Description:FIELD
The present disclosure relates to the field of battery pack assembly, and more particularly relates to a battery lean module for a battery pack.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Generally, a battery backup assembly consists of a battery frame, which is equipped with both a top cover and a bottom cover. These covers serve the purpose of providing structural support and hold a plurality of lithium iron-phosphate (LFP) blade cells. Traditionally, in the process of integrating these LFP blade cells into the battery frame, a cell-to-pack battery pack configuration is employed. In this configuration, the blade cells are directly affixed to the battery frame and subsequently welded together with busbars. To ensure that an appropriate level of packing density is achieved, all the cells are secured in place with adhesive, both to the bottom cover and the top cover.
However, this conventional approach of mounting the blade cells in the battery frame reduces the possibility of serviceability of the different electrical connections.
Moreover, when it becomes necessary to service or repair the battery pack assembly or electrical connections, the task of detaching the blade cells from the battery frame proves to be challenging, rendering the servicing or repair procedures highly burdensome.
Additionally, during the servicing or repair procedures for the battery pack assembly, the extraction of the blade cells from the battery frame causes damage to both the top and bottom covers of the battery pack assembly and thus make it non-reusable.
There is therefore felt a need for a battery lean module for a battery pack that alleviates the aforementioned drawbacks.

OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a battery lean module for a battery pack.
Another object of the present disclosure is to provide a battery lean module for a battery pack that avoids the direct mounting of the battery cells to the top cover.
Still another object of the present disclosure is to provide a battery lean module for a battery pack that facilitates ease of assembly.
Yet another object of the present disclosure is to provide a battery lean module for a battery pack that provides ease in service and repair.
Still another object of the present disclosure is to provide a battery lean module for a battery pack that facilitates ease in extraction of the battery cells from the battery frame.
Yet another object of the present disclosure is to provide a battery lean module for a battery pack that ensures desired level of packing density of the battery cells.
Still another object of the present disclosure is to provide a battery lean module for a battery pack that is economical.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a battery lean module for a battery pack. The battery pack is provided with a frame which consists of at least one cross member and at least one longitudinal member. These cross members and the longitudinal member are arranged in an order to define at least one fixture to receive at least one lean module therein. The lean module has an array of battery cells which comprises a cover plate. The cover plate is configured to be adhesively attached on an operative top surface of the array of battery cells. The cover plate is characterized by at least one flange. The flange is configured to extend longitudinally along an edge of the cover plate and is further configured to be received on an operative top surface of the cross-member during an operative configuration of the battery lean module.
In an embodiment, the flange is stamped or press-forged with a plurality of holes thereon.
In an embodiment, the flange is configured with a plurality of arcuate portion. The arcuate portion is configured to surround at least partially the plurality of holes.
In an embodiment, the flange is configured with at least one slot to provide access for mounting brackets provided on the top portion of the cross member.
In an embodiment, the cover plate is secured to said operative top surface of said array of battery cells by means of structural adhesive selected from a group consisting of moulding resin. The structural adhesive is added to a predetermined thickness in the range of 1.2mm to 1.8mm.
In an embodiment, the cover plate is selected from a group consisting of Aluminum plate.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A battery lean module for a battery pack, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a perspective isometric view of a mounting of battery lean module within a fixture of the battery frame in accordance with the present disclosure;
Figure 2 illustrates an exploded isometric view of the battery lean module in accordance with the present disclosure;
Figure 3 illustrates a cover plate of the battery lean module in accordance with the present disclosure;
Figure 4 illustrates a perspective sectional view of mounting of the cover plate with structural adhesive in accordance with the present disclosure; and
Figure 5 illustrates a perspective view of a cover plate, array of battery module and the battery lean module in accordance with the present disclosure.
LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING
100 Battery Lean Module
10 Array of battery cell
12 Cover Plate
14 Connective means
16 End Cap
18 Link Plate
20 Bus-Bar Holder
22 Battery cell
24 Bus-Bar
26 Sensor
28 Flange
30 Hole
32 Battery Frame
34 Arcuate portion
38 Cross Member
40 Slot
42 Top Portion of cross member
44 Longitudinal Member
48 Structural glue or adhesive
50 Cooling Plate
52 Bottom Surface
54 Fastener
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Generally, a battery backup assembly consists of a battery frame, which is equipped with both a top cover and a bottom cover. These covers serve the purpose of providing structural support and hold a plurality of lithium iron-phosphate (LFP) blade cells. Traditionally, in the process of integrating these LFP blade cells into the battery frame, a cell-to-pack battery pack configuration is employed. In this configuration, the blade cells are directly affixed to the battery frame and subsequently welded together with busbars. To ensure that an appropriate level of packing density is achieved, all the cells are secured in place with adhesive, both to the bottom cover and the top cover. However, this conventional approach of mounting the blade cells in the battery frame reduces the possibility of serviceability of the different electrical connections.
