Claims:1. A horizontal battery module (100) comprising:
a plurality of bus bars (104), where each of said bus bar (104) is adapted to be removably connected to corresponding terminal of corresponding battery cells (102); and
a battery casing (10) comprising a plurality of horizontal battery cassettes (12), each of said horizontal battery cassette (12) is adapted to hold corresponding battery cells (102) in a horizontal position,
wherein
said battery module (100) is adapted to be configured to have more than one battery cell configuration.

2. The battery module (100) as claimed in claim 1, wherein said battery module (100) is adapted to be configured to have more than one battery cell configuration by,
removing said bus bars (104);
at least one of adding at least one horizontal battery cassette (12) with corresponding battery cells (102) loaded thereon, and removing at least one horizontal battery cassette (12);
at least one of changing and not changing a position of terminals of corresponding battery cells (102); and
securing each add-on bar (104A) with corresponding terminal of corresponding battery cells (102) thereby changing the battery cell configuration in said battery module (100).

3. The battery module (100) as claimed in claim 1, wherein said battery module (100) is adapted to be configured to have more than one battery cell configuration by,
removing said bus bars (104);
changing a position of terminals of corresponding battery cells (102); and
securing each add-on bar (104A) with corresponding terminal of corresponding battery cells (102) thereby changing the battery cell configuration in said battery module (100).

4. The battery module (100) as claimed in claim 1, wherein said battery casing (10) comprises,
a top reinforcement member (16) adapted to reinforce said battery casing (10);
a bottom reinforcement member (18) adapted to reinforce said battery casing (10); and
a top cover (14) adapted to isolate corresponding battery cells (102) from said top reinforcement member (16),
wherein
said bottom reinforcement member (18) is adapted to be provided immediately below corresponding said horizontal battery cassette (12) to support said horizontal battery cassettes (12);
said top reinforcement member (16) is provided on said top cover (14); and
at least one of said top cover (14) and said top reinforcement member (16) includes a plurality of fastener receiving inserts adapted to facilitate mounting of a battery management unit

5. The battery module (100) as claimed in claim 4, 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 battery cell (102) and provides the information to the battery management unit; and
a plurality of fuses (106), where each of said fuse (106) is adapted to be connected to corresponding said battery cells (102) to protect corresponding said battery cells (102) in an event of short circuit.

6. The battery module (100) as claimed in claim 1, wherein said battery module (100) comprises at least one thermal management unit (108A , 108B) adapted to be provided in between two separate battery modules (100, 100A),
wherein
said thermal management unit (108A, 108B) is at least one of an air based thermal management unit (108A) and a liquid based thermal management unit (108B); and
said thermal management unit (108A, 108B) is adjacent to a bottom surface (102BP) of battery cells (102) of said battery modules (100, 100A), where said battery module (100) is opposite to another battery module (100A).

7. The battery module (100) as claimed in claim 5, wherein said top cover (14) includes,
a plurality of fuse holding portions (14F) adapted to be integrated with said top cover (14), where each of said fuse holding portion (14F) is adapted to hold corresponding said fuse (106);
a plurality of sensor connector holding portions (14C) adapted to be integrated with said top cover (14), where each of said sensor connector holding portion (14C) is adapted to hold a connector (112C) of corresponding each of said sensor (112); and
a plurality of interconnecting bus bar locating portions (14B) adapted to be integrated with said top cover (14), where said at least one interconnecting bus bar locating portion (14B) is adapted to accommodate at least a portion of corresponding at least one interconnecting bus bar (105) therein to isolate at least one interconnecting bus bar (105) from said top reinforcement member (16).

8. The battery module (100) as claimed in claim 5, wherein at least one of said horizontal battery cassette (12) includes,
a base (12B) adapted to support corresponding battery cells (102);
a plurality of side walls (12SW);
at least one battery cell locator (12L) adapted for locating and holding corresponding said battery cells (102);
a plurality of battery cell stoppers (12S), each of said battery cell stopper (12S) is adapted to restrict a movement of corresponding said battery cells (102) beyond a predetermined position;
a plurality of fuse holding portions (12F) adapted to be integrated with said horizontal battery cassette (12), where each of said fuse holding portion (12F) is adapted to hold corresponding said fuse (106); and
a plurality of sensor connector holding portions adapted to be integrated with said horizontal battery cassette (12), where each of said sensor connector holding portion is adapted to hold a connector (112C) of corresponding each of said sensor (112),
wherein
each of said horizontal battery cassette (12) is adapted to transfer a load of corresponding battery cells (102) to corresponding said at least one horizontal battery cassette (12) through corresponding each of side walls (12SW), battery cell locators (12L) and battery cell stoppers (12S).

9. A method (700) of changing a configuration of battery cells (102) in a horizontal battery module (100), said method (700) comprising:
removing each bus bar (104) from corresponding terminal of corresponding battery cells (102);
changing a position of terminals of corresponding battery cells (102); and
securing each add-on bar (104A) with corresponding terminal of corresponding battery cells (102) thereby changing the battery cell configuration in the battery module (100).

10. The method (700) as claimed in claim 9, wherein said method (700) comprises,
removing a thermal management unit (108A or 108B) from a top reinforcement member (16) and a bottom reinforcement member (18) of the battery casing (10);
removing each interconnecting bus bar (105) from corresponding terminal of corresponding battery cells (102); and
removing a top cover (14) from corresponding horizontal battery cassette (12) of a battery casing (10).

11. A method (800) of changing a configuration of battery cells (102) in a horizontal battery module (100), said method (800) comprising:
removing each bus bar (104) from corresponding terminal of corresponding battery cells (102);
at least one of adding at least one horizontal battery cassette (12) with corresponding battery cells (102) loaded thereon, and removing at least one horizontal battery cassette (12);
at least one of changing and not changing a position of terminals of corresponding battery cells (102); and
securing each add-on bar (104A) with corresponding terminal of corresponding battery cells (102) thereby changing the battery cell configuration in the battery module (100).
