Description:TECHNICAL FIELD
[0001] The present disclosure relates, in general, to the field of the design of battery modules for high-voltage battery packs. More particularly, embodiments of the present disclosure relate to a battery module for high-voltage battery packs. The present disclosure focuses on enhancing safety and efficiency by addressing key issues related to thermal propagation management, venting, and contaminant prevention.
BACKGROUND
[0002] The background information herein below relates to the present disclosure but is not necessarily prior art.
[0003] In recent years, the development of an electric vehicle or a hybrid electric vehicle equipped with a motor driving battery is rapidly progressing. Batteries can be used, for example, as traction batteries for motor vehicles.
[0004] A high-voltage electric vehicle (EV) is an advanced automotive technology that relies on a robust electrical powertrain system, typically operating at voltages well above the levels found in conventional internal combustion engine vehicles. These vehicles are designed to use high-capacity battery packs that store electrical energy, which is then converted into mechanical power to drive the vehicle's wheels.
[0005] A high-voltage battery pack is a sophisticated energy storage system designed for applications that demand significant power output, such as electric vehicles (EVs) and renewable energy systems. These battery packs typically consist of multiple individual battery cells connected in series and parallel configurations to achieve the required voltage and capacity. High-voltage battery packs are known for their ability to store and deliver substantial electrical energy, making them a fundamental component in the electrification of transportation and the integration of renewable energy sources into the grid.
[0006] Typically, the battery module of any high-voltage battery pack consists of multiple cells that are connected in combinations of series & parallel connections via a bus bar. These bus bars are housed in a bus bar frame assembly that is assembled over the cell stack assembly. The entire cell stack with bus bar frame assembly is assembled into a module housing and both the ends of the module housing are covered using end plates.
[0007] Most of the prior art shows that the end plate generally has a single hole in it to allow the cell venting gas to escape from the battery module. The venting gas from any of the cells is collected before the end plate and exits the module via a common hole provided in the end plate. Therefore, recirculation of venting gases between cells occurs very often promoting cross-contamination and triggering venting in neighboring cells.
[0008] Therefore, there is a need to develop a battery module for high-voltage battery packs that can alleviate the aforementioned drawbacks.
OBJECTS
[0009] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
[0010] It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
[0011] The main object of the present disclosure is to provide a battery module for high-voltage battery packs.
[0012] Another object of the present disclosure is to provide a battery module for high-voltage battery packs that provides isolation of battery cells during venting events.
[0013] Another object of the present disclosure is to provide individual venting gas passages for each cell.
[0014] Another object of the present disclosure is to provide a battery module for high-voltage battery packs preventing contaminants from entering the battery module.
[0015] Another object of the present disclosure is to provide a battery module for high-voltage battery packs to accommodate extreme venting gas conditions, considering space and packaging constraints.
[0016] Another object of the present disclosure is to provide a battery module for high-voltage battery packs to prevent thermal propagation.
[0017] Another object of the present disclosure is to provide a very cost-effective battery module for high-voltage battery packs.
[0018] Another object of the present disclosure is to provide a battery module for high-voltage battery packs with minimum maintenance requirements.
[0019] Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY
[0020] This summary is provided to introduce concepts related to a battery module for high-voltage battery packs. The concepts are further described below in the following detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[0021] The present disclosure envisages a battery module for high-voltage battery packs. The battery module comprises a cell stack assembly, a bus bar frame covering an upper surface along with front and rear sides of said cell stack assembly, a module housing, and a pair of end plates.
[0022] The cell stack assembly (cell module) includes a plurality of cells with thermal pads therebetween to define isolated venting passages for each of said plurality of cells.
[0023] The bus bar frame covers an upper surface along with front and rear sides of said cell stack assembly. From said front and rear sides of said cell stack assembly, cell tabs of said cell stack assembly protrude from said bus bar frame.
[0024] The module housing has a top surface, a bottom surface, and side surfaces for accommodating a coupled body of said cell stack assembly and said bus bar frame.
[0025] The pair of end plates is coupled to said front and rear sides of said cell stack assembly where said cell tabs of said cell stack assembly are disposed.
