Claims:1. A battery module (100) comprising:
a battery casing (10);
a plurality of battery cells (102) adapted to be provided inside said battery casing (10), where each of said battery cell (102) includes a positive terminal (102P) and a negative terminal (102N); and
a plurality of bus bars (104), where each of said bus bar (104) is adapted to be removably connected to corresponding terminal of corresponding said battery cells (102),
wherein
each of said bus bar (104) is removed from corresponding said battery cells (102);
a position of terminals (102P and 102N) of corresponding said battery cells (102) is changed; and
said battery module (100) comprises a plurality of add-on bus bars (104A), where each of said add-on bus bar (104A) is secured with corresponding terminal of corresponding said battery cells (102) therein to change a configuration of said battery cells (102).

2. The battery module (100) as claimed in claim 1, wherein said battery module (100) comprises a plurality of sensors (112), where each of said sensor (112) is adapted to detect a temperature and voltage in corresponding at least one of said battery cell (102) and provides the information to a battery management unit.

3. The battery module (100) as claimed in claim 1, wherein said battery casing (10) comprises,
a first battery casing (12) having a plurality of side walls (12SL and 12SR), a front wall (12FW), a rear wall (12RW), a top wall (12TW) and a plurality of foot portions (12FP); and
a second battery casing (14) having a plurality of side walls (14SL and 14SR), a front wall (14FW), a rear wall (14RW) and a plurality of longitudinal support portions (14LS).

4. The battery module (100) as claimed in claim 3, wherein said battery module (100) comprises at least one thermalmanagement unit (108A and 108B) adapted to be provided at a bottom end of said second battery casing (14) and is mounted onto a battery enclosure, where said thermal management unit (108A and 108B) is adapted to maintain a predetermined temperature of battery cells (102), where said thermal management unit (108A and 108B) is at least one of an air based thermal management unit (108A) and a liquid based thermal management unit (108B).

5. The battery module (100) as claimed in claim 4, wherein said second battery casing (14) defines an opening (14X) provided at the bottom end of said second battery casing (14), and defined between the side walls (14SL and 14SR), the front wall (14FW) and the rear wall (14RW),
wherein
said opening (14X) is adapted to facilitate cooling or heating of said battery cells (102).

6. The battery module (100) as claimed in claim 3, wherein said battery module (100) comprises a plurality of fuses (106),
wherein
each of said fuse (106) is adapted to be connected to corresponding said battery cells (102).

7. The battery module (100) as claimed in claim 6, wherein said first battery casing (12) defines a plurality of fuse holding portions (12E) adapted to be integrated with a top portion (12TP) of the top wall (12TW) of said first battery casing (12), where said fuse holding portion (12E) is adapted to hold corresponding said fuse (106).
8. The battery module (100) as claimed in claim 3, wherein said first battery casing (12) defines,
a plurality of cable tie portions (12F) adapted to be integrated with top portion (12TP) of the top wall (12TW), where each of said cable tie portion (12F) is adapted to facilitate tying of corresponding each cable with the top wall (12TW) therein to secure the cable with said first battery casing (12); and
a plurality of battery cell terminal receiving portions (12G) adapted to be provided on the top wall (12TW), where each of said battery cell terminal receiving portion (12G) is adapted to receive corresponding each battery cell terminal (102P and 102N) of corresponding each of said battery cell (102).

9. The battery module (100) as claimed in claim 5, wherein each of said front wall (12FW) and said rear wall (12RW)of said first battery casing (12) defines a ventilation portion (12V) adapted to vent the heat air;
each ventilation portion (12V) is larger than a surface area of corresponding each of said front wall (12FW) and said rear wall (12RW); and
each of said front wall (14FW) and said rear wall (14RW)of said second battery casing defines a ventilation portion (14V) adapted to vent the heat air.

10. The battery module (100) as claimed in claim 3, wherein said first battery casing (12) defines a plurality of battery cell locators (12A) adapted to be integrated with a bottom portion (12TB) of the top wall (12TW) of said first battery casing (12);
said second battery casing (14) defines a plurality of battery cell locators (14A) adapted to be transversely integrated with each of said front and rear wall (14FW and 14RW) and corresponding longitudinal support portions (14LS) respectively; and
said plurality of battery cell locators (12A) of said first battery casing (12) and saidplurality of battery cell locators (14A) of said second battery casing (14) are adapted to locate and hold said battery cells (102).
11. The battery module (100) as claimed in claim 3, wherein said first battery casing (12) defines a plurality of first fastener receiving inserts (12B) adapted to be integrated with each of said foot portion (12FP) of said first battery casing (12);
said second battery casing (14) defines plurality of first fastener receiving inserts (14B) adapted to be integrated with each of said side wall (14SL and 14SR) of said second battery casing (14); and
each of said first fastener receiving insert (12B) of said first battery casing (12) and each of said first fastener receiving insert (14B) of said second battery casing (14) are adapted to receive corresponding fastener (110A) therethrough to secure said first battery casing (12) with said second battery casing (14).

12. The battery module (100) as claimed in claim 3, wherein first battery casing (12) defines a plurality of second fastener receiving inserts (12C) adapted to be integrated with each of said foot portion (12FP) of said first battery casing (12);
said second battery casing (14) defines a plurality of second fastener receiving inserts (14C) adapted to be integrated with each of said side wall (14SL and 14SR) of said second battery casing (14); and
each of said second fastener receiving insert (12C) of said first battery casing (12) and each of said second fastener receiving insert (14C) of said second battery casing (14) are adapted to receive corresponding another fastener therethrough to secure said battery module (100) with abattery enclosure.
13. The battery module (100) as claimed in claim 12, wherein a reference plane of fastening points of at least one of said battery casing (10) and said battery module (102) is coplanar or near to a reference plane of a center of gravity of said battery module (100) thereby providing said battery module (100) with better strength, durability and also to reduce vibration.

14. The battery module (100) as claimed in claim 13, said first battery casing (12) defines a plurality of third fastener receiving inserts (12D) adapted to be integrated with said top wall (12TW), where each of said third fastener receiving insert (12D) is adapted to receive corresponding another fastener therethrough to facilitate mounting of a battery management unit onto said first battery casing (12).

15. The battery module (100) comprising:
a battery casing (10);
a plurality of battery cells (102) adapted to be provided inside said battery casing (10), where each of said battery cell (102) includes a positive terminal (102P) and a negative terminal (102N);
a plurality of bus bars (104), where each of said bus bar (104) is adapted to be removably connected to corresponding terminal of corresponding said battery cells (102);
a plurality of fuses (106), where each of said fuse (106) is adapted to be connected to corresponding said battery cells (102);
at least one thermal management unit (108A and 108B) adapted to be provided at a bottom end of said battery casing (10); and
a plurality of sensors (112), where each of said sensor (112) is adapted to detect a temperature and voltage in corresponding said battery cells (102) and provides the information to a battery management unit,
wherein
each of said bus bar (104) is removed from corresponding said battery cells (102);
a position of terminals (102P and 102N) of corresponding said battery cells (102) is changed; and
said battery module (100) comprises a plurality of add-on bus bars (104A), where each of said add-on bus bar (104A) is secured with corresponding terminal of corresponding said battery cells (102) to change a configuration of said battery cells (102).
16. A battery module (100) comprising:
a battery casing (10) having a first battery casing (12) and a second battery casing (14), where said first battery casing (12) is adapted to be removably connected to said second battery casing (14);
a plurality of battery cells (102) adapted to be provided inside said battery casing (10); and
at least thermal management unit (108A and 108B) adapted to be provided at a bottom end of said second battery casing (14).