Further, when it becomes necessary to service or repair the battery pack assembly or electrical connections, the task of detaching the blade cells from the battery frame proves to be challenging, rendering the servicing or repair procedures highly burdensome. Additionally, during the servicing or repair procedures for the battery pack assembly, the extraction of the blade cells from the battery frame causes damage to both the top and bottom covers of the battery pack assembly and thus make it non-reusable.
To overcome the above-mentioned drawbacks, the present disclosure envisages a battery lean module (100) for a battery pack (hereinafter referred to as “battery lean module (100)). The present disclosure is explained with reference to figure 1- figure 5. The battery pack is provided with a frame which consists of at least one cross member (38) and at least one longitudinal member (44). These cross members (38) and the longitudinal members (44) are arranged in an order to define at least one fixture to receive at least one lean module therein. These cross members (38) and the longitudinal members (44) define a boundary region for the battery lean module (100). Figure 1 illustrates a perspective isometric view of a mounting of battery lean module (100) within a fixture of the battery frame (32) and Figure 2 illustrates an exploded isometric view of the battery lean module (100) in accordance with the present disclosure.
In an embodiment, a plurality of the cross members (38) and a plurality of longitudinal members (44) are arranged to define a plurality of fixtures to receive a plurality of battery lean module (100) therein.
Further, the battery lean module (100) is defined by an array of battery cells (10) with a cover plate (12). Figure 3 illustrates a cover plate (12) of the battery lean module (100) in accordance with the present disclosure. The cover plate (12) is configured to be adhesively attached on an operative top surface of the array of battery cells (10). The cover plate (12) has at least one flange (28), extending longitudinally along an edge of the cover plate (12). The flange (28) is configured to sit or abut or be received on an operative top surface of the cross-member during an operative configuration of the battery lean module (100).
In an embodiment, the cover plate (12) is secured to the operative top surface of the array of battery cells (10) by means of structural adhesive. The structural adhesive is selected from a group consisting of moulding resin or any similar glue with a sufficient bonding strength. Figure 4 shows a perspective sectional view of mounting of the cover plate (12) with structural adhesive in accordance with the present disclosure.
In an embodiment, the structural adhesive is added to a predetermined thickness in the range of 1.2mm to 1.8mm.
Further, the flange (28) portion of the cover plate (12) is stamped or press-forged with a plurality of holes (30) thereon. These holes (30) facilitate the mounting of the cover plate (12) over the operative top surface of the cross members (38) and/ or the longitudinal members (44). In addition, the flange (28) is provided with a plurality of arcuate portion (34). The arcuate portion (34) is configured to surround at least partially the plurality of holes (30).
Advantageously, the configuration of the flange (28) portion, which involves stamping and bending or sloping to achieve a precisely specified depth. This particular configuration offers distinct advantages when it comes to attaching fasteners (54) to the cover plate (12) to mount the battery lean module (100) to the cross members (38) or the longitudinal members (44). It ensures that fasteners' (54) tips do not protrude beyond the desired depth. Consequently, this configuration simplifies the process of securely mounting the cover plate (12) within the specified depth.
In a specific embodiment of this design, the distance between the flange (28) portions and the operative top surface of the cover plate (12) falls within a predetermined range. In an embodiment, the depth of flange (28) portion from the operative top surface of the cover plate (12) is in the range of 1.25mm-2.2mm.
Further, when one battery lean module (100) is being installed in close proximity to another within the battery frame (32), the cover plate (12) comes in contact. Specifically, the flange (28) portion of the first battery lean module (100) comes into contact with or rests upon the operative surface of the second flange (28) portion, precisely where they intersect over the cross members (38). Advantageously, this interaction ensures that the compact mounting of the battery lean module (100) is within the battery frame (32).