[0026] Further, each of said end plates includes multiple venting ports. Also, each of the multiple venting ports corresponds to a respective venting passage defined in the cell stack assembly.
[0027] In an aspect, each of said end plates includes:
• an end plate housing having multiple venting ports through which cell venting gases escape from the cell stack assembly;
• an isolation cover coupled to said end plate housing to guide the cell venting gases toward the multiple venting ports;
• an isolation foil provided between said end plate housing and said isolation cover.
[0028] In an aspect, said end plate housing is a metal housing.
[0029] In an aspect, said isolation foil is of high insulation resistance and high dielectric strength made from polyester material.
[0030] In an aspect, polyester material is Polyethylene terephthalate (PET).
[0031] In an aspect, said plurality of cells are connected in a combination of series and parallel connections through multiple bus bars of said bus bar frame.
[0032] In an aspect, said cell tabs of each of the plurality of battery cells are welded in bent condition with said multiple bus bars to make the series and parallel connections between each of said plurality of cells.
[0033] In an aspect, said plurality of thermal pads are arranged between two adjacent cells to thermally isolate each one of said plurality of cells from other cells.
[0034] In an aspect, said venting passages include angular venting passages at extreme ends of the cell stack assembly.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
[0035] A battery module for high voltage battery packs of the present disclosure will now be described with the help of the accompanying drawing, in which:
[0036] FIG. 1 illustrates a perspective view of a battery module for high-voltage battery packs, in accordance with an embodiment of the present disclosure;
[0037] FIG. 2 illustrates different views of a cell stack assembly of the battery module, in accordance with an embodiment of the present disclosure;
[0038] FIG. 3 illustrates an assembling process of a combined cell stack assembly in a bus bar frame assembly, in accordance with an embodiment of the present disclosure;
[0039] FIG. 4 illustrates different views of an assembling process of the combined cell stack assembly with the bus bar frame assembly into a module housing, in accordance with an embodiment of the present disclosure;
[0040] FIG. 5 illustrates different views of an isolated venting passage within the bus bar frame assembly, in accordance with an embodiment of the present disclosure;
[0041] FIG. 6 illustrates various views of different child parts of an end plate assembly, in accordance with an embodiment of the present disclosure;
[0042] FIG. 7 illustrates various views of different child parts of the end plate assembly, in accordance with an embodiment of the present disclosure;
[0043] FIG. 8 illustrates an assembling process for joining the end plate assembly to the combined cell stack assembly, in accordance with an embodiment of the present disclosure;
[0044] FIG. 9 illustrates an isometric view and a cross-sectional view of a final battery module, in accordance with an embodiment of the present disclosure;
[0045] FIG. 10 illustrates a cross-sectional view of the final battery module at the end plate assembly, in accordance with an embodiment of the present disclosure.

LIST OF REFERENCE NUMERALS USED IN THE DESCRIPTION AND DRAWING:
100 Battery module
102 Cell stack assembly
102A Cells
102B Cell tabs
104 Thermal pads
106 Bus bar frame
106A Bus bars
108 Module housing
108A Top surface of module housing
108B Bottom surface of module housing
108C Side surfaces of module housing
110 Pair of end plates
110A End plate housing
110B Isolation cover
110C Isolation foil
112 Venting ports
114 Venting passage
116 Angular venting passages

DETAILED DESCRIPTION
[0046] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
[0047] 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 apparatus structures, and well-known techniques are not described in detail.
[0048] 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, “comprises”, “comprising”, “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.
[0049] When an element is referred to as being “embodied thereon”, “engaged to”, “coupled to” or “communicatively 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.
[0050] A high-voltage electric vehicle (EV) is an advanced automotive technology that relies on a robust electrical powertrain system, typically operating at voltages well above the levels found in conventional internal combustion engine vehicles. These vehicles are designed to use high-capacity battery packs that store electrical energy, which is then converted into mechanical power to drive the vehicle's wheels.