17. The battery module (100) as claimed in claim 16, wherein said thermal management unit (108A) is an air based thermal management unit comprising,
an air duct (108AD); and
a plurality of air sprayers (108AS),
wherein
said air duct (108AD) is adapted to provide the cool or heat air to said plurality of air sprayers (108AS) which in turn sprays the cool or heat air to said battery cells (102) in a direction from a bottom end towards a top end of said battery module (100); and
the air sprayed onto said battery cells (102) cools or heats said battery cells (102) to maintain a predetermined temperature of said battery cells (102); and
the heat air is vented from a ventilation portion (12V and 14V) of each of said first and second battery casing (12 and 14).

18. The battery module (100) as claimed in claim 16, wherein said thermal management unit (108B) is a liquid basedthermal management unit comprising,
a liquid plate (108BL) adapted to cool or heat said battery cells (102) to maintain a predetermined temperature of said battery cells (102);
a thermal pad (108BP) disposed between a bottom end of said battery cells (102) and said liquid plate (108BL); and
a foam (108BF) disposed below said liquid plate (108BL).
19. A method (200) of changing a configuration of battery cells (102) in a battery module (100), said method (200) comprising:
removing each bus bar (104) from corresponding battery cells (102) by removing fasteners (110B) from corresponding each bus bar (104) and corresponding terminal of corresponding battery cells (102);
changing a position of terminals (102P and 102N) of corresponding battery cells (102); and
engaging each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) by fastening corresponding each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) through fasteners (110B) therein to change the configuration of battery cells (102).

20. The method (200) as claimed in claim 19, wherein said removing each bus bar (104) from corresponding battery cells (102) by removing fasteners (110B) from corresponding each bus bar (104) and corresponding terminal of corresponding battery cells (102) includes,
removing corresponding each sensor (112) from corresponding terminal of corresponding battery cells (102) during removal offasteners (110B) from corresponding each bus bar (104) and corresponding terminal of corresponding battery cells (102).
21. The method (200) as claimed in claim 19, wherein said changing a position of terminals (102P and 102N) of corresponding battery cells (102) includes,
removing corresponding battery cells (102) fromcorresponding battery cell locators (14A) of a battery casing (14) and changing the orientation of corresponding battery cells (102) with respect to the battery casing (14) therein to change the position of terminals (102P and 102N) of corresponding battery cells (102) and re-inserting corresponding battery cells (102) into the same corresponding battery cell locators (14A) of the battery casing (14).

22. The method (200) as claimed in claim 21, wherein said method (200) comprises,
removing a first battery casing (12) from a second battery casing (14)by removing fasteners from the first and second battery casing (12 and 14) prior to said removing corresponding battery cells (102) from corresponding battery cell locators (14A) of the battery casing (14) and changing the orientation of corresponding battery cells (102) with respect to the battery casing (14) therein to change the position of terminals (102P and 102N) of corresponding battery cells (102) and re-inserting corresponding battery cells (102) into the same corresponding battery cell locators (14A) of the battery casing (14).

23. The method (200) as claimed in claim 19, wherein said method (200) comprises,
securing the first battery casing (12) with the second battery casing (14) by fastening the first battery casing (12) with the second battery casing (14) through fasteners after said changing a position of terminals (102P and 102N) of corresponding battery cells (102).
24. The method (200) as claimed in claim 19, wherein said engaging each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) by fastening corresponding each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) through fasteners (110B) therein to change the configuration of battery cells (102) includes,
connecting corresponding each sensor (112) with corresponding terminal of corresponding battery cells (102) during fastening of fasteners (110B) withcorresponding eachadd-on bus bar (104) and corresponding terminal of corresponding battery cells (102).

25. The method (200) as claimed in claim 19, wherein said method (200) comprises,
removing a top cover from a first battery casing (12) and removing a battery management unit from corresponding fastener receiving inserts (12D) of the first battery casing (12) by removing the fasteners from the battery management unit and the fastener receiving inserts (12D) prior to said removing each bus bar (104) from corresponding battery cells (102) by removing fasteners (110B) from corresponding each bus bar (104) and corresponding terminal of corresponding battery cells (102),
wherein
another end of each sensor (112) is dis-connected from the battery management unit during removal of battery management unit from the first battery casing (12).
26. A battery casing (10) comprising:
a first battery casing (12) defining,
a plurality of battery cell locators (12A) adapted to be integrated with said first battery casing (12), where said battery cell locators (12A) are adapted to locate and hold battery cells (102);
a plurality of fuse holding portions (12E) adapted to be integrated with said first battery casing (12), where said fuse holding portion (12E) is adapted to hold corresponding fuse (106); and
a plurality of first fastener receiving inserts (12B) adapted to be integrated with said first battery casing (12).

27. The battery casing (10) as claimed in claim 26, wherein each of said battery cell locator (12A) is integrated with a bottom portion (12TB) of a top wall (12TW) of said first battery casing (12).

28. The battery casing (10) as claimed in claim 26, wherein each of said fuse holding portion (12) is integrated with a top portion (12TP) of top wall (12TW) of said first battery casing (12).
29. The battery casing (10) as claimed in claim 26, wherein said first battery casing (12) includes a plurality of foot portions (12FP), whereeach of said foot portion (12FP) transversely extends from corresponding each side wall (12SL and 12SR) of said first battery casing (12).
30. The battery casing (10) as claimed in claim 29, wherein said plurality offirst fastener receiving inserts (12B) are integrated with each of said foot portion (12FP).
31. The battery casing (10) as claimed in claim 30, wherein said battery casing (10) includes a second battery casing (14) defining,
a plurality of first fastener receiving inserts (14B) adapted to be integrated with each side wall (14SL and 14SR) of said second battery casing (14),
wherein
each of said first fastener receiving insert (12B) of said first battery casing (12) and each of said first fastener receiving insert (14B) of said second battery casing (14) is adapted to receive corresponding fastener (110A) therethrough to secure said first battery casing (12) with said second battery casing (14).

32. The battery casing (10) as claimed in claim 31, wherein said first battery casing (12) defines a plurality of second fastener receiving inserts (12C) adapted to be integrated with each of said foot portion (12FP) of said first battery casing (12); and
said second battery casing (14) defines a plurality of second fastener receiving inserts (14C) adapted to be integrated with each side wall (14SL and 14SR) of said second battery casing (14),
wherein
each of said second fastener receiving insert (12C) of said first battery casing (12) and each of said second fastener receiving insert (14C) of said second battery casing (14) is adapted to receive corresponding fastener therethrough to secure the battery casing (10) with a battery enclosure.
33. The battery casing (10) as claimed in claim 26, wherein said first battery casing (12) defines a plurality of third fastener receiving inserts (12D) adapted to be integrated with top portion (12TP) of top wall (12TW) of said first battery casing (12),
wherein
each of said third fastener receiving insert (12D) is adapted to receive corresponding another fastener therethrough to facilitate mounting of a battery management unit onto the top wall (12TW) of said first battery casing (12).

34. The battery casing (10) as claimed in claim 26, wherein said first battery casing (12) defines a plurality of cable tie portions (12F) adapted to be integrated with top portion (12TP) of top wall (12TW) of said first battery casing (12),
wherein
each of said cable tie portion (12F) is adapted to facilitate tying of corresponding cable with the top wall (12TW) of said first battery casing (12) therein to secure corresponding cable with said first battery casing (12).

