Description:FIELD OF THE INVENTION
[0001] The present subject matter is related, in general to a battery pack, and more particularly, but not exclusively to a battery pack configuration provided with multiple fusing for prevention of thermal runaways in the battery pack.
BACKGROUND OF THE INVENTION
[0002] Advancement of technology has illustrated a dire dependency on electrical energy for operation of various electrical and electronic equipment as well as development of vehicles employing electrical energy. The massive utility that electrical energy presents, puts a concomitant pressure on the development of electrical energy storage devices or system to help realize the utility of electrical energy. The developed electrical energy storage systems are mandatorily equipped with safety mechanisms to cope in an event of malfunctioning of the electrical energy storage systems.
[0003] Further, recently there has been tremendous research and development occurring in the field of mobility with reference to electric and plug-in hybrid vehicles. The demands in the field of electric mobility mandate a requirement of effective monitoring and diagnosis of thermal runaway, short circuiting, and other forms of electrical malfunctioning of the energy storage system. Further, the energy storage systems used in mobility are configured to be rechargeable in pursuit of re-use.
[0004] An energy storage system typically includes a battery pack comprising of a plurality of cells or a plurality of battery modules configured to store electrical energy and supply the stored electrical energy to an external load. The external load draws the electrical energy from the battery pack in continuance of its regular operation.
[0005] Conventionally, lithium-ion (hereinafter referred to as Li-ion) batteries have been a popular choice in the battery packs owing to their high energy density, high power density, excellent cycle performance, and environmental friendliness. The apprehension in usage of Li-ion cells is the uncontrolled exothermic reaction occurring in thermal runaway of Li-ion cells are fast, violent, and self-accelerating. Typically, in thermal runaway there is an accelerated release of heat from the cell due to uncontrolled exothermic reaction where the cell losses the ability to dissipate the heat as quickly as the heat is generated in the cell, ultimately leading to loss of thermal stability of the cell. The heat generated during thermal runaway may propagate to neighbouring cell as well as neighbouring electrical and electronic equipment leading to catastrophic failure. In order to ensure safe operation of the battery packs, the manufacturer has to ensure that the battery packs having parallel cell connections is equipped with a circuit which enables isolation of faulty cells and eliminate the circulating currents.
[0006] Conventionally, the battery packs and other forms of electrical energy storage devices and systems are equipped with a battery management system (hereinafter referred to as BMS). The BMS monitors the health of the battery pack through one or more battery parameters such as voltage, charging current, temperature, and state of charge of the battery cells. The BMS upon detection of discrepancies in the one or more battery parameters cuts-off the functioning of the entire battery pack for coping with the possibility of malfunctioning of the battery which may lead to thermal runaway. The disadvantage of the inclusion of the BMS in coping with individually malfunctioning cells is that the BMS cuts-off the entire functionality of the battery pack yielding complete halt of the battery operations which attenuate associated cost, time, and labour.
[0007] Further, it is known in a prior art to equip the battery pack with additional electronic components configured to isolate an individual malfunctioning cell allowing the other cells of the battery pack continue its normal functioning. The drawback of additional electronic components in the battery pack increases the overall weight, associated cost, and number of components of the battery pack. In automobile industries, mobility demands a high power to weight ratio which makes lighter batteries more desirable to achieve improved vehicle performance.
[0008] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.
SUMMARY
[0009] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
[00010] According to embodiments illustrated herein, the present invention provides a battery pack comprising one or more cells. The one or more cells are connected using one or more interconnectors. Each one or more interconnector has a first neck fusing region, a second neck fusing region, and a third neck fusing region which act as fusing elements configured to blow-off when the current passing through the one or more cell exceeds a pre-defined current. The first neck fusing region, a second neck fusing region, and a third neck fusing region thus isolate the malfunctioning cell from the battery pack circuit and confines as well as negates the possibility of a thermal runway occurring in the battery pack. Thus, the fire hazard is not propagated to the adjacent cells of the battery pack.
[00011] According to embodiments illustrated herein, the first neck fusing region is disposed downwardly from a horizontal plane of the one or more interconnectors, the second neck fusing region and the third neck fusing region is disposed on a first interconnector portion of the one or more interconnectors.
[00012] According to embodiments illustrated herein, the present invention also discloses one or more interconnectors where each of the one or more interconnectors has a first neck fusing region, a second neck fusing region, and a third neck fusing region for acting as fusing elements in the battery pack. The first neck fusing region, the second neck fusing region, and the third neck fusing region are configured to blow-off and isolate the malfunctioning cell from the battery pack circuit in the event of the current circulating in the battery pack exceeds a pre-defined current because of a malfunctioning cell.