[0051] A high-voltage battery pack is a sophisticated energy storage system designed for applications that demand significant power output, such as electric vehicles (EVs) and renewable energy systems. These battery packs typically consist of multiple individual battery cells connected in series and parallel configurations to achieve the required voltage and capacity. High-voltage battery packs are known for their ability to store and deliver substantial electrical energy, making them a fundamental component in the electrification of transportation and the integration of renewable energy sources into the grid.
[0052] Typically, the battery module of any high-voltage battery pack consists of multiple cells that are connected in combinations of series & parallel connections via a bus bar. These bus bars are housed in a bus bar frame assembly that is assembled over the cell stack assembly. The entire cell stack with bus bar frame assembly is assembled into a module housing & both the ends of the module housing are covered using end plates.
[0053] The battery module 100 for high voltage battery packs is described herein with reference to FIGS. 1 to 10.
[0054] FIG. 1 illustrates a battery module 100 for high-voltage battery packs, in accordance with an embodiment of the present disclosure.
[0055] The battery module 100 comprises a cell stack assembly 102, a bus bar frame 106 covering an upper surface along with front and rear sides of said cell stack assembly 102, a module housing 108, and a pair of end plates 110.
[0056] FIG. 2 illustrates different views of the cell stack assembly 102, in accordance with an embodiment of the present disclosure. The cell stack assembly (cell module) 102 includes a plurality of cells 102A with thermal pads 104 therebetween to define isolated venting passages 114 for each of said plurality of cells 102A.
[0057] FIG. 3 illustrates the combined cell stack assembly 102, 102A with a bus bar frame assembly 106, in accordance with an embodiment of the present disclosure.
[0058] The bus bar frame 106 covers an upper surface along with front and rear sides of said cell stack assembly 102. From said front and rear sides of said cell stack assembly 102, cell tabs of said cell stack assembly 102 protrude from said bus bar frame 106.
[0059] In an aspect, said plurality of cells 102A are connected in a combination of series and parallel connections through multiple bus bars 106A of said bus bar frame 106.
[0060] In an aspect, the cell tabs 102B of each of the plurality of cells 102A are welded in bent condition with said multiple bus bars 106A to make the series and parallel connections between each of said plurality of cells 102A.
[0061] FIG. 4 illustrates a side view, a top view, and an isometric view of the the combined cell stack assembly 102 with the bus bar frame assembly 106 while being inserted into a module housing 108, in accordance with an embodiment of the present disclosure. The module housing 108 has a top surface 108A, a bottom surface 108B, and side surfaces 108C for accommodating a coupled body of said cell stack assembly 102 and said bus bar frame 106.
[0062] The pair of end plates 110 is coupled to said front and rear sides of said cell stack assembly 102 where said cell tabs 102B of said cell stack assembly 102 are disposed.
[0063] FIG. 5 illustrates the placement of an isolated venting passage 114 within the bus bar frame assembly 106 via a thermal pad 104, in accordance with an embodiment of the present disclosure.
[0064] Further, in an embodiment, each of said end plates 110 includes multiple venting ports 112. Also, each of the multiple venting ports 112 corresponds to a respective venting passage 114 defined in the cell stack assembly 102.
[0065] In an aspect, said plurality of thermal pads 104 are arranged between two adjacent cells 102A to thermally isolate each one of said plurality of cells 102A from other cells 102A.
[0066] In an aspect, said venting passages 114 include angular venting passages 114 at extreme ends of the cell stack assembly102.
[0067] FIG. 6 illustrates a front view of the child parts of an end plate assembly 110, in accordance with an embodiment of the present disclosure.
[0068] Each of said end plates 110 includes child parts, namely an end plate housing 110A, an isolation cover 110B coupled to said end plate housing 110A, and an isolation foil 110C.
[0069] The end plate housing 110A has multiple venting ports 112 through which cell venting gases escape from the cell stack assembly 102.
[0070] The isolation cover 110B is used to guide the cell venting gases toward the multiple venting ports 112.
[0071] The isolation foil 110C is provided between said end plate housing 110A and said isolation cover 110B.
[0072] In an aspect, said end plate housing 110A is a metal housing.
[0073] In an aspect, said isolation foil 110C is of high insulation resistance and high dielectric strength made from polyester material.