In an embodiment, the space situated between the two flange (28) portions of the battery lean module (100) is equipped with a component configured to dampen or cushion any vibration or impact. This component is selected from a group of a dampener, washer, or a cushioning element. Advantageously, these elements serve as effective shock absorbers, proficiently mitigating any vibrations that may occur and safeguarding the battery lean module (100) from the potentially damaging effects of impacts or external forces. Thus, it offers overall robustness and reliability of the battery lean module (100) installation.
Further, the flange (28) is provided with at least one slot (40) portion. These slots (40) provide access for mounting brackets provided on the top portion of the cross member (38) to pass through. In an embodiment, the slot (40) is intermittently provided between two flange (28) portions. Figure 5 is a perspective view of a cover plate (12), array of battery module and the battery lean module (100) in accordance with the present disclosure.
In an embodiment, the cover plate (12) is selected from a group consisting of Aluminum plate or composite material or any combination thereof.
In addition, the battery lean module includes pair of bus-bar holders (20), a plurality of link plates (18), a pair of bus-bars (24), and a pair of end caps (16). The bus-bar holders are configured to be mounted on a front surface and a rear surface of the array of battery cells (10) and are provided with a plurality of cut-outs. The terminals of the plurality of battery cells (22) in front side and rear side is configured to protrude through the plurality of cut-outs. The plurality of link plates (18) is configured to be received within the plurality of cut-outs and is further configured to connect the set of terminals in series on the front surface, whereas the plurality of link plates (18) is configured to be received within the plurality of cut-outs and is further configured to connect the set of terminals in series on the rear surface. Therefore, a positive output terminal and a negative output terminal are defined by joining the plurality of link plates (18) on the terminals of the array of battery cells (10).
In an embodiment, the link plates (18) are configured to be welded on the terminals of the array of battery cells (10).
Further, the bus-bar (24) is configured to be in communication with the first output terminal and the second output terminal. Each of the end cap (16) is configured to be mounted on the front surface and the rear surface of the array of battery cells (10) and is further configured to conceal the bus-bar and the plurality of link plates (18) therein.
In an embodiment, the battery lean module (100) is configured with a plurality of sensor (26) to measure temperature, current or voltage drop.
In an embodiment, the top surface of the battery lean module (100) is configured to receive a cooling plate (50) thereon and mounted to the cross members (38) and the longitudinal members (44).
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, a battery lean module for a battery pack, that:
• avoids the direct mounting of the battery cells to the top cover;
• facilitates ease of assembly;
• provides ease in service and repair;
• facilitates ease in extraction of the battery cells from the battery frame;
• ensures desired level of packing density of the battery cells; and
• is economical.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, or group of elements, but not the exclusion of any other element, or group of elements.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A battery lean module (100) for a battery pack, the battery pack is provided with a frame having at least one cross member (38) and at least one longitudinal member (44), arranged to define at least one fixture to receive at least one said lean module therein, said lean module having an array of battery cells (10), said battery lean module (100) comprising a cover plate (12) configured to be adhesively attached on an operative top surface of said array of battery cells (10), said cover plate (12) is characterized by at least one flange (28), said flange (28) configured to extend longitudinally along edge of said cover plate (12) and further configured to be received on an operative top surface of the cross-member during an operative configuration of said battery lean module (100).
2. The battery lean module (100) as claimed in claim 1, wherein said flange (28) is stamped or press-forged with a plurality of holes (30) thereon.
3. The battery lean module (100) as claimed in claim 2, wherein said flange (28) is configured with a plurality of arcuate portion (34).
4. The battery lean module (100) as claimed in claim 3, wherein said arcuate portion (34) is configured to surround at least partially said plurality of holes (30).
5. The battery lean module (100) as claimed in claim 1, wherein said flange (28) is configured with at least one slot (40) to provide access for mounting brackets provided on the top portion of the cross member (38).
6. The battery lean module (100) as claimed in claim 1, wherein said cover plate (12) is secured to said operative top surface of said array of battery cells (10) by means of structural adhesive (48) selected from a group consisting of moulding resin.
7. The battery lean module (100) as claimed in claim 6, wherein the structural adhesive (48) is added to a predetermined thickness in the range of 1.2mm to 1.8mm.
8. The battery lean module (100) as claimed in claim 6, wherein cover plate (12) is selected from a group consisting of Aluminum plate.

Dated this 27th day of October, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI