DESC:BATTERY PACK FOR VEHICLE
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202321075057 filed on 03/11/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to battery packs of electric vehicles. Particularly, the present disclosure relates to a battery module for an electric vehicle. Furthermore, the present disclosure relates to a busbar of a battery module.
BACKGROUND
The usage of electric vehicles (EVs) has rapidly increased in the recent years due to growing environmental awareness and advancements in technology. The EVs are offering a cleaner alternative to traditional internal combustion engine vehicles which significantly reduces the greenhouse gas emissions and dependence on fossil fuels. Furthermore, the electric vehicles are providing lower operating costs. As a result, there has been recent push to develop hybrid and fully electric vehicles.
Generally, the electric vehicles are powered by an electric motor that runs on energy stored in a battery pack. The battery pack in electric vehicle (EV) is a collection of interconnected battery cells designed to store electrical energy. The energy stored in interconnected battery cells powers the vehicle’s motor, providing the necessary electricity for propulsion. Furthermore, the battery pack typically uses lithium-ion cells due to its high energy density and long lifespan. Typically, with the increased use of battery packs, several key challenges arise. One of the crucial challenges with battery pack is a thermal runaway in battery packs. The thermal runaway causes a rapid rise in temperature and pressure in the battery cell within battery pack, often leading to the release of gases, fire, or even explosion. The affected cell may severely damage and propagate to neighbouring cells which critically compromising the entire battery pack integrity. During such an event, the damaged cells need to be isolated to stabilize the entire battery pack. The isolation process of the affected cell includes switch-based isolation where a battery management system detects a thermal runaway and triggers electrical isolation mechanism to cut off the affected cell from the rest of the battery cells of battery pack. However, current methods for isolating affected cells may encounter delays which may slow down the detection of thermal runaway influencing factors such as voltage and temperature. Moreover, due to high amount of current, the switching mechanism to isolate the cell might fail leading to propagation of the thermal runaway in the nearby cells.
Thus, there is a need to develop an improved robust mechanism to isolate affected cells during thermal runaways that overcomes the one or more problems as set forth above.
SUMMARY
An object of the present disclosure is to provide a battery module for an electric vehicle.
Another object of the present disclosure is to provide a busbar of a battery module.
Yet another object of the present disclosure is to provide a battery pack for an electric vehicle.
In accordance with an aspect of the present disclosure, there is provided a battery module for an electric vehicle. The battery module comprises a plurality of battery cells at least one cell holder, a plurality of busbars configured to electrically connect the plurality of battery cells. Each busbar of the plurality of busbars comprises a conductive core, a plurality of negative terminal caps, a plurality of positive terminal caps and a plurality of pressure sensitive links configured to connect the plurality of negative terminal caps and the plurality of positive terminal caps with the conductive core.
The present disclosure discloses the battery module of the electric vehicle. The battery module as disclosed by present disclosure is advantageous in terms of enhanced safety, reliability, and performance. Beneficially, the battery modules are designed to quickly and efficiently disconnect affected cells from the conductive core of the busbar in the event of a thermal runaway. Beneficially, the battery module as disclosed by present disclosure performs rapid disconnection which prevents the spread of excessive heat and minimizes the risk of damage to the neighbouring plurality of battery cells. Moreover, the battery module significantly enhances the overall battery safety and reducing the chances of fire hazards. Beneficially, the battery module prevents the propagation of electrical faults to neighboring cells which significantly reduces the risk of a chain reaction that may damage the entire battery module or cause a fire. Beneficially, the battery module provides a passive safety mechanism which requires no external control signals which significantly enhances the response speed and simplifies the overall battery module structure. The battery module further ensures comprehensive protection by allowing the disconnection of either terminal in case of excessive pressure buildup, which significantly adds an extra layer of safety. Furthermore, the battery module beneficially helps to maintain the integrity and operational stability of the remaining cells, allowing the vehicle to continue functioning.
In accordance with another aspect of the present disclosure, there is provided a busbar of a battery module. The busbar comprises a conductive core, a plurality of negative terminal caps, a plurality of positive terminal caps, and a plurality of pressure sensitive links configured to connect the plurality of negative terminal caps and the plurality of positive terminal caps with the conductive core, wherein each of the pressure sensitive link is designed to snap by a pressure of gas-venting in case of a thermal runaway.
In accordance with yet another aspect of the present disclosure there is provided a battery pack for an electric vehicle. The battery pack comprises a battery management system, and at least one battery module as disclosed in the first aspect.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates an exploded view of a battery module of an electric vehicle, in accordance with an aspect of the present disclosure.
Figure 2 illustrates a perspective view of a busbar of the battery module, in accordance with another aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a battery module and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “electric vehicle”, “EV”, and “EVs” are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries which are exclusively charged from an external power source, as well as hybrid-vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheeler, electric three-wheeler, electric four-wheeler, electric pickup trucks, electric trucks and so forth.
As used herein, the term “battery module” and “at least one battery module” are used interchangeably used and refer to an assembled unit of a plurality of cell arrays that are connected together electrically to form a larger energy storage system capable of delivering required amount of energy for high power applications. The battery modules may be arranged in series or parallel configuration depending on the desired voltage and capacity requirements. It is understood that connecting battery modules in series increases the overall voltage of the battery pack, while connecting them in parallel increases the capacity. The electrical connections in the battery module are formed by connecting the terminals of the battery cells with bus bars. Furthermore, in addition to the individual cells, the battery module may also include circuitry for balancing the charge levels of the cells, managing the charging and discharging processes, and providing safety features such as overcharge and over-discharge protection. The battery module, along with the associated electronics and packaging, forms the core component of a battery pack, enabling the efficient and reliable storage and delivery of electrical energy.
As used herein, the terms “battery pack”, “battery”, and “power pack” are used interchangeably and refer to multiple individual battery module connected together to provide a higher combined voltage or capacity than what a single battery module can offer. The battery pack is designed to store electrical energy and supply it as needed to various devices or systems. Battery pack, as referred herein may be used for various purposes such as power electric vehicles and other energy storage applications. Furthermore, the battery pack may include additional circuitry, such as a battery management system (BMS), to ensure the safe and efficient charging and discharging of the battery cells. The battery pack comprises a plurality of battery modules which in turn comprises a plurality of battery cells.
As used herein, the term “plurality of battery cells”, “cell”, “each battery cell” and “battery cell” are used interchangeably and refer to two or more individual battery cells that are arranged together in a system or pack. The plurality of battery cells are typically interconnected, either in series, parallel, or a combination of both, to provide the required voltage and capacity for powering a device or vehicle. Each cell operates as a single electrochemical unit capable of storing and delivering electrical energy and are collectively contribute to the overall performance and functionality of the battery pack.
As used herein, the term “at least one cell holder” refers to a cell holder in a battery pack which is a structural component designed to securely house individual battery cells, ensuring proper alignment, electrical connectivity, and thermal management. The at least one cell holder typically features compartments or slots sized to fit specific battery cells, such as cylindrical or prismatic cells, with integrated contact points for electrical connection. Additionally, the at least one cell holder may incorporate insulation materials or thermal pads to manage heat dissipation and prevent thermal runaway from spreading between cells. The at least one cell holder may also include locking mechanisms to prevent cell movement due to vibrations or external impacts, maintaining the stability of the battery pack during operation.
As used herein, the term “plurality of busbars”, “busbar plate” and “busbar” are used interchangeably and refer to a conductive metal strip or plate used to facilitate the distribution of electrical power or signals within the cell array. The busbar plate serves as a common electrical connection point for plurality of battery cells.
As used herein, the term “conductive core” refers to the central element or material designed to facilitate the efficient transfer of electrical current between various components of the battery pack. The conductive core typically comprises highly conductive materials such as copper, aluminium, or their alloys, which ensure minimal resistance and optimal current flow. The conductive core may also serve as a structural element, connecting battery cells in series or parallel configurations while maintaining electrical continuity.
As used herein, the term “plurality of negative terminal caps” refers to a connecting portion of the busbar that establishes physical contact of the busbar with the negative terminal of the battery cell. The negative terminal cap may provide required surface area for effective conduction of current to the busbar.
As used herein, the term “plurality of positive terminal caps” refers to a connecting portion of the busbar that establishes physical contact of the busbar with the positive terminal of the battery cell. The positive terminal cap may provide required surface area for effective conduction of current to the busbar.
As used herein, the term “plurality of pressure sensitive links” refers to a design element of the busbar that is sensitive to pressure and links the terminal caps of the busbar with the conductive core of the busbar. In the event of thermal runaway, the pressure sensitive links may break due to pressure of the gas-venting from the affected cell leading to the electrical and mechanical isolation of the affected cell.
As used herein, the term “foam” refers to a lightweight, porous material used within the battery module to enhance thermal management, shock absorption, and fire mitigation. The foam may be composed of heat-resistant or fire-retardant materials, designed to provide insulation between battery cells to prevent heat transfer and reduce the risk of thermal runaway propagation. Additionally, the foam may be used as a structural support, filling gaps between battery components to minimize vibrations and mechanical stress during operation.
As used herein, the term “battery management system” and “BMS” are used interchangeably and refer to an electronic control system designed to monitor, manage, and regulate the performance of an energy storage system, typically comprised of multiple battery modules. The BMS is responsible for ensuring the safe and efficient operation of the battery pack by monitoring key parameters such as voltage, current, temperature, and state of charge (SOC). Additionally, the BMS provides protection by controlling charging and discharging processes, detecting and responding to faults, balancing cell performance, and managing thermal conditions. The system may also include communication interfaces to provide real-time data and control signals for system optimization and fault recovery.
As used herein, the term “support plate” refers to a structural component designed to provide mechanical stability and support for the plurality of battery cells and the busbars. Typically, the support plate may be made from materials such as metal or high-strength polymer which ensures proper alignment and spacing between individual battery cells. Furthermore, a first face of the support plate may be configured to provide structural support for the plurality of battery cells, which significantly ensures that the plurality of battery cells are securely held in place during operation. Furthermore, a second face of the support plate may be configured to support the plurality of busbars, which connects the plurality of battery cells electrically.
As used herein, the term “insulation plate” refers to a specialized component designed to provide electrical and thermal insulation between the plurality of busbars and the support plate. The insulation plate serves to prevent unintended electrical conduction to the support plate or the cell holder. The insulation plate may be composed of materials with high dielectric strength and thermal resistance, ensuring durability and effectiveness under varying operational conditions.
As sued herein, the term “module management unit” refers to a component of a battery module that monitors and manages the operation and health of individual battery cell within the battery module. The module management unit monitors key parameters such as voltage, current, and temperature for each module, ensuring optimal performance and safety. The module management unit (MMU) may detects abnormalities in battery module, manage charging and discharging processes, and implement protective measures to prevent conditions that may leads to thermal runaway or other failures of the battery pack. Additionally, the module management unit facilitates communication between the battery modules and the vehicle's central control unit, enables real-time data analysis and enhances the overall efficiency of the battery pack.
As used herein, the term “plurality of sensors” refers to a group of multiple sensors strategically integrated within the battery module to monitor various operational parameters. The plurality of sensors measures the critical factors such as temperature, voltage, current, and state of charge across different battery cells and battery module. By employing a plurality of sensors, the battery module enhances the capability for real-time data collection and enables more accurate assessments of the battery module performance and health.
Figure 1, in accordance with an embodiment describes a battery module 100 for an electric vehicle. The battery module 100 comprises a plurality of battery cells 102, at least one cell holder 104, a plurality of busbars 106 configured to electrically connect the plurality of battery cells 102. Each busbar of the plurality of busbars 106 comprises a conductive core 108, a plurality of negative terminal caps 110, a plurality of positive terminal caps 112 and a plurality of pressure sensitive links 114 configured to connect the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 with the conductive core 108.
The present disclosure discloses the battery module 100 of the electric vehicle. The battery module 100 as disclosed by present disclosure is advantageous in terms of enhanced safety, reliability, and performance of battery module 100. Beneficially, by incorporating the plurality of pressure-sensitive links 114, the battery module 100 ensures that the affected battery cell is quickly and efficiently disconnected from the conductive core 108 of the busbar 106. The battery module 100 as disclosed by present disclosure advantageously provides isolation for affected battery cell, thereby preventing the spread of heat or electrical faults to neighbouring plurality of battery cells 102. Beneficially, the battery module 100 significantly reduces the risk of a chain reaction that may damage the entire battery pack or cause a fire. Beneficially, the pressure-sensitive links 114 provide a passive safety mechanism, require no external control signals to cut off the affected cell. The pressure sensitive links 114 as disclosed by present disclosure beneficially enhances the response speed and simplifies the overall design for battery module 100. The integration of the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 provides enhanced protection, facilitating terminal disconnection in response to excessive pressure buildup or gas venting.
In an embodiment, the at least one cell holder 104 is configured to mechanically support the plurality of battery cells 102. Beneficially, the at least one cell holder 104 is designed to securely house plurality of battery cells 102, ensures proper alignment and stability of the plurality of cells 102 during operation. The at least one cell holder 104 may be constructed from a durable, non-conductive material, such as high-strength plastic or composite which significantly provides insulation between the plurality of battery cells 102 and other battery module components.
In an embodiment, the conductive core 108 is configured to conduct current between the plurality of battery cells 102. The conductive core 108 is positioned in the plurality of busbars 106 to electrically connect the plurality of cells 102 via the plurality of negative terminals 110 and the plurality of positive terminal 112 which ensures efficient current flow throughout the battery module 100. The conductive core 108 may be made from a highly conductive material, such as copper or aluminum, to minimize resistance and optimize energy transfer. Beneficially, the conductive core 108 ensures continued operation of unaffected cells while isolating the affected battery cell, thereby enhance both the safety and performance of the battery module 100.
In an embodiment, the plurality of negative terminal caps 110 are connected to a plurality of negative terminals of the plurality of battery cells 102. Each of the plurality of negative terminal caps 110 may be designed to securely attach to the corresponding negative terminal of each of the plurality of battery cells 102 which ensures stable electrical conductivity throughout the battery module 100. The plurality of negative terminal caps 110 facilitate efficient electrical connection between the plurality of battery cells 102 and the conductive core 108 of the plurality of busbars 106, which enables power transfer across the battery module 100. Beneficially, each of the plurality of negative terminal cap 110 may be configured to work simultaneously with the plurality of pressure sensitive links 114, significantly allows for the disconnection of the negative terminal cap from the conductive core 108 in case of a thermal runaway. Beneficially, the disconnection of affected battery cell serves to isolate the affected battery cell from the rest of the battery module 100, thereby preventing the escalation of thermal events and improving overall safety of battery module 100. Moreover, the plurality of negative terminal caps 110 beneficially provide effective surface area for the conduction of electrical current.
In an embodiment, the plurality of positive terminal caps 112 are connected to a plurality of positive terminals of the plurality of battery cells 102. Each of the plurality of positive terminal caps 112 may be designed to ensure stable electrical contact between the positive terminal of the plurality of battery cells 102 and the plurality of busbars 106, facilitates efficient current flow within the battery module 100. Beneficially, the plurality of positive terminal caps 112 are integrated with the plurality of pressure sensitive links 114, which significantly enables the disconnection of affected battery cell from the conductive core 108. Beneficially, the disconnection of affected battery cell serves to isolate the affected battery cell from the rest of the battery module 100, thereby preventing the escalation of thermal events and improving overall safety of battery module 100. Moreover, the plurality of positive terminal caps 112 beneficially provide effective surface area for the conduction of electrical current.
In a preferred embodiment, the plurality of positive terminal caps 112 are integrated with the plurality of pressure-sensitive links 114, facilitating the disconnection of the positive terminal from the conductive core 108 in the event of thermal runaway. The disconnection of the positive terminal integrated with the pressure sensitive link occurs because of the pressure exerted during gas venting from the affected cell in the event of thermal runaway. Beneficially, the disconnection of affected battery cell serves to isolate the affected battery cell from the rest of the battery module 100, thereby preventing the escalation of thermal events and improving overall safety of battery module 100.
In an embodiment, the plurality of pressure sensitive links 114 are configured to disconnect at least one of the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 from the conductive core 108 in case of a thermal runaway. The pressure-sensitive links 114 may be designed to react to pressure buildup caused by thermal runaway events within individual battery cells of battery module 100. Beneficially, the plurality of pressure sensitive links 114 automatically sever the electrical connection between at least one of the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 from the conductive core 108. Beneficially, the disconnection mechanism for the affected battery cell operates independently of external control, which relies solely on pressure changes, thereby offering a rapid and fail-safe method to enhance safety within the battery module 100.
In an embodiment, each of the pressure sensitive link is designed to snap by a pressure of gas-venting in case of the thermal runaway. The pressure sensitive link snaps when a predefined pressure threshold is reached due to gas within the affected battery cell. The snapped pressure sensitive link disconnects and isolates the affected battery cell from conductive core 108 leading to disconnection of the affected cell. Beneficially, the disconnection of the affected cell effectively isolates the cell from the other plurality of battery cells 102 in the battery module 100, thereby enhances both the safety and performance of the battery module 100.
In an embodiment, the battery module 100 comprises a foam 116 filled in an empty space between the plurality of battery cells 102. The foam 116 may be designed to serve multiple functions within the battery module 100. The foam 116 provides thermal insulation between the plurality of battery cells 102, helps to manage the heat generated during operation and reduces the risk of thermal propagation in case of cell failure. Furthermore, the foam 116 also functions as a shock absorber which significantly protects the plurality of battery cells 102 from mechanical stresses, vibrations, or impacts that may occur during the vehicle's operation. Additionally, the foam 116 may be made from fire-resistant materials to improve the safety of the battery module 100 and prevents the spread of fire in case of a thermal runaway or similar event. Beneficially, the foam 116 enhances both the safety and durability of the battery module 100 in various operational conditions. Beneficially, the combination of the foam 116 and the plurality of pressure sensitive links 114 enhances the safety of the battery module by effectively isolating the affected cell during the thermal runaway.
In an embodiment, the battery module 100 comprises a support plate 118 configured between the plurality of battery cells 102 and the plurality of busbars 106. The support plate 118 is designed to provide structural stability to the battery module 100 by maintaining the alignment of the plurality of battery cells 102 and busbars 106, significantly ensures consistent electrical connectivity. The first face of the support plate 118 may be configured to provide structural support for the plurality of battery cells 102, which ensures that the plurality of battery cells 102 are securely placed during operation. Furthermore, the second face of the support plate 118 may be configured to support the plurality of busbars 106, which connects the plurality of battery cells 102 electrically. Beneficially, the support plate 118 facilitates efficient electrical conductivity by creating a separation between the plurality of battery cells 102 and the plurality of busbars 106. The support plate 118 may be mounted on the at least one cell holder 104 with the help of screws.