, Description:TECHNICAL FIELD
[001] The embodiments herein generally relate to a battery system and more particularly, to a horizontal battery module and methods of changing configuration of battery cells in the horizontal battery module. Further, embodiments herein relate to a horizontal 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 housing a 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 a battery casing with another one or more battery casings to secure the battery cells provided therein. However, such metallic battery casings increase an overall weight of the battery module. Battery casings which are made 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 cells within the battery casings is difficult and cumbersome. Some plastic battery casings use more child parts such as side metal plates and long studs for securing the battery cells within 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. Some batteries 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 pack 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 in 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] Further, each battery module requires a dedicated separate thermal management unit for maintaining predetermined temperate of battery cells. Providing dedicated separate thermal management unit incurs high cost and employs separate inlet and outlet connections for the thermal management units and requires longer pipes and consumes more packaging space and is subjected to more number of failure modes. Further, the assembly of the battery modules is complex, cumbersome and a time consuming process. Providing a common thermal management unit for two battery modules is complex in design and is difficult and is one of the challenges posed to the original equipment manufacturers (OEM’S).
[006] 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 cells in the same single battery module is complex in design and is difficult and is one of the challenges posed to the original equipment manufacturers (OEM’s).
[007] Further, providing battery modules in the vehicle where height and space requirement to accommodate the battery modules is less, is complex in design and is difficult and is one of the challenges posed to the original equipment manufacturers (OEM’s).
[008] Therefore, there exists a need for a horizontal battery module and methods of changing configuration of battery cells in the horizontal battery module, which obviates the aforementioned drawbacks. Further, there exists a need for a horizontal battery casing, which obviates the aforementioned drawbacks

OBJECTS
[009] The principal object of embodiments herein is to provide a horizontal battery module.
[0010] Another object of embodiments herein is to provide methods of changing configuration of battery cells in a horizontal battery module.
[0011] Another object of embodiments herein is to provide a horizontal battery casing.
[0012] Another object of embodiments herein is to provide a common thermal management unit for maintaining predetermined temperature of battery cells provided in two separate battery modules.

[0013] Another object of embodiments herein is to provide a single modular horizontal battery module, which accommodates various configurations of battery cells in the single battery module.
[0014] Another object of embodiments herein is to provide a horizontal battery module, which is scalable.
[0015] Another object of embodiments herein is to provide horizontal 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.
[0016] Another object of embodiments herein is to provide a horizontal battery module, which has prolonged life and improved performance.
[0017] Another object of embodiments herein is to provide a horizontal battery module, which has a thermal management unit provided adjacent to a bottom surface of battery cells and is vertically mounted on a battery casing.
[0018] Another object of embodiments herein is to provide a horizontal battery module, which has effective thermal management of battery cells to achieve prolonged battery life.
[0019] Another object of embodiments herein is to provide a horizontal battery module, which has dedicated fuses for battery cells along a sensing line of the battery module.
[0020] Another object of embodiments herein is to provide a light weight horizontal battery casing, which is durable and provides better stability while insertion of fasteners and has better noise, vibration and harness (NVH) characteristics.
[0021] Another object of embodiments herein is to provide a horizontal battery module, which supports air or liquid based thermal management unit adapted to facilitate uniform cooling or heating of battery cells.
[0022] Another object of embodiments herein is to provide a horizontal battery module, which is easy to assemble.
[0023] Another object of embodiments herein is to provide a horizontal battery module, which has better Eigen frequency which is above road induced vibration (ISO 12405 Random vibration profile).
[0024] Another object of embodiments herein is to provide a horizontal battery module, which has optimized structural design.
[0025] These and other objects of embodiments herein 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
[0026] 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:
[0027] Fig. 1 depicts a perspective view of a horizontal battery module with 3P-4S battery cells configuration, according to embodiments as disclosed herein;
[0028] Fig. 2a depicts a perspective view of a horizontal battery cassette of a horizontal battery casing, according to another embodiments as disclosed herein;
[0029] Fig. 2b depicts a top view of the horizontal battery cassette, according to embodiments as disclosed herein;
[0030] Fig. 3a depicts a perspective view of a top cover of the battery casing, according to embodiments as disclosed herein;
[0031] Fig. 3b depicts a top view of the top cover, according to embodiments as disclosed herein;
[0032] Fig. 4a depicts a perspective view of a top reinforcement member of the battery casing, according to embodiments as disclosed herein;
[0033] Fig. 4b depicts a bottom view of the top reinforcement member, according to embodiments as disclosed herein;
[0034] Fig. 5a depicts a perspective view of a bottom reinforcement member of the battery casing, according to embodiments as disclosed herein;
[0035] Fig. 5b depicts a bottom view of the bottom reinforcement member, according to embodiments as disclosed herein;
[0036] Fig. 6a depicts a cross-sectional view of the horizontal battery module with an air based thermal management unit, according to embodiments as disclosed herein;
[0037] Fig. 6b depicts a cross-sectional view of the horizontal battery module with a liquid based thermal management unit, according to embodiments as disclosed herein;
[0038] Fig. 7a depicts a side view of the horizontal battery module with 1P-12S battery cells configuration, according to embodiments as disclosed herein;
[0039] Fig. 7b depicts a side view of the horizontal battery module with 1P-16S battery cells configuration, according to embodiments as disclosed herein;
[0040] Fig. 8a depicts a perspective view of another horizontal battery module with 1P-6S battery cells configuration, according to another embodiments as disclosed herein;
[0041] Fig. 8b depicts a perspective view of a horizontal battery cassette of the horizontal battery module with 1P-6S battery cells configuration; according to another embodiments as disclosed herein;
[0042] Fig. 9a depicts a perspective view of another horizontal battery module with 2P-4S battery cells configuration, according to another embodiments as disclosed herein;
[0043] Fig. 9b depicts a front view of another battery module with 1P-16S battery cells configuration, according to another embodiments as disclosed herein;
[0044] Fig. 10a depicts a perspective view of another horizontal battery module with 3P-3S battery cells configuration, according to another embodiments as disclosed herein;
[0045] Fig. 10b depicts a perspective view of a horizontal battery cassette of the battery module with 3P-3S battery cells configuration; according to another embodiments as disclosed herein;
[0046] Fig. 11 depicts a perspective view of a horizontal battery cassette, according to another embodiments as disclosed herein;
[0047] Fig. 12a depicts a perspective view of the horizontal battery module with thermal management unit mounted thereon, where the battery module is adapted to be mounted onto a battery enclosure, according to embodiments as disclosed herein;
[0048] Fig. 12b depicts a perspective view of another horizontal battery module without thermal management unit, where the battery cells of another battery module is adapted to be provided in contact the thermal management unit of the horizontal battery module which is mounted on the battery enclosure, according to embodiment as disclosed herein;
[0049] Fig. 13 depicts a flowchart indicating a method of changing configuration of battery cells in the horizontal battery module, according to embodiments as disclosed herein; and
[0050] Fig. 14 depicts a flowchart indicating a method of changing configuration of battery cells in the horizontal battery module, according to another embodiment as disclosed herein.

DETAILED DESCRIPTION
[0051] 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.
[0052] The embodiments herein achieve a horizontal battery module. Further, embodiments herein achieve methods of changing configuration of battery cells in the horizontal battery module. Further, embodiments herein achieve a single modular horizontal battery module, which accommodates various configurations of battery cells in the single horizontal battery module. Furthermore, embodiments herein achieve a horizontal battery casing. Further, embodiments herein achieve a common air or liquid based thermal management unit for cooling or heating battery cells provided in two separate battery modules thereby maintaining predetermined temperature of battery cells. Referring now to the drawings Figs 1 through 14, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0053] Fig. 1 depicts a perspective view of a horizontal battery module (100) with 3P-4S battery cells configuration, according to embodiments as disclosed herein. In an embodiment, the horizontal battery module (100), hereinafter referred to as battery module) includes a horizontal battery casing (10), hereinafter referred to as battery casing), a plurality of battery cells (102), a plurality of bus bars (104), a plurality of add-on bus bars (104A), as shown in fig. 7a and fig. 7b), a plurality of interconnecting bus bars (105), a plurality of fuses (106), at least one thermal management unit (108A and 108B), as shown in fig. 7a and fig. 7b), a plurality of fasteners (110A, 110B1, 110B2 and 110C), as shown in fig. 1 and fig. 6b), a plurality of sensors (112) and a plurality of brackets (114). In an embodiment, the battery casing (10) includes a plurality of horizontal battery cassettes (12), a top cover (14), a top reinforcement member (16) and a bottom reinforcement member (18), as shown in fig. 5a and fig. 5b). 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 banks, power systems and any other applications, without otherwise deterring the intended function of the battery module (100) as can be deduced from the description and corresponding drawings. In one embodiment, a battery management unit (not shown) is mounted onto the battery module (100). In another embodiment, the battery management unit (not shown) is disposed away from the battery module (100).
[0054] Fig. 2a depicts a perspective view of a horizontal battery cassette (12) of the battery casing (10), according to another embodiments as disclosed herein. Fig. 2b depicts a top view of the horizontal battery cassette (12), according to embodiments as disclosed herein. Each horizontal battery cassette (12) is adapted to hold corresponding battery cells (102) in a horizontal position. In an embodiment, each horizontal battery cassette (12) includes a base (12B), a plurality of side walls (12SW), a plurality of battery cell locators (12L), a plurality of battery cell stoppers (12S) and a plurality of embossing portions (12R). The base (12B) of each horizontal battery cassette (12) is adapted to support corresponding battery cells (102). Each side wall (12SW) of each horizontal battery cassette (12) defines a plurality of fastener receiving portions (12SF), where each fastener receiving portion (12SF) is adapted to receive corresponding each fastener (110A) therethrough to secure each horizontal battery cassette (12) with corresponding another horizontal battery cassette (12) thereby securing the battery cells (102) within the battery casing (10). For the purpose of this description and ease of understanding, each fastener receiving portion (12SF) is considered to be an opening. Each side wall (12SW) of each horizontal battery cassette (12) defines a plurality of another fastener receiving portions (12SE), where each another fastener receiving portion (12SE) is adapted to receive corresponding another fastener (not shown) therethrough to secure the battery module (100) with the battery enclosure (B), as shown in fig. 12a and fig. 12b). For the purpose of this description and scope of understanding, each another fastener receiving portion (12SE) is considered to be at least an oblong opening. Each side wall (12SW) of each horizontal battery cassette (12) is parallel and opposite and disposed away with respect to another side wall (12W). The battery cell locator (12L) of each horizontal battery cassette (12) is adapted to be transversely integrated on the base (12B). The battery cell locator (12L) of each horizontal battery cassette (12) is adapted for locating and holding corresponding battery cells (102) in a desired position. The battery cell locator (12L) of each horizontal battery cassette (12) is adapted to separate corresponding battery cell (102) from corresponding another at least one battery cell (102) and to transfer a load of the battery cells (102) to corresponding horizontal battery cassettes (12) stacked below thereof. In an embodiment, each battery cell locator (12L) is at least one of a rib, a protrusion and a partition. Each battery cell stopper (12S) of each horizontal battery cassette (12) is adapted to restrict a movement of corresponding battery cells (102) beyond a predetermined position. Each battery cell stopper (12S) is adapted to transfer the load of battery cells (102) to corresponding horizontal battery cassettes (12) stacked thereof. The embossing portions (12R) of each horizontal battery cassette (12) is adapted to be integrated on the base (12B) to reinforce to horizontal battery cassette (12). The embossing portion (12R) of each horizontal battery cassette (12) is adapted to provide frictional engagement of the corresponding battery cells (102) with the horizontal battery cassettes (12). Each horizontal battery cassette (12) is made of non-metallic material. For example, each horizontal battery cassette (12) is made of plastic. However, it is also within the scope of this invention to provide each battery cassette (12) to be made of any other material without otherwise deterring the intended function of the horizontal battery cassettes (12) as can be deduced from the description and corresponding drawings. In an embodiment, each horizontal battery cassette (12) includes a plurality of fuse holding portions (12F) adapted to be integrated with the horizontal battery cassette (12), where each fuse holding portion (12F) is adapted to hold corresponding fuse (106). Each horizontal battery cassette (12) includes a plurality of sensor connector holding portions (not shown) adapted to be integrated with the horizontal battery cassette (12), where each sensor connector holding portion is adapted to hold a connector (112C) of corresponding each sensor (112). Each horizontal battery cassette (12) is adapted to transfer a load of corresponding battery cells (102) to corresponding at least one horizontal battery cassette (12) through corresponding each of side walls (12SW), battery cell locators (12L) and battery cell stoppers (12S).
[0055] Fig. 3a depicts a perspective view of a top cover (14) of the battery casing (10), according to embodiments as disclosed herein. Fig. 3b depicts a bottom view of the top cover (14), according to embodiments as disclosed herein. The top cover (14) is adapted to insulate the battery cells (102) from the top reinforcement member (16). The top cover (14) is adapted to isolate at least one interconnecting bus bar (105) from the top reinforcement member (16). The top cover (14) is adapted to hold fuses (106) and connectors (112C) of sensors (112). In an embodiment, top cover (14) includes a plurality of interconnecting bus bar locating portions (14B) adapted to be integrated with a top portion (12TP) of the top cover (14). At least one interconnecting bus bar locating portion (14B) of the top cover (14) is adapted to accommodate at least a portion of corresponding at least one interconnecting bus bar (105) therein to isolate at least one interconnecting bus bar (105) from the top reinforcement member (16). Each interconnecting bus bar locating portion (14B) is provided substantially in a L shaped channel. In another embodiment, each interconnecting bus bar locating portion (14B) is at least a partition. However, it is also within the scope of the invention to provide interconnecting bus bar locating portion (14B) in any other shape and size corresponding to the shape and size of the interconnecting bus bar (105). For the purpose of this description and ease of understanding, each interconnecting bus bar locating portion (14B) is considered to be any of a channel and protrusions spaced away from each other. However, it is also within the scope of the invention to provide each interconnecting bus bar locating portion (14B) in form of any of grooves and slots without otherwise deterring the intended function of the interconnecting bus bar locating portions (14B) as can be deduced from the description and corresponding drawings. In an embodiment, the top cover (14) includes a plurality of fuse holding portions (14F) adapted to be integrated onto the top portion (12TP) of the top cover (14). Each fuse holding portion (14F) of the top cover (14) is adapted to hold corresponding fuse (106). For the purpose of this description and ease of understanding, each fuse holding portion (14F) is considered to be a pair of L-shaped arms provided on the top portion (14TP) of the top cover (14), where each L-shaped arm is parallel and spaced away from the other L-shaped arm. However, it is also within the scope of the invention to provide the top cover (14) with any of channels, grooves, protrusions and slots to hold fuses (106) without otherwise deterring the intended function of the fuse holding portion (14F) as can be deduced from the description and corresponding drawings. In an embodiment, the top cover (14) includes a plurality of sensor connector holding portions (14C) adapted to be integrated on the top portion (14TP) of the top cover (14). Each sensor connector holding portion (14C) is adapted to hold the connector (112C) of corresponding each sensor (112). For the purpose of this description and ease of understanding, each sensor connector holding portion (14C) is considered to a pair of L-shaped arms provided on the top portion (14TP) of the top cover (14), where each L-shaped arm is opposite and spaced away from the other L-shaped arm. However, it is also within the scope of the invention to provide the top cover (14) with any of channels, grooves, protrusions and slots to hold sensors (112). The top cover (14) includes a plurality of fastener receiving portions (14FA), where each fastener receiving portion (14FA) is adapted to receive corresponding each fastener (110A) therethrough to secure the bottom reinforcement member (18) with top reinforcement member (16) thereby securing the battery cells (102) within the battery casing (10). For the purpose of this description and ease of understanding, each fastener receiving portion (14FA) of the top cover (14) is considered to be an opening. In an embodiment, the top cover (14) defines a plurality of another fastener receiving portions (14FB), where each another fastener receiving portion (14FB) is adapted to receive corresponding another fastener (not shown) therethrough to secure the battery module (100) with the battery enclosure (B). For the purpose of this description and ease of understanding, each another fastener receiving portion (14FB) of the top cover (14) is considered to be at least an oblong opening. In an embodiment, the top cover (14) defines a plurality of embossing portions (14R) adapted to be integrated with a bottom portion (14BP) of the top cover (14). The embossing portions (14R) are adapted to reinforce the top cover (14). The top cover (14) is made of non-metallic material. For example, the top cover (14) is made of plastic. However, it is also within the scope of this invention to provide the top cover (14) to be made of any other material without otherwise deterring the intended function of the top cover (14) as can be deduced from the description and corresponding drawings. In an embodiment, the top cover (14) includes a plurality of fastener receiving inserts (not shown) adapted to facilitate mounting of the battery management unit (not shown).