[0074] In an aspect, polyester material is Polyethylene terephthalate (PET).
[0075] Each venting passage 114 is isolated from each other. The venting path is isolated using the thermal pad 104 within the bus bar frame assembly 106. Once the gas leaves the bus bar frame assembly 106, the venting gas is further isolated and guided by the isolation cover 110B within the end plate assembly 110. The venting gas punctures and opens the isolation foil 110C and exits the battery module 100.
[0076] 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 AND ECONOMIC SIGNIFICANCE
[0077] The present disclosure described herein above has several technical advantages including, but not limited to, a battery module 100 for high voltage battery packs, which:
• provides the user(s) with a battery module 100 having separate isolated venting passages 114 provided for each cell 102A to ensure that the venting gas from one cell does not recirculate and trigger the venting of another cell 102A and prevents the thermal propagation;
• provides the user(s) with a battery module 100 providing cell venting passage isolation within bus bar frame assembly 106 via a thermal pad 104;
• provides the user(s) with a battery module 100 providing cell venting passage isolation and guidance in the end plate assembly 110; and
• provides the user(s) with a battery module 100 preventing the entry of any contaminants into the battery module 100.
[0078] The present disclosure described herein above has several economic advantages including, but not limited to:
• is cost-effective, compared to the state-of-the-art equipment used for high-voltage battery packs; and
• low-maintenance, compared to the state-of-the-art equipment used for high voltage battery packs.
[0079] 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.
[0080] 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.
[0081] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
[0082] Any discussion of documents, acts, materials, devices, articles, or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
[0083] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
[0084] 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 module (100) for a high voltage battery pack, said battery module (100) comprises:
a cell stack assembly (cell module) (102) including a plurality of cells (102A) with thermal pads (104) therebetween to define isolated venting passages (114) for each of said plurality of cells (102A);
a bus bar frame (106) covering an upper surface along with front and rear sides of said cell stack assembly (102), wherein from said front and rear sides, cell tabs (102A) of said cell stack assembly (102) protrude from said bus bar frame (106);
a module housing (108) having a top surface (108A), a bottom surface (108B), and side surfaces (108C) for accommodating a coupled body of said cell stack assembly (102) and said bus bar frame (106); and
a pair of end plates (110) coupled to said front and rear sides of said cell stack assembly (102) where said cell tabs (102A) of said cell stack assembly (102) are disposed,
wherein each of said end plates (110) includes multiple venting ports (112), each of which corresponds to a respective venting passage (114) defined in the cell stack assembly (102).
2. The battery module (100) as claimed in claim 1, wherein each of said end plates (110) includes:
an end plate housing (110A) having multiple venting ports (112) through which cell venting gases escape from the cell stack assembly (102);
an isolation cover (110B) coupled to said end plate housing (110A) to guide the cell venting gases toward the multiple venting ports (112); and
an isolation foil (110C) provided between said end plate housing (110A) that prevents the entry of any contaminants into the battery module and said isolation cover (110B)
3. The battery module (100) as claimed in claim 2, wherein said end plate housing (110A) is a metal housing.
4. The battery module (100) as claimed in claim 2, wherein said isolation foil (110C) is of high insulation resistance and high dielectric strength made from polyester material.
5. The battery module (100) as claimed in claim 4, wherein polyester material is Polyethylene terephthalate (PET).
6. The battery module (100) as claimed in claim 1, wherein said plurality of cells (102A) are connected in a combination of series and parallel connections through multiple bus bars (106A) of said bus bar frame (106).
7. The battery module (100) as claimed in claim 7, wherein said cell tabs (102B) of each of the plurality of cells (102A) are welded in bent condition with said multiple bus bars (106A) to make the series and parallel connections between each of said plurality of cells (102A).
8. The battery module (100) as claimed in claim 1, wherein said plurality of thermal pads (104) are arranged between two adjacent cells to (102A) thermally isolate each one of said plurality of cells (102A) from other cells (102A).
9. The battery module (100) as claimed in claim 1, wherein said venting passages (114) include angular venting passages at extreme ends of the cell stack assembly (102).

Dated this 16th day of November, 2023

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