In an embodiment, the battery module 100 comprises an insulation plate 120 configured between the support plate 118 and the plurality of busbars 106. The insulation plate 120 may be composed of materials that exhibit high thermal resistance and low electrical conductivity. Beneficially, the insulation plate 120 prevents the electrical contact between the plurality of busbars 106 and the support plate 118. Moreover, the insulation plate 120 safeguards the battery module 100 against short circuits and also enhances the overall thermal stability of the battery module 100 by reducing heat transfer from the plurality of busbars 106 to the support plate 118.
In an embodiment, the battery module 100 comprises a module management unit 122 connected to the plurality of busbars 106. The module management unit 122 may be configured to monitor and control the performance of the plurality of battery cells 102 within the battery module 100. Beneficially, the module management unit 122 ensures optimal operation and safety of the battery module 100. The module management unit 122 tracks the key parameters such as voltage, current, and temperature across the plurality of busbars 106, enables real-time assessment of the battery module health. Beneficially, the integration of the module management unit 122 with the plurality of busbars 106, significantly enhances the overall safety, reliability, and efficiency of the battery module 100.
In an embodiment, the module management unit 122 comprises a plurality of sensors 124. Beneficially, the plurality of sensors 124 strategically positioned throughout the battery module 100 to gather real-time data on various parameters, such as temperature, voltage, current, and state of charge. Each sensor of plurality of sensors 124 may be calibrated to provide accurate measurements which facilitates the early detection of anomalies that may indicate potential thermal runaway or other safety concerns.
In an embodiment, the battery module 100 comprises the plurality of battery cells 102, the at least one cell holder 104, the plurality of busbars 106 configured to electrically connect the plurality of battery cells 102. Each busbar of the plurality of busbars 106 comprises the conductive core 108, the plurality of negative terminal caps 110, the plurality of positive terminal caps 112 and the plurality of pressure sensitive links 114 configured to connect the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 with the conductive core 108. Furthermore, the plurality of positive terminal caps 112 is integrated with the plurality of pressure-sensitive links 114, facilitating the disconnection of the positive terminal from the conductive core 108 in the event of thermal runaway. Furthermore, the at least one cell holder 104 is configured to mechanically support the plurality of battery cells 102. Furthermore, the conductive core 108 is configured to conduct current between the plurality of battery cells 102. Furthermore, the plurality of negative terminal caps 110 are connected to the plurality of negative terminals of the plurality of battery cells 102. Furthermore, the plurality of positive terminal caps 112 are connected to the plurality of positive terminals of the plurality of battery cells 102. Furthermore, the plurality of pressure sensitive links 114 are configured to disconnect at least one of the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 from the conductive core 108 in case of the thermal runaway. Furthermore, each of the pressure sensitive link is designed to snap by the pressure of gas-venting in case of the thermal runaway. Furthermore, the battery module 100 comprises the foam 116 filled in an empty space between the plurality of battery cells 102. Furthermore, the battery module 100 comprises the support plate 118 configured between the plurality of battery cells 102 and the plurality of busbars 106. Furthermore, the battery module 100 comprises the insulation plate 120 configured between the support plate 118 and the plurality of busbars 106. Furthermore, the battery module 100 comprises the module management unit 122 connected to the plurality of busbars 106. Furthermore, the module management unit 122 comprises the plurality of sensors 124. Furthermore, the busbar 106 of the battery module 100. The busbar 106 comprises the conductive core 108, the plurality of negative terminal caps 110, the plurality of positive terminal caps 112 and the plurality of pressure sensitive links 114 configured to connect the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 with the conductive core 108. Each of the pressure sensitive link 114 is designed to snap by the pressure of gas-venting in case of the thermal runaway. Furthermore, the battery pack for electric vehicles. The battery pack comprises the battery management system and the at least one battery module.