[0056] Fig. 4a depicts a perspective view of a top reinforcement member (16) of the battery casing (10), according to embodiments as disclosed herein. Fig. 4b depicts a bottom view of the top reinforcement member (16), according to embodiments as disclosed herein. The top reinforcement member (16) is adapted to reinforce the battery casing (10). The top reinforcement member (16) is adapted to facilitate mounting of the thermal management unit (108A and 108B) with the battery casing (10). The top reinforcement member (16) is adapted to facilitate mounting of the brackets (114). The top reinforcement member (16) includes a base (16B), a plurality of embossing portions (16R) and a portion (16M) transversely extending from one side of the base (16B). The base (16B) of top reinforcement member (16) defines a plurality of fastener receiving portions (16BF), where each fastener receiving portion (16BF) is adapted to receive corresponding each fastener (110A) therethrough to secure the top reinforcement member (16) with the bottom reinforcement member (18) thereby securing the battery cells (102) within the battery casing (10). For the purpose of this description and ease of understanding, each fastener receiving portion (16BF) of the base (16B) is considered to be an opening. The base (16B) of top reinforcement member (16) defines at least one another fastener receiving portion (16BE) adapted to receive corresponding another fastener (not shown) therethrough to secure the battery module (100) with the battery enclosure (B). For the purpose of this description and ease of understanding, another fastener receiving portion (16BE) of the base (16B) is considered to be at least an oblong opening. The plurality of embossing portions (16R) is integrated on a top portion (16TP) of the base (16B) to reinforce the top reinforcement member (16). The base (16B) of the top reinforcement member (16) defines a plurality of openings (16BP) adapted to provide access to the connectors (112C) of the sensors (112) and to reduce the weight of the top reinforcement member (16). The plurality of embossing portions (16R) is integrated on the top portion (16BP) of the base (16B) to reinforce the top reinforcement member (16). In an embodiment, the portion (16M) of the top reinforcement member (16) is adapted to facilitate mounting of the thermal management member (108A or 108B). The portion (16M) of the top reinforcement member (16) defines a plurality of another fastener receiving portion (not shown), where each another fastener receiving portion (not shown) is considered to be an opening which receives corresponding another fastener (110C) therethrough to secure the thermal management unit (108A or 108B) with the top reinforcement member (16) thereby mounting the thermal management unit (108A or 108B) on the battery casing (10). The top reinforcement member (16) is made of metallic material. However, it is also within the scope of the invention to provide the top reinforcement member (16) to be made of any other material without otherwise deterring the intended function of the top reinforcement member (16) as can be deduced from the description and corresponding drawings. In an embodiment, the top reinforcement member (16) includes a plurality of fastener receiving inserts (not shown) adapted to facilitate mounting of the battery management unit (not shown).
[0057] Fig. 5a depicts a perspective view of a bottom reinforcement member (18) of the battery casing (10), according to embodiments as disclosed herein. Fig. 5b depicts a bottom view of the bottom reinforcement member (18), according to embodiments as disclosed herein. The bottom reinforcement member (18) is adapted to reinforce the battery casing (10). The bottom reinforcement member (18) is adapted to facilitate mounting of the thermal management unit (108A or 108B) with the battery casing (10). The bottom reinforcement member (18) includes a base (18B), a plurality of embossing portions (18R) and a portion (18P) transversely extending from one side of the base (18B). The base (18B) defines a plurality of fastener receiving portions (18BF), where each fastener receiving portion (18BF) is adapted to receive corresponding each fastener (110A) therethrough to secure the bottom reinforcement member (18) with the top reinforcement member (16) thereby securing the battery cells (102) within the battery casing (10). For the purpose of this description and ease of understanding, each fastener receiving portion (18BF) of the base (18B) is considered to be an opening. The base (18B) defines a plurality of another fastener receiving portions (18BE), where each fastener receiving portion (18BE) is adapted to receive corresponding another fastener (not shown) therethrough to secure the battery module (100) with the battery enclosure (B). For the purpose of this description and ease of understanding, each another fastener receiving portion (18BE) of the base (18B) is considered to be at least an oblong opening. The plurality of embossing portions (18R) is integrated on a bottom portion (18BP) of the base (18B) to reinforce the bottom reinforcement member (18). The base (18B) of the bottom reinforcement member (18) defines a plurality of openings (18BQ) adapted to reduce the weight of the bottom reinforcement member (18). In an embodiment, the portion (18P) of the bottom reinforcement member (18) is adapted to facilitate mounting of the thermal management member (108A or 108B) with the battery casing (10). The portion (18P) of the bottom reinforcement member (18) defines a plurality of another fastener receiving portions (not shown), where each another fastener receiving portion (not shown) is considered to be opening which receives corresponding another fastener (110C) therethrough to secure the thermal management unit (108A and 108B) with the bottom reinforcement member (18) to facilitate mounting of the thermal management unit (108A and 108B) onto the battery casing (10). The bottom reinforcement member (18) is made of metallic material. However, it is also within the scope of the invention to provide the bottom reinforcement member (18) to be made of any other material without otherwise deterring the intended function of the bottom reinforcement member (18) as can be deduced from the description and corresponding drawings.
[0058] The plurality of battery cells (102) are collectively called as battery pack. Each battery cell (102) includes a positive terminal (not shown) and a negative terminal (not shown). For the purpose of this description and ease of understanding, each battery cell (102) is considered to be a prismatic lithium ion battery cell. However, it is also within the scope of the invention to consider each battery cell (102) as any other type of battery cells, without otherwise deterring the intended function of the battery cells (102) as can be deduced from the description and corresponding drawings. Each battery cell (102) is placed on corresponding horizontal battery cassette (12) in a horizontal position. Each battery cell (102) is located and held by corresponding at least one battery cell locator (12L) of corresponding each horizontal battery cassette (12). Each battery cell (102) is horizontally placed on the base (12B) of corresponding each horizontal battery cassette (12). When there is a requirement to change the configuration of battery cells (102), each bus bar (104) is removed from corresponding battery cells (102) and at least one of adding and removing at least one horizontal battery cell cassette (102) and at least one of changing and not changing a position of terminals of corresponding battery cells (102) and each add-on bus bar (104A), as shown in fig.7a and fig. 7b) is secured with corresponding terminals of corresponding battery cells (102) by using fasteners (110B1). The terminals (not shown) of each battery cell (102) are provided with internal threads therein to facilitate insertion of fasteners (110B1) therethrough to secure bus bars (104) or add-on bus bars (not shown) with battery cells (102) based on the configuration of battery cells (102).
[0059] Each bus bar (104) or each add-on bus bar (104A) is secured with corresponding terminals of battery cells (102) through corresponding fastener (110B1) based on the configuration of battery cells (102). It is also within the scope of this invention to integrate locking elements with the bus bar (104) and the add-on bus bar (104A) for securing the bus bar (104) or the add-on bus bar (104A) with corresponding terminals of corresponding battery cells (102) based on the configuration of battery cells (102). When there is a requirement to change the configuration of battery cells (102), each bus bar (104) is removed from corresponding battery cells (102) and at least one of adding and removing at least one horizontal battery cell cassette (102) and at least one of changing and not changing a position of terminals of corresponding battery cells (102) and each add-on bus bar (104A), as shown in fig. 7a and fig. 7b) is secured with corresponding 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 shape and size of each add-on bus bar (104A) varies from at least one of shape and size of the removed bus bar (104) based on the configuration of battery cells (102).
[0060] The plurality of interconnecting bus bars (105) are adapted to connect the battery cells (102) of the battery module (100) with another battery cells (not shown) provided in corresponding another battery modules (not shown). For example, one interconnecting bus bar (105) is adapted to connect the positive terminals (not shown) of the battery cells (102) with negative terminal (not shown) of another battery cells (not shown) provided in another battery module (not shown) through corresponding another interconnecting bus bar (not shown), whereas the another interconnecting bus bar (105) is adapted to connect the negative terminals (not shown) of the battery cells (102) with positive terminal of another battery cells (not shown) of corresponding another battery module (not shown) through corresponding another interconnecting bus bar (105), where the battery module (100) is placed between two another battery modules (not shown). Each interconnecting bus bar (105) is secured to corresponding terminals of corresponding battery cells (102) through corresponding fasteners (110B2), where one end of each interconnecting bus bar (105) is connected with another corresponding interconnecting bus bar (not shown) of corresponding another battery module (not shown). It is also within the scope of this invention to integrate locking elements with the interconnecting bus bar (105) for securing the interconnecting bus bar (105) with corresponding terminals of corresponding battery cells (102) and/or to secure the interconnecting bus bar (105) with corresponding another interconnecting bus bar (not shown) of corresponding another batter module (not shown). In an embodiment, the shape and size of one interconnecting bus bar (105) is not same as that of the shape and size of the other interconnecting bus bar (105). In another embodiment, the shape and size of each interconnecting bus bar (105) is same.
[0061] Each fuse (106) is adapted to be held by corresponding fuse holding portion (14F or 12F) of at least one of the top cover (14) and corresponding horizontal battery cassette (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. It is within the scope of this invention to provide any number of fuses (106) and correspondingly the fuse holding portions (14F or 12F) can be provided in at least one of the top cover (14) and corresponding horizontal battery cassette (12) of the battery module (100).
[0062] The thermal management unit (108A and 108B), as shown in fig. 6a and 6b) is adapted to maintain a predetermined temperature of the battery cells (102) for proper functioning of battery cells (102). The thermal management unit (108A and 108B) is provided adjacent to the bottom surface (102BP) of battery cells (102) and vertically mounted onto the battery casing (10) through the top reinforcement member (16) and the bottom reinforcement member (18). The thermal management unit (108A and 108B), as shown in fig. 12b) is provided in between two separate battery modules (100, 100A) such that it acts as a common thermal management unit to maintain predetermined temperature of battery cells (102) provided in two separate battery modules (100, 100A), where one battery module (100) is opposite to the other battery module (100A). This configuration of thermal management unit (108A and 108B) reduces the number of inlet and outlet connections for the thermal management unit (108A and 108B), reduces the length of the pipes or ducts being used to carry fluid to the thermal management unit (108A and 108B), and consumes less packaging space and eases the assembly process.
[0063] Fig. 6a depicts a cross-sectional view of the battery module (100) with an air based thermal management unit (108A), according to embodiments as disclosed herein. The 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). In an embodiment, the air based thermal management unit (108A) mainly includes an 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 bottom surface (102BP) of the battery cells (102) to maintain the predetermined temperature of the battery cells (102) based on the hot or cold temperature conditions.
[0064] Fig. 6b depicts a cross-sectional view of the battery module (100) with a liquid based thermal management unit (108B), according to embodiments as disclosed herein. In an embodiment, the liquid based thermal management unit (108B) mainly includes a liquid plate (108BL) and a thermal pad (108BP). The thermal pad (108BP) is disposed between the bottom surface (102BP) of 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 horizontal battery cassettes (12). 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).
[0065] The plurality of fasteners (110A) are adapted to secure the bottom reinforcement member (18) with the top reinforcement member (16) thereby securing the battery cells (102) within the battery casing (12). Each fastener (110A) is a pre-assembly fastener which is inserted from below the bottom reinforcement member (18) in an upward direction such that each fastener (110A) is being received by corresponding fastener receiving portions (18BF, 12SF, 14FA and 16BF) of the bottom reinforcement member (18), horizontal battery cassettes (12), the top cover (14) and the upper reinforcement member (16), and the upper threaded end of each fastener (110A) which is disposed above the top reinforcement member (16), is fastened with corresponding nut (not shown) to secure the battery cells (102) within the battery casing (10). Other fasteners (110B1) are adapted to secure each bus bar (104) or each add-on bus bar (104A) with the corresponding terminals of corresponding battery cells (102). Another fasteners (110B2) is adapted to secure corresponding each interconnecting bus bar (105) with corresponding terminals of the battery cells (102). Another fastener (110C) is adapted to secure the thermal management unit (110A and 110B) with the top reinforcement member (16) and the bottom reinforcement member (18) of the battery casing (10). Another fasteners (not shown) are adapted to secure the battery module (100) with the battery enclosure (B). In an embodiment, each of fasteners (110A, 110B1, 110B2 and 110C) 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 (B), the bus bars (104) or add-on bus bars (104A) with the corresponding terminals of the battery cells (102), the interconnecting bus bars (105) with corresponding terminals of the battery cells (102), and the battery module (100) with the battery enclosure (B) without otherwise deterring the intended function of fasteners (110A, 110B1, 110B2 and 110C) as can be deduced from the description and corresponding drawings.
[0066] In an embodiment, a reference plane (not shown) of the fastening points of at least one of the battery casing (10) and the battery module (100) is near to a reference plane (not shown) of a center of gravity of the battery module (100). For example, the reference plane (not shown) 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 42.5 mm from the reference plane (not shown) of the center of gravity of the battery module (100) thereby providing the battery module (100) with better strength, durability and also reduces vibration. It is also within the scope of this invention to space the reference plane (not shown) 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 (not shown) of the center of gravity of the battery module (100).
[0067] Each sensor (112) is adapted to detect a temperature and voltage in corresponding battery cells (102) and provide the information to the battery management unit (not shown). One end (112f), as shown in fig. 1) of some sensors (112) are 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 (110B1) and another end (112C), as shown in fig. 1) of each sensor (112) is adapted to be connected to the battery management unit (not shown). Whereas one end (112f, as shown in fig. 1) of at least one sensor (112) is connected to corresponding terminal of corresponding terminals of corresponding battery cells (102) through corresponding at least one interconnecting bus bar (105) by using fasteners (110B2). For the purpose of this description and ease of understanding, another end (112C) of each sensor (112) is considered to be a connector. The connector (112C) of each sensor (112) is adapted to be held of the sensor connector holding portion (14C) of at least one of the top cover (14) and corresponding horizontal battery cassette (12). It is also within the scope of this invention to provide any number of sensors (112) and correspondingly the number of sensor connector holding portion (14C) can be provided in at least one of the top cover (14) and corresponding horizontal battery cassette (12).
[0068] The brackets (114), as shown in fig. 1) are adapted to be held by user for lifting the battery module (100). In one embodiment, each bracket (114) is a separate part that is connected to the top reinforcement member (16). In another embodiment, each bracket (114) is an integral part of the top reinforcement member (16). The brackets (114) are secured onto the top reinforcement member (16) by using fasteners (110A). It is also within the scope of this invention to weld the brackets (114) with the top reinforcement member (16).
[0069] Fig. 7a depicts a side view of the horizontal battery module (100) with 1P-12S battery cells configuration, according to embodiments as disclosed herein. In an embodiment, the battery module (100) is adapted to be configured to have more than one battery cell configuration by removing each bus bar (104) from corresponding terminal of corresponding battery cells (102), changing a position of terminals of corresponding battery cells (102) and securing add-on bars (104A) with corresponding terminal of corresponding battery cells (102) thereby changing the 3P-4S battery cell configuration (as shown in fig. 1) into 1P-12S battery cell configuration (as shown in fig. 7a).
[0070] Further, the battery module (100) is adapted to be configured to have more than one battery cell configuration by removing each bus bar (104) from corresponding terminal of corresponding battery cells (102), adding and removing at least one horizontal battery cassette (12), at least one of changing and not changing a position of terminals of corresponding battery cells (102) and securing each add-on bar (104A) with corresponding terminals of corresponding battery cells (102) thereby changing the 3P-4S battery cell configuration (as shown in fig. 1) or 1P-12S battery cell configuration (as shown in fig. 7a) into 1P-16S battery cell configuration (as shown in fig. 7b). At least one of adding corresponding battery cells (102) on at least one added horizontal battery cell cassette (102) and removing corresponding battery cells (102) along with at least one removed horizontal battery cassette (12). Similarly, the 12 battery cell configuration (as shown in fig. 1 and fig. 7a) can be converted into 8 battery cell configuration or 9 battery cell configuration or 6 battery cell configuration or 4 battery cell configuration or any number of battery cell configuration based on the requirement.
[0071] Fig. 8a depicts a perspective view of another battery module (200) with 1P-6S battery cell configuration, according to another embodiment as disclosed herein. In an embodiment, another battery module (200) includes a horizontal battery casing (20), a plurality of battery cells (202), a plurality of bus bars (204), a plurality of add-on bus bars (not shown) and a plurality of interconnecting bus bars (205) and a battery management unit (not shown). The horizontal battery casing (20) includes a plurality of horizontal battery cassettes (22), a top cover (24) and a bottom cover (26). Fig. 8b depicts a perspective view of a horizontal battery cassette (22) of the battery module (200) with 1P-6S battery cells configuration, according to another embodiments as disclosed herein. Each horizontal battery cassette (22) includes a base (22B), a plurality of side walls (22SW), at least one battery cell locator (22L), a plurality of battery cell stoppers (22S) and a plurality of embossing portions (22R). Each side wall (22SW) of each horizontal battery cassette (22) defines a plurality of first fastener receiving inserts (22SF) adapted to be integrated with the side wall (22SW), where each first fastener receiving portion (22SF) is adapted to receive corresponding each fastener (not shown) therethrough to secure each horizontal battery cassette (22) with corresponding other horizontal battery cassette (22) thereby securing the battery cells (202) within the battery casing (20). Each side wall (22SW) of each horizontal battery cassette (22) defines a plurality of another fastener receiving inserts (22SE), where each another fastener receiving inserts (22SE) is adapted to receive corresponding another fastener (not shown) therethrough to secure the battery module (100) with the battery enclosure (not shown). Each horizontal battery cassette (22) is made of non-metallic material. For example, each horizontal battery cassette (22) is made of plastic. However, it is also within the scope of this invention to provide each battery cassette (22) to be made of any other material without otherwise deterring the intended function of the horizontal battery cassettes (22) as can be deduced from the description and corresponding drawings. The number of horizontal battery cassette (22) is 3. The top cover (24) defines a plurality of fastener receiving inserts (24F) adapted to facilitate mounting of battery management unit (not shown). Each of top cover (24) and the bottom cover (26) is made of non-metallic material. For example, each of top cover (24) and the bottom cover (26) is made of plastic. The number of battery cells (202) is 6. The number of horizontal battery cassette (22) is 3, where each horizontal battery cassette (22) is adapted to hold 2 battery cells.
[0072] Fig. 9a depicts a perspective view of another battery module (300) with 2P-4S battery cell configuration, according to another embodiment as disclosed herein. In an embodiment, another battery module (300) includes a horizontal battery casing (30), a plurality of battery cells (302), a plurality of bus bars (304), a plurality of add-on bus bars (not shown), a plurality of interconnecting bus bars (305), a plurality of fuses (not shown), at least one thermal management unit (not shown), a plurality of fasteners (not shown), a plurality of sensors (not shown) and a plurality of brackets (314). The number of battery cells is 8. The number of horizontal battery cassettes (32) is 2, where each horizontal battery cassette (32) is adapted to hold 4 battery cells.
[0073] Fig. 10a depicts a perspective view of another battery module (400) with 3P-3S battery cell configuration, according to another embodiment as disclosed herein. Fig. 9b depicts a perspective view of a horizontal battery cassette (40) of the battery module (400) with 3P-3S battery cells configuration; according to another embodiments as disclosed herein In an embodiment, another battery module (400) includes a horizontal battery casing (40), a plurality of battery cells (402), a plurality of bus bars (404), a plurality of add-on bus bars (not shown), a plurality of interconnecting bus bars (405), a plurality of fuses (not shown), at least one thermal management unit (not shown), a plurality of fasteners (not shown) and a plurality of sensors (not shown). The number of battery cells (402) is 9. The number of horizontal battery cassettes (42) is 3, where each horizontal battery cassette (42) is adapted to hold 3 battery cells.
[0074] Fig. 9b depicts a perspective view of another battery module (500) with a 1P-16S battery cell configuration, according to another embodiment as disclosed herein. In an embodiment, another battery module (500) includes a horizontal battery casing (50), a plurality of battery cells (502), a plurality of bus bars (504), a plurality of add-on bus bars (not shown), a plurality of interconnecting bus bars (not shown), a plurality of fuses (not shown), at least one thermal management unit (not shown), a plurality of fasteners (not shown), a plurality of sensors (not shown) and a plurality of brackets (not shown). The number of battery cells (502) is 16. The number of horizontal battery cassettes (52) is 4, where each horizontal battery cassette (52) is adapted to hold 4 battery cells.
[0075] Fig. 11 depicts a perspective view of a horizontal battery cassette (62), according to another embodiment as disclosed herein. The horizontal battery cassette (62) is adapted to hold one battery cell (not shown). The horizontal battery cassette (62) includes a base (62B), a plurality of side walls (62SW) and a plurality of battery cell stoppers (62S).
[0076] Fig. 13 depicts a flowchart indicating a method (700) of changing configuration of battery cells (102) in the horizontal battery module (100), according to embodiments as disclosed herein. For the purpose of this description and ease of understanding, the method (700) 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 (700) in a same manner or in a different manner or with omission of at least one step to the method (700) or with any addition of at least one step to the method (700) 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 (700) as can be deduced from the description and corresponding drawings. In an embodiment, the method (700) includes, removing each bus bar (104) from corresponding terminal of corresponding battery cells (102), step (702), changing a position of terminals of corresponding battery cells (102), step (704) and securing each add-on bar (104A) with corresponding terminal of corresponding battery cells (102) thereby changing the battery cell configuration in the battery module (100), step (706).
[0077] The method (700) includes removing a top cover (14) from corresponding horizontal battery cassette (12) of a battery casing (10), step (701).
[0078] The method (700) includes removing a thermal management unit (108A or 108B) from a top reinforcement member (16) and a bottom reinforcement member (18) of the battery casing (10) prior to the method step (701) of removing the top cover (14) from corresponding horizontal battery cassette (12).
[0079] Further, the method (700) includes removing each interconnecting bus bar (105) from corresponding terminal of corresponding battery cells (102).
[0080] The method step (701) of removing the top cover (14) from corresponding horizontal battery cassette (12) includes, removing the top reinforcement member (16) from the top cover (14) during removal of fasteners (110A) and another fasteners (not shown).
[0081] Fig. 14 depicts a flowchart indicating a method (800) of changing configuration of battery cells (102) in the horizontal battery module (800), according to embodiments as disclosed herein. For the purpose of this description and ease of understanding, the method (800) 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 (800) in a same manner or in a different manner or with omission of at least one step to the method (800) or with any addition of at least one step to the method (800) 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 (800) as can be deduced from the description and corresponding drawings. In an embodiment, the method (800) includes, removing each bus bar (104) from corresponding terminal of corresponding battery cells (102), step (802), at least one of adding and removing at least one horizontal battery cell cassette (102, step (804), at least one of changing and not changing a position of terminals of corresponding battery cells (102), step 806) and securing add-on bars (104A) with corresponding terminals of corresponding battery cells (102) thereby changing the battery cell configuration in said battery module (100) thereby changing the battery cell configuration in the battery module (100), step (808).
[0082] The method step (804) of at least one of adding and removing at least one horizontal battery cell cassette (102) includes at least one of adding corresponding battery cells (102) on at least one said added horizontal battery cell cassette (102) and removing corresponding battery cells (102) along with at least one said removed horizontal battery cassette (12).
[0083] The method (800) includes removing a top cover (14) from corresponding horizontal battery cassette (12) of a battery casing (10), step (801).
[0084] The method (800) includes removing a thermal management unit (108A or 108B) from a top reinforcement member (16) and a bottom reinforcement member (18) of the battery casing (10) prior to the method step (801) of removing the top cover (14) from corresponding horizontal battery cassette (12).
[0085] Further, the method (800) includes removing each interconnecting bus bar (105) from corresponding terminal of corresponding battery cells (102).
[0086] The method step (801) of removing the top cover (14) from corresponding horizontal battery cassette (12) includes, removing the top reinforcement member (16) from the top cover (14) during removal of fasteners (110A).
[0087] 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.