[00013] According to embodiments illustrated herein, the first neck fusing region is disposed downwardly from a horizontal plane of the one or more interconnectors, the second neck fusing region and the third neck fusing region is disposed on the first interconnector portion of the one or more interconnectors.

BRIEF DESCRIPTION OF THE DRAWINGS
[00014] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention.
[00015] Figure 1(a) illustrates a side perspective view of a battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure.
[00016] Figure 1(b) illustrates a side perspective exploded view of the battery pack with the multiple fusing elements, in accordance with embodiments of the present disclosure.
[00017] Figure 2(a) illustrates a top view of an interconnector of the battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure.
[00018] Figure 2(b) illustrates a side view of the interconnector of the battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure.
[00019] Figure 3(a) and 3(b) illustrates a localized view of the interconnector of the battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[00020] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented, and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[00021] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[00022] The present invention now will be described more fully hereinafter with different embodiments. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather those embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the invention to those skilled in the art.
[00023] The present invention is illustrated with a battery pack. However, a person skilled in the art would appreciate that the present invention is not limited to a battery pack and certain features, aspects and advantages of embodiments of the present invention can be used with other types and forms of energy storage devices or energy storage packs used in conjunction with various types of vehicles such as electric vehicle and plug-in hybrid vehicles as well as other electrical equipment and external electrical loads employing a rechargeable energy storage pack. In an embodiment, the electric vehicles, hybrid vehicle, electrical equipment, external electrical load draw electric current from the energy storage pack.
[00024] It is an object of the present subject matter to provide a battery pack with multiple fusing necks configured to isolate malfunctioning cells from the battery pack circuit to ensure normal functioning of the battery pack and alleviate occurrences of thermal runaway in the battery pack.
[00025] To this end, the present subject matter discloses a battery pack comprising one or more cells connected using one or more interconnectors. Each one or more interconnectors comprises of the one or more of neck fusing regions which is a first neck fusing region, a second neck fusing region, and a third neck fusing region. The one or more neck fusing regions is configured to act like a fusing element.
[00026] In accordance with the configuration of the one or more neck fusing regions, the one or more neck fusing regions is configured to blow-off when the current passing through the cell exceeds a pre-defined current. In the event of an electrical mishap or malfunctioning of a cell of the battery pack, the current circulating through the one or more cells is dumped on the malfunctioning cell, the one or more neck fusing regions senses the higher current value passing through the malfunctioning cell and blows-off to isolate the malfunctioning cell from the circuit and allow the remaining cells of the battery pack circuit to operate normally. The blow-off of the one or more neck fusing regions isolates the malfunctioning cell from the one or more cells of the circuit and protects the functioning of the adjacent cells. The battery pack configuration comprising of the one or more neck fusing regions reduces the risk of thermal runaway propagating to the adjacent cells of the battery pack and keeps the working environment of the battery pack safe and secure from potential fire hazards.
[00027] It is known in the art, to provide a battery management system (hereinafter referred to as BMS) for assessing and monitoring the state of health and state of charge of the plurality of cells of the battery pack. Any malfunction of a cell of the battery pack would lead to dumping of current on the malfunctioning cell which would lead to rise in temperature of the battery pack. The BMS configured to monitor the state of health and state of charge of the battery pack detects the abnormal rise in temperature and cuts-off or ceases the entire functionality of the battery pack in pursuit of avoidance of thermal runaway in the battery pack. The evident drawback of the BMS as illustrated above results in complete halt of the functionality of the battery pack and the entire electrical equipment or vehicle coming to a standstill.
[00028] The disclosed subject matter addresses this exact drawback of the known art by isolating the malfunctioning cell from the adjacent cells of the battery pack, allowing the battery pack to resume its normal functioning. The halt in the operation of the battery pack yields a wastage of concomitant time, money, and energy which the present subject matter appositely solves.
[00029] It is a further object of the present subject matter to provide an active paralleling circuits in a battery pack comprising of one or more cells electrically connected in parallel.
[00030] In operation, when the one or more cells of the battery pack are connected in parallel configuration the current circulating through the cells connected in parallel is distributed in the entire battery pack. In the event of a cell malfunctioning, the current circulating through the circuit is dumped on the malfunctioning cell which would lead the entire battery pack to go into thermal runaway resulting in catastrophic failure.
[00031] To this end and in accordance with the configuration of the battery pack comprising of one or more cells connected in parallel, the interconnector connecting the one or more cells are provided with one or more neck fusing regions. The neck fusing regions senses the rise in temperature of the malfunctioning cell which is a manifestation of the current being dumped on the malfunctioning cell. The one or more neck fusing regions of the one or more interconnector is configured to blow-off when the higher current value of the malfunctioning cell exceeds the pre-defined current, thus isolating the malfunctioning cell from the one or more cells of the battery pack in parallel configuration.
[00032] It is a further object of the present subject matter to provide a means for isolating malfunctioning cells from the battery pack circuit without increasing the overall weight, size, cost, and number of components of the battery pack.
[00033] In operation, the battery packs used in mobility operations strive to attain a high power to weight ratio which requires keeping the weight of the battery pack and associated components minimal to achieve improved vehicle performance.
[00034] To this end, the one or more interconnectors provided in the battery pack are configured to include one or more neck fusing regions which blow-off to isolate a malfunctioning cell when the current passing through the cell exceeds a pre-defined current. The integration of the one or more neck fusing regions in the one or more interconnector negates the requirement of additional electrical or electronic components performing fusing function which would unnecessarily increase the overall weight, size, cost, and number of components of the battery pack.
[00035] In addition, the configuration of the battery pack with minimum number of components reduces the associated manufacturing and assembly time of the battery pack in accordance with the present disclosure.
[00036] In accordance with the configuration of the present subject matter, the usage of the one or more interconnectors integrated with a second portion acting as fusing element reduces the number of components of the battery pack and eases and enhances the accessibility, serviceability, and maintenance of the components of the disclosed battery pack.
[00037] It is known in the art to provide additional electrical fuses connected to a printed circuit board (hereinafter referred to as PCBs) in connection with the battery pack to isolate the malfunctioning battery pack. However, the disclosed configuration known in the art results in an excessive increase in the number of components associated with the battery pack and the corresponding weight and size of the battery pack. Further, addition of extra components such as electrical fuses connected to PCBs increases the manufacturing and assembly time of the battery pack as well as the cost associated with the battery pack. The configuration of the known art further apprehensively impacts the serviceability, maintainability, and accessibility of the components of the battery pack as already known in the prior art.
[00038] It is a further object of the present subject matter to provide an interconnector with multiple neck fusing regions easily implementable in conventional battery packs without necessitating a revamping of core manufacturing process.
[00039] To this end, the disclosed subject matter relating to an interconnector with a plurality of neck fusing regions acting as fusing elements can be easily implemented in traditional battery pack, energy storage pack configuration and layout without significant manufacturing deviations. The disclosed subject matter enables implementation in modified versions of existing battery packs with minimal changes in the battery pack design, electrical connections in the battery pack and even the manufacturing set-up without major revamping of the core manufacturing process.
[00040] It is an object of the present subject matter to provide a battery pack having flexibility in size, range of power supply, and battery pack capacity.
[00041] In accordance with the configuration of the disclosed subject matter, an additional advantage of the disclosed battery pack is the flexibility to manufacture variants in forms of size of the battery pack, range of power supply, and capacity of the battery pack. The one or more interconnector comprising of the one or more neck fusing regions can be easily implemented and modified in accordance with the electrical demands of the external electrical load.
[00042] The embodiments of the present invention will now be described in detail with reference to a battery pack along with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[00043] Figure 1(a) exemplarily illustrates a side perspective view of a battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure. Figure 1(b) illustrates a side perspective exploded view of the battery pack with the multiple fusing elements, in accordance with embodiments of the present disclosure. Figure 1(a) and Figure 1(b) shall be discussed together.
[00044] With reference to Figure 1(b), 100 denotes a battery pack, 102 denotes one or more cells, 104 denotes one or more bus bars, 106 denotes one or more interconnectors.
[00045] In an embodiment, the battery pack 100 comprises of one cells 102. The one or more cells 102 are connected by one or more interconnectors 106. Each of the one or more interconnectors 106 secures an electrical connection between adjacent cells of the battery pack by connecting cell terminals and then giving it to one or mor busbars 104.
[00046] In an embodiment, the battery pack 100 disclosed in relation to the present subject matter includes any electrical energy storage device or system configured to store electrical energy and may include an energy storage pack, one or more battery cells, a plurality of battery modules and other forms of electrical energy storage equipment. The battery pack is rechargeable and is configured to have a charged and discharged state. In a charged state of the battery pack, the battery pack supplies the stored electrical energy to an external electrical load, an electrical or electronic equipment, electric or hybrid vehicle as and when required.
[00047] In an aspect of the present invention, the battery pack 100 comprises of a the one or more cells 102. The one or more cells 102 of the battery pack 100 are electrically connected either in series configuration or parallel configuration based on the intended use of the battery pack 100.
[00048] In an aspect of the present invention, the connection of the one or more cells 102 in series or parallel is based on the sector in which the battery pack 100 is utilised, and the energy demands of the external electrical load, electrical or electronic equipment or the electric vehicle. The difference in series configuration and parallel configuration of the one or more cells 102 is the impact the same holds on the output voltage of the battery pack 100 and the capacity of the battery pack 100.
[00049] In an embodiment, the battery pack 100 disclosed in accordance with the present disclosure comprises of the one or more cells 102 electrically connected in parallel configuration.
[00050] In an aspect of the present invention, the one or more cells 102 of the battery pack 100 are connected in a parallel configuration when the current flowing through the battery pack 100 is to be distributed in the entire battery pack 100. In the event of an electrical shock because of a cell malfunctioning, the parallel configuration of the one or more cells 102 would lead to the occurrence of thermal runaway in the entire battery pack 100 leading to a fire hazard in the entire battery pack 100. During malfunctioning of the cell 102, the current circulating through the pack 100 is dumped on the malfunctioning cell leading to thermal runaway in the battery pack 100.
[00051] Figure 2(a) exemplarily illustrates a top view of the interconnector of the battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure. Figure 2(b) illustrates a side view of the interconnector of the battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure. Figure 2(a) and Figure 2(b) shall be discussed together. In an embodiment, the one or more cells 102 is connected using one or more interconnectors 106 to ensure electrical connectivity between the one or more cells 102 and carry current in the circuit of the battery pack 100.
[00052] In an aspect of the present invention, the one or more interconnectors 106 are composed of a material. The material used for composition of the one or more interconnectors 104 is selected from at least one of or a combination of aluminium, nickel, and copper. The material used for one or more interconnectors 106 should allow electrical connectivity between the one or more cells 102 in the battery pack 100.
[00053] In an aspect of the present invention, the battery pack 100 comprises a plurality of battery modules and each battery modules comprises of one or more battery cells 102. The one or more interconnectors 106 connect the one or more cells 102 as well as the plurality of battery modules either in series configuration or parallel configuration.
[00054] In an embodiment, the cell terminals of adjacent cells of the one or more cells 102 are connected to each other using the one or more interconnectors 106. The one or more interconnectors 106 are spot welded on each cell terminal of the one or more cells 102. The one or more interconnectors 106 carry electric current between adjacent cells of the one or more cells 102 in the battery pack 100.
[00055] Figure 3(a) and 3(b) illustrates a localized view of the interconnector of the battery pack with multiple fusing elements, in accordance with embodiments of the present disclosure. Figure 3(a) and Figure 3(b) shall be discussed together. In an embodiment, each of the one or more interconnector 106 comprises of one or more neck fusing regions. Each one or more neck fusing region of the one or more interconnector 106 comprises of a first neck fusing region 108a, a second neck fusing region 108b, and a third neck fusing region 108c. Each interconnector additionally includes a first interconnector portion 108d.
[00056] In an aspect of the present invention, the one or more neck fusing regions comprising of the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c are configured to act as fusing elements which blow-off in the event of current through a cell exceeds a pre-defined current. In the event of a cell malfunctioning, the current through the one or more cells 102 are typically dumped on the malfunctioning cell leading to higher currents in the malfunctioning cell which exceed the pre-defined current value.
[00057] In an aspect of the present invention, the first neck fusing region 108a is disposed downwardly from a horizontal plane of each of the one or more interconnectors 106.
[00058] In an aspect of the present invention, the second neck fusing region 108b and the third neck fusing region 108c of the one or more interconnector 106 is disposed on the first interconnector portion 108d of the one or more interconnector 106.
[00059] In an aspect of the present invention, the first interconnector portion 108d extends parallelly below the one or more interconnector 106.
[00060] In an aspect of the present invention, the first interconnector 108d comprises of a horizontal slit opening 110 which is disposed on a top portion where the first neck fusing region 108a of the interconnector 106 connects to the first interconnector portion 108d.
[00061] In an aspect of the present invention, the second neck fusing region 108b and the third neck fusing region 108c of the interconnector 106 is defined at edges of the horizontal slit opening 110.
[00062] In an aspect of the present invention, the first neck fusing region 108a extends downwardly from a middle portion of a first opening 112 provided to encompass the first interconnector portion 108a.
[00063] In operation, the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c are configured to act as fusing elements which blow-off in the event of current through a cell exceeds a pre-defined current value. In the event of a cell malfunctioning in the battery pack 100, the current through the one or more cells 102 are typically dumped on the malfunctioning cell leading to higher currents in the malfunctioning cell which exceed the pre-defined current value.
[00064] In an aspect of the present invention, the width of the first neck fusing region 108a of the interconnector 106 is more than the width of the second neck fusing region 108b and the third neck fusing region 108c of the interconnector 106.
[00065] In an aspect of the present invention, the cross-sectional area of each of the one or more interconnectors 106 has an associated diameter of 0.2mm.