Figure 2, in accordance with another aspect describes a busbar 106 of a battery module 100. The busbar 106 comprises a conductive core 108, a plurality of negative terminal caps 110, a plurality of positive terminal caps 112 and a plurality of pressure sensitive links 114 configured to connect the plurality of negative terminal caps 110 and the plurality of positive terminal caps 112 with the conductive core 108. Each of the pressure sensitive link 114 is designed to snap by a pressure of gas-venting in case of a thermal runaway. Beneficially, the plurality of pressure-sensitive links 114, the battery module 100 ensures that the affected battery cell is quickly and efficiently disconnected from the conductive core 108. Beneficially, the isolation of affected cell significantly reduces the risk of a chain reaction that may damage the entire battery module 100.
In yet another aspect, a battery pack for an electric vehicle is disclosed. The battery pack comprises a battery management system (BMS) and at least one battery module 100. The BMS is configured to monitor the voltage, temperature, and state of charge of each battery cell of plurality of battery cell 102 within the at least one battery module 100, which ensures the optimal performance and safety of the battery pack. Moreover, the BMS includes safety features that detect abnormal conditions, such as overcharging or thermal runaway within the battery module 100. Beneficially, the battery pack is designed with thermal management features to maintain optimal operating temperatures which significantly enhances the efficiency and longevity of the at least one battery module 100.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:We Claim:
1. A battery module (100) for an electric vehicle, wherein the battery module (100) comprises:
- a plurality of battery cells (102);
- at least one cell holder (104);
- a plurality of busbars (106) configured to electrically connect the plurality of battery cells (102), wherein each busbar of the plurality of busbars (106) comprises:
- a conductive core (108);
- a plurality of negative terminal caps (110);
- a plurality of positive terminal caps (112); and
- a plurality of pressure sensitive links (114) configured to connect the plurality of negative terminal caps (110) and the plurality of positive terminal caps (112) with the conductive core (108).
2. The battery module (100) as claimed in claim 1, wherein the at least one cell holder (104) is configured to mechanically support the plurality of battery cells (102).
3. The battery module (100) as claimed in claim 1, wherein the conductive core (108) is configured to conduct current between the plurality of battery cells (102).
4. The battery module (100) as claimed in claim 1, wherein the plurality of negative terminal caps (110) are connected to a plurality of negative terminals of the plurality of battery cells (102).
5. The battery module (100) as claimed in claim 1, wherein the plurality of positive terminal caps (112) are connected to a plurality of positive terminals of the plurality of battery cells (102).
6. The battery module (100) as claimed in claim 1, wherein the plurality of pressure sensitive links (114) are configured to disconnect at least one of the plurality of negative terminal caps (110) and the plurality of positive terminal caps (112) from the conductive core (108) in case of a thermal runaway.
7. The battery module (100) as claimed in claim 6, wherein each of the pressure sensitive link is designed to snap by a pressure of gas-venting in case of the thermal runaway.
8. The battery module (100) as claimed in claim 1, wherein the battery module (100) comprises a foam (116) filled in an empty space between the plurality of battery cells (102).
9. The battery module (100) as claimed in claim 1, wherein the battery module (100) comprises a support plate (118) configured between the plurality of battery cells (102) and the plurality of busbars (106).
10. The battery module (100) as claimed in claim 1, wherein the battery module (100) comprises an insulation plate (120) configured between the support plate (118) and the plurality of busbars (106).
11. The battery module (100) as claimed in claim 1, wherein the battery module (100) comprises a module management unit (122) connected to the plurality of busbars (106).
12. The battery module (100) as claimed in claim 11, wherein the module management unit (122) comprises a plurality of sensors (124).
13. A busbar (106) of a battery module (100), wherein the busbar (106) comprises:
- a conductive core (108);
- a plurality of negative terminal caps (110);
- a plurality of positive terminal caps (112); and
- a plurality of pressure sensitive links (114) configured to connect the plurality of negative terminal caps (110) and the plurality of positive terminal caps (112) with the conductive core (108), wherein each of the pressure sensitive link (114) is designed to snap by a pressure of gas-venting in case of a thermal runaway.
14. A battery pack for an electric vehicle, wherein the battery pack comprises:
- a battery management system; and
- at least one battery module (100) as claimed in claim 1.