially perpendicular through the top face, the bottom face, the first side face and the second side face proximal to the front open end, and a plurality of housing bores extending substantially perpendicularly through the top face, the bottom face, the first side face and the second side face proximal to the rear open end;
• a battery disposed within the rectangular housing;
• a rear plate, the rear plate closing the rear open end of the rectangular housing, the rear plate relieved from the rear open end of the rectangular housing by a rear plate flanged surface and including a plurality of rear plate bores extending through the rear plate flanged surface and in axial alignment with the plurality of housing bores proximal the rear open end of the rectangular housing;
• and
• a front plate, the front plate closing the front open end of the rectangular housing, the front plate relieved from the front open end of the rectangular housing by a front plate flanged surface, the front plate flanged surface contacting the top face, the bottom face, the first side face, and the second side face along an entire perimeter of the front plate flanged surface, and the front plate including a positive terminal and a negative terminal electrically connected to the battery and the positive and negative terminals each protruding from an exterior side of the front plate, the battery being sealed within the rectangular housing, the rear plate, and the front plate, the front plate including a plurality of front plate bores extending through the front plate flanged surface and in axial alignment with the plurality of housing bores proximal the front open end of the rectangular housing;
• disposing a rectangular housing of a first battery module of the plurality of battery modules adjacent a rectangular housing of a second battery module of the plurality of battery modules;
• disposing a first coupler through a rear plate bore of the first battery module, a housing bore through the rectangular housing of the first battery module, a housing bore through the rectangular housing of the second battery module, and a rear plate bore of the second battery module to secure the first and second battery module together;
• disposing a second coupler through a front plate bore of the second battery module, a housing bore through the rectangular housing of the second battery module, a housing bore through the rectangular housing of the first battery module, and a front plate bore of the first battery module to secure the second and first battery module together;
• and
• connecting a plurality of electrical cables to the positive and negative terminals of respective individual battery modules.