[00066] In operation, the first neck fusing region 108a of the interconnector 106 is configured to possess high resistance in comparison to the resistance possessed by the second neck fusing region 108b and the third neck fusing region 108c. The higher resistance of the first neck fusing region 108a in comparison to the second neck fusing region 108b and the third neck fusing region 108c is a result of the width of the second neck fusing region 108b and the third neck fusing region 108c being lesser than the width of the first neck fusing region 108a of the interconnector 106.
[00067] In an embodiment, the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 is composed of a material which is different from the remaining material used for composing the interconnector 106.
[00068] In an embodiment, the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 is composed of the same material as the material used to compose the remaining material of the interconnector 106. The width of the first neck fusing region 108a being more than the second neck fusing region 108b and the third neck fusing region 108c results in increased resistivity of the first neck fusing region 108a despite the same material being used in the composition of the remaining parts of the interconnector 106.
[00069] In an aspect of the present invention, the material used for composing at least one of the first neck fusing region 108a, second neck fusing region 108b, third neck fusing region 108c and the remaining material of the interconnector 106 comprises of two or more distinct metals or alloys having different properties. The two or more distinct metals or alloys used in composing the material must possess electrical conductivity to allow passage of electric current through the one or more cells 102 connected by the interconnector 106.
[00070] In an aspect of the present invention, the two or more distinct metals or alloys used for composing the material are metallurgically bonded together to achieve the functional benefits which are otherwise deemed unachievable by a single metal.
[00071] In an aspect of the present invention, the material used for composing at least one of the first neck fusing region 108a, second neck fusing region 108b, third neck fusing region 108c, and the remaining material of the interconnector 106 is selected from a combination of at least one of aluminium, nickel and copper.
[00072] In an embodiment, each interconnector 106 comprises of the first interconnector portion 108d having a plurality of second openings 114 where the plurality of second openings 114 enables spot welding of the first interconnector portion 108d of the interconnector 106 to at least one of a positive terminal of the cells the interconnector 106 connects.
[00073] In an embodiment, each interconnector 106 comprises of the first interconnector portion 108d having a plurality of second openings 114 where the plurality of second openings 114 enables spot welding of the first interconnector portion 108d of the interconnector 106 to at least one of a negative terminal of the cells the interconnector 106 connects.
[00074] In an aspect of the present invention, each interconnector 106 of the one or more interconnectors 106 comprises of a first neck fusing region 108a, a second neck fusing region 108b, and a third neck fusing region 108c configured to act as fusing elements. The first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c is configured to blow-off in the event of current in the battery pack 100 exceeding a pre-defined current.
[00075] In operation, in the event of an electrical mishap or malfunctioning cell in the battery pack 100, the current through the battery pack 100 circuit is dumped on the malfunctioning cell leading to higher currents being detected at the malfunctioning cell. The first neck fusing region 108a, second neck fusing region 108b, and the third neck fusing region 108c in the event of detection of higher currents exceeding a pre-defined value blows-off to isolate the malfunctioning cell from the battery pack 100. The disclosed configuration of the interconnector 106 comprising of a first neck fusing region 108a, a second neck fusing region 108b, and a third neck fusing region 108c eliminates the occurrence of thermal runaway in the battery pack 100 due to a malfunctioning cell and also enables the remaining cells of the battery pack 100 to continue its normal operation without any halt in application.
[00076] For example, the pre-defined current for the purpose of fusing in the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 is 10 A and there are 5 cells of the plurality of cells 102 connected in parallel and configured to carry a maximum of 8A of current. In the unfortunate event of an electrical mishap where one cell behaves abnormally or is deemed to malfunction, the electric current flowing through the one or more cells 102 is dumped on the malfunctioning cell. The first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 having necks formed carries the current flowing through the one or more cells 102. The current passing through the interconnector 106 is sensed by the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c and when the current passing through the interconnector 106 exceeds 10A, the heat generated due to the high current is transmitted to the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c. In the event of the current passing through the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 exceeding 10A, the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c would blow out due to the transmitted heat, disconnecting or isolating the malfunctioning cell from the one or more cells 102. Thus, the disclosed configuration achieves isolation of the malfunctioning cell from the remaining cells of the battery pack 100 circuit by employing a battery pack 100 provided with multiple fusing.
[00077] The above-mentioned example is only provided in pursuit of clarity, illustration and elucidation purposes of the present subject matter and shall not be construed to limit the scope of the present subject matter to abovementioned aspects of the invention.
[00078] The disclosed configuration of the present subject matter isolates the malfunctioning cell from the circuit without any hinderance in operation being caused to the adjacent cell and reducing the risk of fire hazard in the battery pack 100. Owing to the disclosed configuration of the battery pack 100, thermal runaway in the battery pack 100 is not only eliminated but also protection is accorded to the operational environment of the battery pack 100.