35. The battery casing (10) as claimed in claim26,wherein said first battery casing (12) defines a plurality of battery cell terminal receiving portions (12G) adapted to be provided on top portion (12TP) of top wall (12TW) of said first battery casing (12),
wherein
each of said battery cell terminal receiving portion (12G) is adapted to receive corresponding each battery cell terminal (102P and 102N) of corresponding each battery cell (102).

36. The battery casing (10) as claimed in claim 26, wherein said first battery casing (102) includes,
a front wall (12FW) extending between corresponding ends of side walls (12SL and 12SR); and
a rear wall (12RW) extending between corresponding another ends of side walls (12SL and 12SR), where said rear wall (12RW) is parallel, opposite and disposed away with respect to said front wall (12FW),
wherein
each of said front wall (12FW) and said rear wall (12RW)defines a ventilation portion (12V) adapted to vent the heat air; and
each ventilation portion (12V) is larger than a surface area of corresponding each of said front wall (12FW) and said rear wall (12RW).

37. The battery casing (10) as claimed in claim31, wherein said second battery casing (14) defines a plurality of battery cell locators (14A) adapted to be transversely integrated with each front and rear wall (14FW and 14RW) and corresponding longitudinal support portions (14LS) respectively;
said battery cell locators (14A) are adapted to locate and hold battery cells (102) in a required position corresponding to said first battery casing (12); and
each of said battery cell locator (14A) is at least one of a rib, a protrusion and a partition.

38. The battery casing (10) as claimed in claim 26, wherein each of said battery cell locator (12A) of said first battery casing (12) is at least one of a rib, a protrusion and a partition.

39. The battery casing (10) as claimed in claim 31, wherein said second battery casing (14) defines at least one holding portion (14H) integrated with corresponding each side wall (14SL and 14R) of said second battery casing (14),
wherein
each holding portion (14H) is adapted to facilitate lifting of said battery casing (10).

40. The battery casing (10) as claimed in claim 31, wherein said second battery casing (14) includes,
a front wall (14FW) extending between corresponding ends of side walls (14SL and 14SR); and
a rear wall (14RW) extending between corresponding another ends of side walls (14SL and 14SR), where said rear wall (14RW) is parallel, opposite and disposed away with respect to said front wall (14FW),
wherein
each of said front wall (14FW) and said rear wall (14RW)defines a ventilation portion (14V) adapted to vent the heat air.

41. The battery casing (10) as claimed in claim 40, wherein said second battery casing (14) definesan opening (14X) provided at a bottom end of said second battery casing (14), and defined between the side walls (14SL and 14SR), the front wall (14FW) and the rear wall (14RW),
wherein
said opening (14X) is adapted to facilitate cooling or heating of battery cells (102).

42. The battery casing (10) as claimed in claim 31, wherein a reference plane of the fastening points of at least one of said battery casing (10) is coplanar or near to a reference plane of a center of gravity of said battery casing (10) thereby providing saidbattery casing (10) with better strength, durability and also reduces vibration.

43. A battery casing (10) comprising:
a first battery casing (12) defining,
a plurality of battery cell locators (12A) adapted to be integrated with said first battery casing (12), where said battery cell locators (12A) are adapted to locate and hold battery cells (102);
a plurality of fuse holding portions (12E) adapted to be integrated with a top portion (12TP) of a top wall (12TW) of said first battery casing (12), where said fuse holding portion (12E) is adapted to hold corresponding fuse (106);
a plurality of battery cell terminal receiving portions (12G) adapted to be provided on the top wall (12TW), where each of said battery cell terminal receiving portion (12G) is adapted to receive corresponding each battery cell terminal (102P and 102N) of corresponding each battery cell (102); and
a plurality of fastener receiving inserts (12D) adapted to be integrated with the top wall (12TW); where each of said fastener receiving insert (12D) is adapted to receive corresponding fastener therethrough to facilitate mounting of a battery management unit onto said first battery casing (12).
44. The battery casing (10) as claimed in claim 43, wherein said first battery casing (12) defines a plurality of cable tie portions (12F) adapted to be integrated with the top portion (12TP) of the top wall (12TW),
wherein
each of said cable tie portion (12F) is adapted to facilitate tying of corresponding each cable with the top wall (12TW) therein to secure the cable with said first battery casing (12).

45. The battery casing (10) as claimed in claim 43, wherein said first battery casing (12) defines a plurality of openings (12BV) provided on the top wall (12TW), where each of said opening (12BV) is adapted to facilitate venting of air from corresponding each battery cell (102).

46. The battery casing (10) comprising:
a first battery casing (12) defining a plurality of first fastener receiving inserts (12B) adapted to be integrated with said first battery casing (12); and
a second battery casing (14) defining a plurality of first fastener receiving inserts (14B) adapted to be integrated with said second battery casing (14),
wherein
each of said first fastener receiving insert (12B) of said first battery casing (12) and each of said first fastener receiving insert (14B) of said second battery casing (14) are adapted to receive corresponding fastener (110A) therethrough to secure said first battery casing (12) with said second battery casing (14).

47. The battery casing (10) as claimed in claim46, wherein said first battery casing (12) defines a plurality of second fastener receiving inserts (12C) adapted to be integrated with said first battery casing (12);
said second battery casing (14) defines a plurality of second fastener receiving inserts (14C) adapted to be integrated with said second battery casing (14); where each of said second fastener receiving insert (12C) of said first battery casing (12) and each of said second fastener receiving insert (14C) of said second battery casing (14) are adapted to receive corresponding another fastener therethrough to secure the battery casing (10) with a battery enclosure.

48. The battery casing (10) as claimed in claim 46, wherein said first battery casing (12) defines a plurality of third fastener receiving inserts (12D) adapted to be integrated with a top wall (12TW), where each of said third fastener receiving insert (12D) is adapted to receive corresponding another fastener therethrough to facilitate mounting of a battery management unit onto said first battery casing (12).

49. The battery casing (10) comprising:
a battery casing (14) having,
a plurality of side walls (14SL and 14SR);
a front wall (14FW) extending between corresponding ends of said side walls (14SL and 14SR); and
a rear wall (14RW) extending between corresponding another ends of said side walls (14SL and 14SR), where said rear wall (14RW) is parallel, opposite and disposed away with respect to said front wall (14FW),
wherein
said battery casing (14) definesan opening (14X) provided at a bottom end of said battery casing (14), and defined between said side walls (14SL and 14SR), said front wall (14FW) and said rear wall (14RW);
said opening (14X) is adapted to facilitate cooling or heating of battery cells (102); and
said battery casing (14) is adapted to be provided in communication with a thermal management unit (108A and 108B) provided at the bottom end and adjacent to the opening (14X) of said battery casing (14).
, Description:TECHNICAL FIELD
[001] The embodiments herein generally relate to a batterysystem and more particularly, to abattery module and a method of changing configuration of battery cells in the battery module. Further, embodiments herein relate to a battery casing.

BACKGROUND
[002] Generally, battery modules are used in various applications such as automotive industry, industrial applications and the like. Usually, the battery module includes a battery casing which is used for housinga plurality of battery cells.The battery casings which are made of metallic materials such as aluminum or steel have required strength and enables proper fastening of abattery casing with another one or more battery casingstherein to secure the battery pack provided therein.However, such metallic battery casingsincrease an overall weight of the battery module. Battery casings which aremade of light weigh non-metallic materials such as plastic reduces the overall weight of the battery module. However, plastic battery casings may not have required strength and fastening the battery casings for securing the battery packs within the battery casings is difficult and cumbersome. Some plastic battery casings use more child parts such asside metal plates and long studs for securing the battery cells with the battery casings,is complex and the assembly process is tedious and incur additional costs.
[003] Most battery modules are subjected to increased vibration which in turn reduces the life of the battery module and results in breakage of bus bars and short circuit and also affects the performance of the battery cells.Further, the battery cells provided inside the battery casing are in direct contact with adjacent battery cells results in possibility of electrical interference between the battery cells, which is undesirable. Most prismatic lithium ion batteries do not employ a dedicated fuse in the sensing lines of the battery module. Somebatteries include insulating films to protect the battery in an event of short circuit. However, insulating films are costly.
[004] Heat generated during charging and discharging of battery cells is relatively large, and since,the temperature is a major parameter for the battery performance, it is necessary to increase the cooling performance in order to ensure a predetermined performance of the battery cells.Usually, the battery cells housed inside the battery modules are cooled by blowing air through the battery cells along a lateral direction of the battery module.However, this cooling arrangement leads to uneven cooling of battery cells due to narrow air passages, and the heat dissipation from the battery cells is not at a required rate which in turn affects the proper functioning of the battery cells and reduces the life of battery pack.For example, the bottom portion of the battery cells is not cooled which in turn reduces the life of battery cells due to flow of air along the lateral direction.The uneven cooling of battery cells leads to thermal runaway, which is a major safety concern. Some battery module utilize air cooling for cooling the battery cells, whereas other battery modules utilize liquid cooling for cooling the battery cells. Further, the battery module is subjected to faster capacity fade of part or full battery pack due to operation and storage at high temperature. Providing air cooling or liquid cooling to the same battery module is complex in design and is difficult and is one of the challenges posed to the original equipment manufacturers (OEM’s). Further, the battery packs are not completely charged due to heat generation at higher ambient temperature.Improper heating of the battery cells at low temperatures results in cold start problem and reduced performance of the battery cells.
[005] Usually, a single battery module accommodates only a single configuration of battery cells due to welding of bus bars with the terminals of battery cells, and fixed structural design of the bus bars. Further,making of battery modules for accommodating various configurations of battery cells requires various tools which in turn incur high costs.Therefore, manufacturing a single battery module for accommodating various configurations of battery cellsin the same single battery module is complex in designand is difficult and is one of the challenges posed to the original equipment manufacturers (OEM’s).
[006] Therefore, there exists a need for abattery module and a method of changing configuration of battery cells in the battery module, which obviates the aforementioned drawbacks. Further, there exists a need for a battery casing, which obviates the aforementioned drawbacks.

OBJECTS
[007] The principal object of embodimentsherein is toprovide abattery module.
[008] Another object of embodiments herein is to provide a method of changing configuration of battery cells in a battery module.
[009] Anotherobject of embodiments herein is to provide a battery casing.
[0010] Another object of embodiments herein is to providea single modular battery module, which accommodates various configurations of battery cells in the single battery module.
[0011] Another object of embodiments herein is to provide battery casings, which accommodates corresponding number of battery cells, where each battery casings is manufactured using a single family tool by changing a length of the battery casing.
[0012] Another object of embodiments herein is to provide a light weight battery module, which is durable and provides better stability and has better noise, vibration and harness (NVH) characteristics.
[0013] Another object of embodiments herein is to provide a battery module, which has prolonged life and improved performance.
[0014] Another object of embodiments herein is to provide a battery module, which has effective thermal management of battery cells to achieve prolonged battery life.
[0015] Another object of embodiments herein is to provide a vertical battery module.
[0016] Another object of embodiments herein is to provide a battery module, which has dedicated fuses for battery cells along a sensing line of the battery module.
[0017] Another object of embodiments herein is to provide a light weight battery casing, which is durable and provides better stability while insertion of fasteners and has better noise, vibration and harness (NVH) characteristics.
[0018] Another object of embodiments herein is to provide a battery module, which supports air or liquid based thermal management unit provided at a bottom end of the battery module, where the thermal management unit is adapted to facilitate uniform cooling or heating of battery cells.
[0019] Another object of embodiments herein is to provide a battery module, which is easy to assemble.
[0020] Another object of embodiments herein is to provide a battery module, which has better Eigen frequency which is above road induced vibration (ISO 12405 Random vibration profile).
[0021] Another object of embodiments herein is to provide a battery module, which has optimized structural design.
[0022] These and other objects of embodimentsherein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0023] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0024] Fig. 1 depicts a perspective view of abattery modulewith a 3P-4S battery cells configuration, according to embodiments as disclosed herein;
[0025] Fig. 2a depicts a perspective view of a first battery casing, according to embodiments as disclosed herein;
[0026] Fig. 2b depicts a bottom view of the first battery casing, according to embodiments as disclosed herein;
[0027] Fig. 3a depicts a perspective view of a second battery casing, according to embodiments as disclosed herein;
[0028] Fig. 3b depicts a top view of the second battery casing, according to according to embodiments as disclosed herein;
[0029] Fig. 4a depicts a cross-sectional view of the battery module with an air based thermal management unit provided at a bottom end of the second battery casing, according to embodiments as disclosed herein;
[0030] Fig. 4b depicts a cross-sectional view of the battery module with a liquid based thermal management unit provided at the bottom end of the second battery casing, according to embodiments as disclosed herein;
[0031] Fig. 5 depicts a perspective view of the battery module, where a reference plane of fastening points of at least one of the battery casing and the battery module is near to a reference plane of a center of gravity of the battery module, according to embodiments as disclosed herein;
[0032] Fig. 6a depicts a perspective view of the battery module with a 1P-12S battery cells configuration,according to embodiments as disclosed herein;
[0033] Fig. 6b depicts a perspective view of the battery module with a 2P-6S battery cells configuration,according to embodiments as disclosed herein;
[0034] Fig. 7a depicts a perspective view of another battery module with a 1P-8S battery cell configuration, according to embodiments as disclosed herein;
[0035] Fig. 7b depicts a perspective view of another battery module a 1P-4S battery cell configuration, according to embodiments as disclosed herein;
[0036] Fig. 8 depicts a table indicating various configurations of battery cells, according to embodiments as disclosed herein; and
[0037] Fig. 9 depicts a flowchart indicating a method ofchanging configuration of battery cells in the battery module, according to embodimentsas disclosed herein.