[00079] In an embodiment, the first interconnector portion 108d of the interconnector 106 is configured to have a plurality of openings 114. The plurality of second openings 114 of the first interconnector portion 108d enable spot welding of a portion of the interconnector to at least one of a positive terminal or a negative terminal of a cell of the one or more cells 102 of the battery pack 100.
[00080] In an aspect of the present invention, the disclosed subject matter additionally discloses one or more interconnectors 106 having a plurality of neck fusing regions and the first interconnector portion. The plurality of neck fusing regions comprise of a first neck fusing region 108a, a second neck fusing region 108b, and a third neck fusing region 108c configured to act as fusing elements and blow-off in the event of a current circulating through the one or more cells 102 exceeds a pre-defined current.
[00081] In an aspect of the present invention, the interconnectors 106 connects one or more cells 102 of the battery pack 100. The material used for composition of the one or more interconnectors 106 is selected from at least one of or a combination of aluminium, nickel, and copper.
[00082] In an aspect of the present invention, the interconnector has necks formed in the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 which act as fusing elements when the current passing through the interconnector 106 and the one or more cells 102 surpasses a pre-defined current.
[00083] The disclosed configuration of the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c permits numerous possibilities in developing different layouts for the interconnector 106 as well as the battery pack 100.
[00084] As an illustration, the pre-defined current in the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 for fusing purpose is configured to be 10A. Figuratively, 5 cells 102 of the battery pack 100 are connected in parallel configuration with each cell configured to carry a maximum current of 8A. In the event of an electrical mishap where one of the 5 cells behave abnormally, the electric current flowing through the 5 cells is dumped on the abnormally functioning cell leading to heat generation in the malfunctioning cell. Upon the current being dumped on the malfunctioning cell, the current sensed at the interconnector of the malfunctioning cell exceeds the pre-defined current of 10A. The first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 having necks senses the exceeded current and blows-out due to the transmitted heat and isolates the malfunctioning cell from the circuit of the battery pack 100.
[00085] In an aspect of the present invention, the first neck fusing region 108a extends downwardly from a middle portion of a first opening 112 so as to encompass the first interconnector portion 108d.
[00086] In an aspect of the present invention, the width of the first neck fusing region 108a is more than the second neck fusing region 108b and the third neck fusing region 108c. Further, the resistance of the first neck fusing region 108a is higher than the resistance of the second neck fusing region 108b and the third neck fusing region 108c owing to the different widths attributed to the first neck fusing region 108a, the second neck fusing region 108b and the third neck fusing region 108c.
[00087] In an aspect of the present invention, the first interconnector portion 108d extends parallelly below the interconnector 106. The first interconnector portion 108d is provided with a plurality of second openings 114 to enable spot welding of the first interconnector portion 108d to at least one of a positive terminal or a negative terminal of the cells.
[00088] In an aspect of the present invention, the first neck fusing region 108a is disposed downwardly from a horizontal plane of the interconnector 106 while the second neck fusing region 108b and the third neck fusing region 108c being disposed on the first interconnector portion 108d of the interconnector 106.
[00089] In an aspect of the present invention, the first interconnectors portion 108d comprises of a horizontal slit opening 110 disposed on a top portion of the first neck fusing region 108a which connects to the first interconnector portion 108d of the interconnector 106.
[00090] In an aspect of the present invention, the second neck fusing region 108b and the third neck fusing region 108c of the interconnector 106 is defined at the edges of the horizontal slit opening 110.
[00091] In an embodiment, the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 is composed of a material which is different from the remaining material used for composing the interconnector 106.
[00092] In an embodiment, the first neck fusing region 108a, the second neck fusing region 108b, and the third neck fusing region 108c of the interconnector 106 is composed of the same material as the material used to compose the remaining material of the interconnector 106.
[00093] In an aspect of the present invention, the material is made of two or more distinct metals or alloys with very different properties which are metallurgically bonded together to achieve functional benefits unachievable with a single metal. The material is made from a combination of at least aluminum, nickel and copper.
[00094] In an embodiment, the plurality of neck fusing regions of the interconnector are communicatively connected to an external electronic device configured to alert authorities in the event of detection of a malfunctioning cell and blow-off of the fusing regions of the interconnector.
[00095] The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the invention(s)” unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but not limited to”, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.