DETAILED DESCRIPTION
[0038] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed 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.
[0039] The embodiments herein achieve abattery module. Further, embodiments herein achieve a method of changing configuration of battery cells in the battery module. Further, embodiments herein achieve asingle modular battery module, which accommodates various configurations of battery cells in the single battery module. Furthermore, embodiments herein achieve a battery casing.Referring now to the drawings Figs 1 through 9, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0040] Fig. 1 depicts a perspective view of a battery module (100) with a 3P-4S battery cells configuration, according to embodiments as disclosed herein. In an embodiment, the battery module (100) includes a battery casing (10), a plurality of battery cells (102), a plurality of bus bars (104), a plurality of add-on bus bars (104A), as shown in fig. 6a and fig. 6b), a plurality of fuses (106), at least onethermal management unit (108A and 108B), a plurality of fasteners (110A and 110B), a plurality of sensors (112), a battery management unit (not shown), a top cover (not shown) and a battery enclosure (not shown). In an embodiment, the battery casing (10) includes a first battery casing (12) and a secondbattery casing (14). For the purpose of this description and ease of understanding, the battery module (100) is explained herein below with reference to having prismatic lithium ion battery cells for use in any of an electric vehicle and a hybrid vehicle. However, it is also within the scope of this invention to practice/ implement the battery module (100) having any other type of battery cells for use in any of electric vehicles, hybrid vehicles, industrial applications, static power bank, power systemsand any other applications, without otherwise deterring the intended function of the battery module (100) as can be deduced from the description and corresponding drawings.
[0041] Fig. 2a depicts a perspective view of a first battery casing (12), according to embodiments as disclosed herein. In an embodiment, the first battery casing (12) includes a plurality of side walls (12SL and 12SR), a front wall (12FW), a rear wall (12RW), a top wall (12TW) and a plurality of foot portions (12FP). The side wall (12L) is parallel and opposite and disposed away with respect to another side wall (12SR). The front wall (12FW) extends between corresponding ends of the side walls (12SL and 12SR), where the front wall (12FW) is parallel and opposite and disposed away with respect to the rear wall (12RW). The rear wall (12RW) extends between corresponding another ends of the side walls (12SL and 12SR), where the rear wall (12RW) is parallel and opposite and disposed away with respect to the front wall (12FW). The top wall (12TW) is provided on top of the side walls (12SL and 12SR), the front wall (12FW) and the rear wall (12RW).Each foot portion (12FP) transversely extends from corresponding each side wall (12SL and 12SR)in an outward direction, where each foot portion (12FP) is opposite to the other foot portion (12FP). Each foot portion (12FP) is parallel and opposite to the top wall (12TW). For the purpose of this description and ease of understanding, the first battery casing (12) is considered to be a top battery casing.
[0042] The first battery casing (12) defines a plurality of battery cell locators (12A, as shown in fig. 2b) adapted to be integrated with a bottom portion (12TB) of the top wall (12TW) of the firstbattery casing (12). However, it is also within the scope of this invention to integrate the plurality of battery cell locators (12A) with any of the side walls (12SL and 12SR), the front wall (12FW) and the rear wall (12RW) without otherwise deterring the intended function of the battery cell locators (12A) as can be deduced from the description and corresponding drawings. The plurality of battery cell locators(12A) is adapted to locate and hold the battery cells(102) in a required position. In an embodiment, each battery cell locator (12A) is at least one of a rib, a protrusionand a partition. However, it is also within the scope of this invention to integrate grooves or any other holding portions with any of the side walls (12SL and 12SR), the front wall (12FW) and the rear wall (12RW) without otherwise deterring the intended function of the battery cell locators (12A) as can be deduced from the description and corresponding drawings.
[0043] In an embodiment, the first battery casing (12) defines a plurality of first fastener receiving inserts (12B), as shown in fig. 2a and fig. 2b) adapted to be integrated with each foot portion (12FP) of thefirst battery casing (12).It is also within the scope of this invention to integrate the plurality of first fastener receiving inserts (12B) with any of the side walls (12SL and 12SR), the front wall (12FW) and the rear wall (12RW). Each first fastener receiving insert (12B) is adapted to receive corresponding fastener (110A) therethrough to secure the first battery casing (12) with the second battery casing (14). It is also within the scope of this invention to provide each first fastener receiving insert (12B) to receive locking pins or any other locking elements therethrough to secure the first battery casing (12) with the second battery casing (14). Each first fastener receiving insert (12B) is at least a metal sleeve.It is also within the scope of this invention to provide each first fastener receiving insert (12B) to be made of any other material with better strength. Each first fastener receiving insert (12B) provides better stability and durability to the first battery casing (12) while insertion of fasteners (110A) there through. The outer portion of each first fastener receiving insert (12B) is serrated to facilitate molding of each first fastener receiving insert (12B) with corresponding foot portion (12FP) of the first battery casing (12). In an embodiment, the number of first fastener receiving insert (12B) provided on each foot portion (12FP) is at least two. However, it is also within the scope of this invention to provide any number of first fastener receiving insert (12B) on each foot portion (12FP) of the first battery casing (12) without otherwise deterring the intended function of the first fastener receiving insert (12B) as can be deduced from the description and corresponding drawings.
[0044] In an embodiment, the top battery casing (12) defines a plurality of second fastener receiving inserts (12C, as shown in fig. 2a and fig. 2b) adapted to be integrated with each foot portion (12FP) of the first battery casing (12). However, it is also within the scope of this invention to integrate the plurality of second fastener receiving inserts (12C) with any of the side walls (12SL and 12SR), the front wall (12FW) and the rear wall (12RW). Each second fastener receiving insert (12C) is adapted to receive correspondinganother fastener (not shown) therethrough to secure the battery module (100) with the battery enclosure (not shown). It is also within the scope of this invention to provide each second fastener receiving insert (12C) to receive locking pins or any other locking elements therethrough to secure the battery module (100) with the battery enclosure. Each second fastener receiving insert (12C) is at least a metal sleeve. It is also within the scope of this invention to provide each secondfastener receiving insert (12C) to be made of any other material with better strength. Each second fastener receiving insert (12C) provides better stability and durability to the first battery casing (12) while insertion of corresponding fasteners (not shown) there through. In an embodiment, the number of second fastener receiving insert (12C) provided on each foot portion (12FP) is at least two. However, it is also within the scope of this invention to provide any number of second fastener receiving insert (12C) on each foot portion (12FP) of the first battery casing (12) without otherwise deterring the intended function of the second fastener receiving insert (12C) as can be deduced from the description and corresponding drawings. Each second fastener receiving insert (12C) is provided inwards of corresponding each first fastener receiving insert (12B) of the first battery casing (12).
[0045] In an embodiment, the first battery casing (12) defines a plurality of third fastener receiving inserts (12D), as shown in fig. 2a) adapted to be integrated with the top portion (12TP) of the top wall (12TW) of the first battery casing (12). Each third fastener receiving insert (12D) is adapted to receive corresponding another fastener (not shown) therethrough to facilitate mounting of the battery management unit (not shown) onto the top wall (12TW) of the first battery casing (12).It is also within the scope of this invention to provide each third fastener receiving insert (12D) to receive locking pins or any other locking elements therethrough to facilitate mounting of the battery management unit (not shown) onto the top wall (12TW) of the first battery casing (12). Each third fastener receiving insert (12D) is at least a metal sleeve with internal threads.It is also within the scope of this invention to provide each third fastener receiving insert (12D) to be made of any other material with better strength. Each third fastener receiving insert (12D) provides better stability and durability to the first battery casing (12) while insertion of corresponding fasteners (not shown) there through. In an embodiment, the number of third fastener receiving insert (12D) provided on top portion (12TP) of the top wall (12TW) is at least two. However, it is also within the scope of this invention to provide any number of third fastener receiving inserts (12D) on top portion (12TP) of the top wall (12TW) without otherwise deterring the intended function of the third fastener receiving insert (12D) as can be deduced from the description and corresponding drawings.
[0046] In an embodiment, the first battery casing (12) defines a plurality of fuse holding portions (12E), as shown in fig. 2a) adapted to be integrated with the top portion (12TP) of the top wall (12TW) of the first battery casing (12). Each fuse holding portion (12E) is adapted to receive and hold corresponding each fuse (106). In an embodiment, the first battery casing (12) defines a plurality of cable tie portions (12), as shown in fig. 2a) adapted to be integrated with the top portion (12TP) of top wall (12TW) of the first battery casing (12). Each cable tie portion (12F) is adapted to facilitate tying of the cable (not shown) with the top wall (12TW) of the first battery casing (12) therein to secure the cable with the first battery casing (12).
[0047] In an embodiment, the first battery casing (12) defines a plurality of battery cell terminal receiving portions(12G, as shown in fig. 2a) adapted to be provided on the top portion (12TP) of the top wall (12TW) of the first battery casing (12).Each battery cell terminal receiving portion (12G) is adapted to receive corresponding each battery cell terminal (102P and 102N) of corresponding each battery cell (102). For the purpose of this description and ease of understanding, each battery cell terminal receiving portion (12G) is considered to be an opening.
[0048] In an embodiment, each of the front wall (12FW) and the rear wall (12RW) defines a ventilation portion (12V), as shown in fig. 2a) adapted to ventthe heat air from the battery module (100). Each ventilation portion (12V) is larger than the surface area of corresponding each of the front wall (12FW) and the rear wall (12RW).In an embodiment, the first battery casing (12) defines a plurality of openings (12BV, as shown in fig. 2a and fig. 2b), where each opening (12BV) is adapted to facilitate venting of air from corresponding each battery cells (102).
[0049] The battery cell locators (12A), the first fastener receiving inserts (12B), the second fastener receiving inserts (12C), the third fastener receiving inserts (12D), the fuse holding portions (12E), the cable tie portions (12F), the battery cell terminal receiving portions (12G)and the openings (12BV) are integrated with the first battery casing (12) by molding process. However, it is also within the scope of this invention to integrate the aforementioned elements (12A-12BV) with the first battery casing (12) through any other manufacturing process without otherwise deterring the intended function of the aforementioned elements (12A-12BV) as can be deduced from the description and corresponding drawings.
[0050] Fig. 3a depicts a perspective view of a second battery casing (14), according to embodiments as disclosed herein. Fig. 3b depicts a top view of the second battery casing (14), according to embodiments as disclosed herein. In an embodiment, the second battery casing (14) includes a plurality of side walls (14SL and 14SR), a front wall (14FW), a rear wall (14RW), a top wall (14TW) and a plurality of longitudinal support portions (14LS). The side wall (14L) is parallel and opposite and disposed away with respect to another side wall (14SR). The front wall (14FW) extends between corresponding ends of the side walls (14SL and 14SR), where the front wall (14FW) is parallel and opposite and disposed away with respect to the rear wall (14RW). The rear wall (14RW) extends between corresponding another ends of the side walls (14SL and 14SR), where the rear wall (14RW) is parallel and opposite and disposed away with respect to the front wall (14FW). The top wall (14TW) is provided on top of the side walls (14SL and 14SR), the front wall (14FW) and the rear wall (14RW).The longitudinal support portion (14LS) is adapted to transversely extend froma bottom end of the front wall (14FW) in a direction towards the rear wall (14RW). Another longitudinal support portion (14LS) is adapted to transversely extend from a bottom end of the rear wall (14RW) in a direction towards the front wall (14FW). The longitudinal support portion (14LS) is opposite to other longitudinal support portion (14LS). For the purpose of this description and ease of understanding, the second battery casing (14) is considered to be a bottom battery casing.
[0051] The second battery casing (14) defines a plurality of battery cell locators (14A, as shown in fig. 3a and fig. 3b) adapted to be integrated with the secondbattery casing (14), where the plurality of battery cell locators (14A) are adapted to be transversely integrated with each of the front and rear wall (14FW and 14RW) and corresponding longitudinal support portions (14LS) respectively. The plurality of battery cell locators(14A) are adapted to locate and hold the battery cells(102) in a required position corresponding to the first battery casing (12). In an embodiment, each battery cell locator (14A) is at least one of a rib, a protrusion and a partition. However, it is also within the scope of this invention to integrate grooves or any other holding portions with any of the side walls (14SL and 14SR), the front wall (14FW) and the rear wall (14RW) without otherwise deterring the intended function of the battery cell locators (14A) as can be deduced from the description and corresponding drawings.
[0052] In an embodiment, the second battery casing (14) defines a plurality of first fastener receiving inserts (14B, as shown in fig. 3a) adapted to be integrated with each side wall (14SL and 14SR) of thesecond battery casing (14). Each first fastener receiving insert (14B) is adapted to receive corresponding fastener (110A) therethrough to secure the first battery casing (12) with the second battery casing (14). It is also within the scope of this invention to provide each first fastener receiving insert (14B) to receive locking pins or any other locking elements therethrough to secure the first battery casing (12) with the second battery casing (14). Each first fastener receiving insert (14B) is at least a metal sleeve with internal threads. It is also within the scope of this invention to provide each first fastener receiving inserts (14B) to be made of any other materials with better strength. Each first fastener receiving insert (14B) provides better stability and durability to the second battery casing (14) while insertion of corresponding fasteners (110A) there through. The outer portion of each first fastener receiving insert (14B) is serrated to facilitate molding of each first fastener receiving insert (14B) with corresponding side wall (14SL and 14SR) of the second battery casing (14). In an embodiment, the number of first fastener receiving inserts (14B) provided on each side wall (14SL and 14SR) is at least two. It is also within the scope of this invention to provide any number offirst fastener receiving inserts (14B) provided on each side wall (14SL and 14SR) of the second battery casing (14) without otherwise deterring the intended function of the first fastener receiving inserts (14B) as can be deduced from the description and corresponding drawings.
[0053] In an embodiment, the second battery casing (14) defines a plurality of second fastener receiving inserts (14C, as shown in fig. 3a) adapted to be integrated with each side wall (14SL and 14SR) of the bottom battery casing (14). Each second fastener receiving insert (14C) is adapted to receive another fastener (not shown) therethrough to secure the battery module (100) with the battery enclosure. It is also within the scope of this invention to provide each second fastener receiving insert (14C) to receive locking pins or any other locking elements therethrough to secure the battery module (100) with the battery enclosure (not shown). Each second fastener receiving insert (14C) is at least a metal sleeve.It is also within the scope of this invention to provide each second fastener receiving insert (14C) to be made of any other materials with better strength. In an embodiment, the number of second fastener receiving inserts (14C) provided on each side wall (14SL and 14SR) is at least two. It is also within the scope of this invention to provide any number ofsecond fastener receiving inserts (14C) provided on each side wall (14SL and 14SR) of the bottom battery casing (14) without otherwise deterring the intended function of the second fastener receiving inserts (14C) as can be deduced from the description and corresponding drawings. Each second fastener receiving insert (14C) is provided inwards of corresponding each first fastener receiving insert (14B) of the second battery casing (14).