[00096] The disclosed claimed limitations and the disclosure provided herein provides a battery pack 100 with an interconnector 106 comprising of one or more neck fusing regions. The claimed invention in an aspect provides enhanced safety and security in the operating environment of the battery pack 100. In an embodiment, the interconnector 106 comprises of multiple neck fusing necks configured to act as fusing element which blow-off once the current passing through the interconnector exceeds a pre-defined current resulting in isolation of the malfunctioning cell from the one or more cells, alleviate occurrences of thermal runaway and enable normal functioning of the other cells of the battery pack. The disclosed configuration in turn saves money, time and energy by allowing normal functioning of the battery pack after isolating the malfunctioning cell.
[00097] Conventional battery packs employing BMS fail to isolate the malfunctioning cell from the other cells of the battery pack which results in halting of the operation of the battery pack. The present subject matter addresses this exact drawback through the disclosed configuration of multiple fusing neck regions of the interconnector.
[00098] In an aspect, the disclosed configuration of the battery pack does not require the involvement of additional semiconductor components to isolate the malfunctioning cell by forming plurality of neck fusing regions in the interconnector itself. Consequently, the disclosed configuration does not affect the overall weight, size, number of components, and cost of the battery pack.
[00099] Further, in accordance with the present disclosure, the disclosed configuration enhances accessibility, serviceability and maintenance of the battery pack. Additionally, the disclosed configuration allows adaptability of the interconnector configuration in conventional battery pack without any significant deviations or revamping of the core manufacturing process. The flexibility of manufacturing variants accorded as per the present disclosure allows battery pack variants in forms of size of the battery pack, range of power supply and capacity of the battery pack.
[000100] To this extent, the reduced weight of the battery pack achieved in accordance with the present disclosure provides a high power to weight ratio in the vehicle where the battery pack is employed, ultimately yielding improved vehicle performance.
[000101] Further, the present disclosure of the battery pack achieves active paralleling circuits in the battery pack where the plurality of cells are connected in parallel configuration.
[000102] In light of the above-mentioned advantages and the technical advancements provided by the disclosed method and system, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the device itself as the claimed steps provide a technical solution to a technical problem.
[000103] A description of an embodiment with several components in communication with another does not imply that all such components are required, On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention.
[000104] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[000105] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[000106] The present disclosure may be realized in hardware, or a combination of hardware and software. The present disclosure may be realized in a centralized fashion, in at least one computer system, or in a distributed fashion, where different elements may be spread across several interconnected computer systems, a computer system or other apparatus adapted for carrying out the methods described herein may be suited. A combination of hardware and software may be a general-purpose computer system with a computer program that, when loaded and executed, may control the computer system such that it carries out the methods described herein. The present disclosure may be realized in hardware that comprises a portion of an integrated circuit that also performs other functions.
[000107] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[000108] Those skilled in the art will appreciate that any of the aforementioned steps and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and system modules, and are not limited to any particular computer hardware, software, middleware, firmware, microcode, and the like. The claims can encompass embodiments for hardware and software, or a combination thereof.
[000109] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure is not limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.

List of reference numerals:
100: Battery pack
102: One or more cells
104: One or more busbars
106: One or more interconnectors
108a: First neck fusing region
108b: Second neck fusing region
108c: Third neck fusing region
108d: First interconnector portion
110: Horizontal slit opening
112: First opening
114: Plurality of second openings
 
, Claims:We claim:
1. A battery pack (100) comprising:
one or more cells (102); each of the one or more cells (102) are connected to form one or more modules;
one or more interconnectors (106), the one or more cells (102) are connected using one or more interconnectors (106); and
one or more busbar (104), the one or more busbar (104) being configured to collect power from the battery pack (100);
wherein the one or more interconnectors (106) includes one or more neck fusing regions;
wherein each of the one or more neck fusing regions comprises a first neck fusing region (108a), a second neck fusing region (108b), and a third neck fusing region (108c).

2. The battery pack (100) as claimed in claim 1, wherein the first neck fusing region (108a) being disposed downwardly from a horizontal plane of the one or more interconnectors (106).
3. The battery pack as claimed in claim 1, wherein the second neck fusing region (108b) and the third neck fusing region (108c) being disposed on a first interconnector portion (108d) of the one or more interconnectors (106).
4. The battery pack (100) as claimed in claim 1, wherein the first interconnector portion (108d) includes a horizontal slit opening (110) disposed on a top portion where the first neck fusing region (108a) connects with the first interconnector portion (108d) of the one or more interconnectors (106).
5. The battery pack (100) as claimed in claim 1, wherein the second neck fusing region (108b) and the third neck fusing region (108c) being defined at one or more edges of the horizontal slit opening (110).
6. The battery pack (100) as claimed in claim 1, wherein the first neck fusing region (108a) extends downwardly from a middle portion of a first opening (112) provided to encompass the first interconnector portion (108d).