[0054] In an embodiment, the second battery casing (14) defines at least one holding portion (14H), as shown in fig. 3a) integrated with corresponding each side wall (14SL and 14SR) of the second battery casing (14). Each holding portion (14H) is adapted to be held by user for lifting the battery module (100). For the purpose of this description and ease of understanding, each holding portion (14H) is considered to be at least one of a slot, a cavity, protrusion and a handle. However, it is also within the scope of this invention to provide any other type of holding portion for lifting the battery module (100) without otherwise deterring the intended function of the holding portion (14H) as can be deduced from the description and corresponding drawings. In an embodiment, each of the front wall (14FW) and the rear wall (14RW) defines a ventilation portion (14V), as shown in fig. 3a) adapted to vent the heat air from the battery module (100). In an embodiment, the second battery casing (14) includes a relatively large opening (14X, as shown in fig. 3b) provided at a bottom end of the second battery casing (14) and defined between the side walls (14SL and 14SR), the front wall (14FW) and the rear wall (14RW).The opening (14X) is adapted to facilitate cooling or heating of the battery cells (102). For example, the opening (14X) is adapted to facilitate entry of cool air or hot air from the thermal management unit (108A, as shown in fig. 4a) to the battery cells (102).
[0055] In an embodiment, a reference plane (10R), as shown in fig. 5) of the fastening points of at least one of the battery casing (10) and the battery module (100) is near to a reference plane (100R), as shown in fig. 5) of a center of gravity of the battery module (100). For example, the reference plane (10R) of the fastening points of at least one of the battery casing (10) and the battery module (100) is spaced at a distance of at least 15 mm from the reference plane (100R) of the center of gravity of the battery module (100). It is also within the scope of this invention to space the reference plane (10R) of the fastening points of at least one of the battery casing (10) and the battery module (100) at any distance from the reference plane (100R) of the center of gravity of the battery module (100). In another embodiment, the reference plane (10R) of the fastening points of at least one of the battery casing (10) and the battery module (100) is coplanar to thereference plane (100R) of thecenter of gravity of the battery module (100)thereby providing the battery module (100) with better strength, durability and also reduces vibration.
[0056] The plurality of battery cells locators (14A), the plurality of first fastener receiving inserts (14B), the plurality of second fastener receiving inserts (14C) and the holding portion (14H) are adapted to be integrated with the bottom battery casing (14) bymolding process. However, it is also within the scope of this invention to integrate the aforementioned elements (14A-14C and 14H) with the second battery casing (14) through any other manufacturing process without otherwise deterring the intended function of the aforementioned elements (14A-14C and 14H) as can be deduced from the description and corresponding drawings.
[0057] The plurality of battery cells (102) are collectively called as battery pack. Each battery cell (102) includes a positive terminal (102P), as shown in fig. 5) and a negative terminal (102N),as shown in fig. 5). For the purpose of this description and ease of understanding, each battery cell (102) is considered to be a prismatic lithium ion battery cell.It is also within the scope of this invention to consider each battery cell (102) as any other type of battery cells. Each battery cell (102) is located and held by corresponding battery cell locators (12A and 14A) of the first battery casing (12) and the second battery casing (14).When there is a requirement to change the configuration of battery cells (102), each bus bar (104) is removed from corresponding battery cells (102),the position of terminals (102P and 102N) of corresponding battery cells (102) are changed by changing the orientation of corresponding battery cells (102) and each add-on bus bar (104A), as shown in fig. 6a and fig. 6b)is secured with corresponding terminals of corresponding battery cells (102)by using fasteners (110B). The terminals (102P and 102N) of each battery cell (102) are provided with internal threads therein to facilitate insertion of fasteners (110B) therethrough to secure bus bars (104) or add-on bus bars (104A) with battery cells (102).
[0058] Each bus bar (104) is secured with corresponding terminals of battery cells (102) through corresponding fastener (110B).It is also within the scope of this invention to integrate locking elements with the bus bar (104) for securing the bus bar (104) with corresponding terminals of corresponding battery cells (102). When there is a requirement to change the configuration of battery cells (102), each bus bar (104) isremoved from corresponding battery cells (102),the position of terminals (102P and 102N) of corresponding battery cells (102) are changed by changing the orientation of corresponding battery cells (102) and each add-on bus bar (104A) as shown in fig. 6a and fig. 6b)is secured with terminals of corresponding battery cells (102).A length of each add-on bus bar (104A) is not as same as a length of the removed bus bar (104). The size of each add-on bus bar (104A) varies from the size of the removed bus bar (104) according to the configuration of battery cells (102).
[0059] Each fuse (106) is adapted to be received and held by corresponding fuse holding portion (12E) of the first battery casing (12). Each fuse (106) is provided for corresponding battery cells (102) along a sensing line of the battery module (100). Each fuse (106) is adapted to protect corresponding battery cells (102) in an event of short circuit.
[0060] Fig. 4a depicts a cross-sectional view of the battery module (100) with an air based thermal management unit (108A) provided at a bottom end of the second battery casing (14), according to embodiments as disclosed herein. The thermal management unit (108A and 108B) is adapted to maintain a predetermined temperatureof the battery cells (102) for proper functioning of battery cells (102). The thermal management unit (108A and 108B) is provided below the second battery casing (14) and mounted onto the battery enclosure (not shown). The thermal management unit (108A and 108B) is at least one of an air based thermal management unit (108A) and a liquid based thermalmanagement unit (108B).The thermal management unit (108A and 108B) is provided at the bottom end of the second battery casing (14).In an embodiment, the air based thermal management unit (108) mainly includesan air duct (108AD) and a plurality of air sprayers (108AS). The air duct (108AD) is adapted to provide the cool or heat air to the plurality of air sprayers (108AS) which in turn sprays the cool or heat air to the battery cells (102) in a direction from a bottom end towards a top end of the battery module (100)to maintain the predetermined temperature of the battery cells (102) based on the hot or cold temperature conditions. The air sprayed onto the bottom of battery cells (102) cools orheats the battery cells (102) and the air is vented from the ventilation portion (12V and 14V) of the first and the second battery casing (12 and 14) and the openings (12BV) of the first battery casing (12).
[0061] Fig. 4b depicts a cross-sectional view of the battery module (100) with a liquid based thermal management unit (108B) provided at the bottom end of the second battery casing (14), according to embodiments as disclosed herein. In an embodiment, the liquid based thermal management unit (108B) mainly includes a liquid plate (108BL), a thermal pad (108BP) and a foam (108BF). The thermal pad (108BP) is disposed between the battery cells (102) and the liquid plate (108BL). The thermal pad (108BP) is adapted to ensure effective heat transfer through conduction and convection. The liquid plate (108BL) is not subjected to any load from the battery cells (102) as the battery cells (102) are being supported by the battery enclosure (not shown). The foam (108BF) is disposed between the liquid plate (108BL) and the battery enclosure (not shown).For the purpose of this description and ease of understanding, the battery enclosure (not shown) is considered to be a bottom battery enclosure.The liquid plate (108BL) is adapted to cool or heat the battery cells (102) to maintain the predetermined temperature of battery cells (102). The liquid plate (108BL) includes an inlet (not shown) facilitate entry of cool or heat liquid into the liquid plate (108BL) and an outlet (not shown) adapted to facilitate exit of liquid from the liquid plate (108BL).
[0062] The plurality of fasteners (110A) are adapted to secure the first battery casing (12) with the second battery casing (14). The fasteners (110A) are pre-assembly fasteners which are provided onto the first battery casing (12) prior to the assembly process of the battery module (100). The plurality of another fasteners (not shown) are adapted to secure the battery module(100)with the battery enclosure (not shown). Another fasteners (110B) are adapted to secure each bus bar (104) or each add-on bus bar (104A)with the corresponding terminals of corresponding battery cells (102). In an embodiment, each of fasteners (110A and 110B) is at least a bolt. It is also within the scope of this invention to provide any other threaded element, threaded insert, locking pins or any other locking means or fastening means for securing any of the battery module (100) with the battery enclosure (not shown), the first battery casing (12) with the second battery casing (14) and the bus bars (104) or add-on bus bars (104A) with the terminals of the battery cells (102), without otherwise deterring the intended function of fasteners (110A and 110B) as can be deduced from the description and corresponding drawings.