7. The battery pack (100) as claimed in claim 1, wherein the first interconnector portion (108d) extends parallelly below the one or more interconnectors (106).
8. The battery pack (100) as claimed in claim 1, wherein the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) being configured to act as a fusing element when a current passing through the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) exceeds a pre-defined current.
9. The battery pack (100) as claimed in claim 1, wherein a width of the first neck fusing region (108a) being more than a width of the second neck fusing region (108b) and the third neck fusing region (108c).
10. The battery pack (100) as claimed in claim 1, wherein resistance of the first neck fusing region (108a) being higher than resistance of the second neck fusing region (108b) and the third neck fusing region (108c) as width of the second neck fusing region (108b) and the third neck fusing region (108c) being less than the first neck fusing region (108a).
11. The battery pack (100) as claimed in claim 1, wherein material of the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) being different from that of remaining material of the one or more interconnectors (106).
12. The battery pack (100) as claimed in claim 1, wherein the material of the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) being same as that of the remaining material of the one or more interconnectors (106).
13. The battery pack (100) as claimed in claim 11, wherein the material being made of two or more distinct metals or alloys with different properties, wherein the two or more distinct metals or alloys being metallurgically bonded together.
14. The battery pack (100) as claimed in claim 11, wherein the material being made from a combination of aluminum, nickel, and copper.
15. The battery pack (100) as claimed in claim 1, wherein the one or more interconnectors (106) being made from one of a nickel or copper.
16. The battery pack (100) as claimed in claim 1, wherein the first interconnector portion (108d) has a plurality of second openings (114), wherein the plurality of second openings (114) enables spot welding of the first interconnector portion (108d) to at least one of a positive terminal or a negative terminal of the one or more cells (102).

17. An interconnector (106), the interconnector (106)comprising:
one or more neck fusing regions;
wherein one or more neck fusing regions comprises a first neck fusing region (108a), a second neck fusing region (108b), and a third neck fusing region (108c);
wherein the first neck fusing region (108a) is disposed downwardly from a horizontal plane of the one or more interconnectors (106); and
wherein the second neck fusing region (108b) and the third neck fusing region (108c) being disposed on a first interconnector portion (108d) of the each of the plurality of interconnectors (106).

18. The interconnector (106) as claimed in claim 17, wherein the first interconnector portion (108d) includes a horizontal slit opening (110) disposed on a top portion where the first neck fusing region (108a) connects with the first interconnector portion (108d) of the one or more interconnectors (106).
19. The interconnector (106) as claimed in claim 17, wherein the second neck fusing region (108b) and the third neck fusing region (108c) being defined at one or more edges of the horizontal slit opening (110) disposed on the top portion where the first neck fusing region (108a) connects with the first interconnector portion (108d).
20. The interconnector (106) as claimed in claim 17, wherein the first neck fusing region (108a) extends downwardly from a middle portion of a first opening (112) provided to encompass the first interconnector portion (108d).
21. The interconnector (106) as claimed in claim 17, wherein the first interconnector portion (108d) extends parallelly below the one or more interconnectors (106).
22. The interconnector (106) as claimed in claim 17, wherein the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) being configured to act as a fusing element when a current passing through the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) exceeds a pre-defined current.
23. The interconnector (106) as claimed in claim 17, wherein a width of the first neck fusing region (108a) being more than a width of the second neck fusing region (108b) and third neck fusing region (108c).
24. The interconnector (106) as claimed in claim 17, wherein resistance of the first neck fusing region (108a) being higher than the second neck fusing region (108b) and the third neck fusing region (108c) as width of the second neck fusing region (108b) and the third neck fusing region (108c) being less than the first neck fusing region (108a).
25. The interconnector (106) as claimed in claim 17, wherein material of the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) being different from that of remaining material of the one or more interconnectors (106).
26. The interconnector (106) as claimed in claim 17, wherein material of the first neck fusing region (108a), the second neck fusing region (108b), and the third neck fusing region (108c) is same as that of the remaining material of the one or more interconnectors (106).
27. The interconnector (106) as claimed in claim 25, wherein the material being made of two or more distinct metals or alloys with different properties, wherein the two or more distinct metals or alloys being metallurgically bonded together.
28. The interconnector (106) as claimed in claim 25, wherein the material being made from a combination of at least aluminium, nickel, and copper,
29. The interconnector (106) as claimed in claim 17, wherein the one or more interconnectors (106) being made from one of a nickel, or copper.
30. The interconnector (106) as claimed in claim 17, wherein the first interconnector portion (108d) has a plurality of second openings (114), wherein the plurality of second openings (114) enable spot welding of the first interconnector portion (108d) to at least one of a positive terminal or a negative terminal of the one or more cells (102).