[0063] Each sensor (112) is adapted to detect atemperature and voltage in corresponding battery cells (102) and provide the information to the battery management unit (not shown). One end (112f) of each sensor (112) is adapted to be connected to corresponding terminal of corresponding battery cells (102) through corresponding bus bar (104) or add-on bus bar (104A) by using fasteners (110B) and another end (112s) of each sensor (112) is adapted to be connected to the battery management unit (not shown).
[0064] The assembly of the battery module (100) is as follows. The second battery casing (14) is placed onto any of a working platform, a working table and a working bed. Thereafter, the battery cells (102) are positioned into the second battery casing (14) through the battery cell locators (14A). Thereafter, the first battery casing (12) is mounted onto the second battery casing (14) in which the battery cells (102) is positioned with the battery cells locators (12A) of the first battery casing (12). Thereafter, the first battery casing (12) is fastened with the second battery casing (14) by using fasteners (110A). Thereafter, the battery module (100) is secured with the battery enclosure (not shown) by using anotherfasteners (not shown). Thereafter, each bus bar (104) or add-on buss bar (104A) and one end of each sensor (112) is fastened with corresponding terminals of corresponding battery cells (102) by using another fasteners (110B) based on configuration of battery cells (102).Thereafter, another end of each sensor (112) is connected to the battery management unit (not shown). The battery management unit (not shown) is fastened onto the top wall (12TW) of the first battery casing (12) through the third fastener receiving inserts (12D) by using fasteners (not shown). Thereafter, the top cover (not shown) is mounted on to the first battery casing (12).
[0065] Fig. 6a depicts a perspective view of the battery module (100) with a 1P-12S battery cell configuration,according to embodiments as disclosed herein. Each bus bar (104), as shown in fig. 1) is removed from corresponding battery cells (102). The position of terminals of corresponding battery cells (102) are changed by changing the orientation of corresponding battery cells (102) with respect to the battery cell locators (104A) of the second battery casing (104) and each add-on bus bars (104A, as shown in fig. 6a) is fastened with corresponding terminals of corresponding battery cells (102) therein to change the 3P-4S battery cell configuration (as shown in fig. 1) to 1P-12S battery cell configuration (as shown in fig. 6a).
[0066] Fig. 6b depicts a perspective view of the battery module (100) with a 2P-6S battery cell configuration,according to embodiments as disclosed herein. Each bus bar (104), as shown in fig. 1) is removed from corresponding battery cells (102). The position of terminals of corresponding battery cells (102) are changed by changing the orientation of corresponding battery cells (102) with respect to the battery cell locators (104A) of the second battery casing (104) and each add-on bus bar (104A, as shown in fig. 6b) is fastened with corresponding terminals of corresponding battery cells (102) to change the 3P-4S battery cell configuration (as shown in fig. 1) to 2P-6S battery cell configuration (as shown in fig. 6a).
[0067] Fig. 7a depicts a perspective view of another battery module (300) with a 1P-8S battery cell configuration, according to embodiments as disclosed herein. The number of battery cells (302) in the battery module (300) is 8. The length of the battery casing (30) is half a length of the battery casing (10) of the battery module (100). Fig. 7b depicts a perspective view of another battery module (400) with a 1P-4S battery cell configuration, according to embodiments as disclosed herein. The number of battery cells (302) in the battery module (400) is 4. The length of the battery casing (40) is half the length of the battery casing (30) of the battery module (300). The battery casing (10, 30 and 40) are manufactured using a same family tool by changing the length of the battery casing according to number of battery cells.
[0068] Fig. 8 depicts a table indicating various configurations of battery cells, according to embodiments as disclosed herein. The battery module (100) incudes 1P-12S, 2P-6S, 3P-4S and 4P-3S battery cell configurations. The battery module (300) includes 1P-8S, 2P-4S and 4P-2S battery cell configurations. The battery module (400) includes 1P-4S, 2P-4S and 4P-1S battery cell configurations. The battery module with 16 battery cells, includes 1P-16S, 2P-8S and 4P-4S battery cell configurations.
[0069] Fig. 9 depict a flowchart indicating a method (200) of changing configuration of battery cells (102) in the battery module (100), according to embodiments as disclosed herein. For the purpose of this description and ease of understanding, the method (200) is explained herein below with reference to changing configuration of battery cells (102) in the battery module (100) to be used in any of an electric vehicle and a hybrid vehicle. However, it is also within the scope of this invention to practice/implement the entire steps of the method (200)in a same manner or in a different manner or with omission of at least one step to the method (200) or with any addition of at least one step to the method (200)for changing configuration of battery cells (102) in the battery module (100) to be used in any of electric vehicles, hybrid vehicles, industrial applications, power systems and any other applications, without otherwise deterring the intended function of the method (200) as can be deduced from the description and corresponding drawings. In an embodiment, the method (200) includes, removing each bus bar (104) from correspondingbattery cells (102) by removing fasteners (110B) from each bus bar (104) and corresponding terminal of correspondingbattery cells (102), step 202; changing a position of terminals (102P and 102N) of corresponding battery cells (102), step 204; and engaging each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) by fastening each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) through fasteners (110B) therein to change the configuration of battery cells (102), step (206). The method step (202) of removing each bus bar (104) from correspondingbattery cells (102) by removing fasteners (110B) from each bus bar (104) and corresponding terminal of corresponding battery cells (102) includes, removing each sensor (112) from corresponding terminal of corresponding battery cells (102) during removal offasteners (110B) from correspondingeach bus bar (104) and corresponding terminal of corresponding battery cells (102). The method step (204) of changing a position of terminals (102P and 102N) of corresponding battery cells (102) includes, removing corresponding battery cells (102) from corresponding battery cell locators (14A) of a battery casing (14) and changing the orientation of corresponding battery cells (102) with respect to the battery casing (14) therein to change the position of terminals (102P and 102N) of corresponding battery cells (102) and re-inserting corresponding battery cells (102) into the corresponding battery cell locators (14A) of the battery casing (14), step (204A).
[0070] Further, the method (200) includes removing a first battery casing (12) from a second battery casing (14) by removing fasteners from the first and second battery casing (12 and 14) prior to method step (204A) of removing corresponding battery cells (102) from corresponding battery cell locators (14A) of the battery casing (14) and changing the orientation of corresponding battery cells (102) with respect to the battery casing (14) therein to change the position of terminals (102P and 102N) of corresponding battery cells (102) and re-inserting corresponding battery cells (102) into the corresponding battery cell locators (14A) of the battery casing (14).
[0071] The method (200) includes securing the first battery casing (12) with the second battery casing (14) by fastening the first battery casing (12) with the second battery casing (14) through fasteners, step (205) after method step (204) of changing a position of terminals (102P and 102N) of corresponding battery cells (102).
[0072] The method step (206) of engaging each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) by fastening each add-on bus bar (104A) with corresponding terminal of corresponding battery cells (102) through fasteners (110B) therein to change the configuration of battery cells (102) includes,connecting each sensor (112) with corresponding terminal of corresponding battery cell (102) during fastening of fasteners (110B) with corresponding each add-on bus bar (104A) and corresponding terminal of corresponding battery cells (102).
[0073] Further, the method (200) includes removing a top cover from a first battery casing (12) and removing a battery management unit from corresponding fastener receiving inserts (12D) of the first battery casing (12) by removing the fasteners from the battery management unit and the fastener receiving inserts (12D), step (201) prior to method step (202) of removing each bus bar (104) from corresponding battery cells (102) by removing fasteners (110B) from corresponding each bus bar (104) and corresponding terminal of corresponding battery cells (102), wherein another end of each sensor (112) is dis-connected from the battery management unit during removal of battery management unit from the first battery casing (12).
[0074] The foregoing description of the specific embodiments will so fully reveal 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 embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.