Description:FIELD
The present disclosure generally relates to a high-voltage busbar assembly with ingress protection (IP) sealing to eliminate a potential risk of water leakage or water entry into a battery pack of an electric automotive vehicle. In particular, the present disclosure relates to a high-voltage busbar assembly for routing through a cooling plate from a bottom module to a top-mounted electrical and electronic box of a battery pack.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Generally, automotive vehicle manufacturers are implementing electrification technologies in many vehicle line-ups, both passenger and light commercial vehicles, to improve fuel economy and meet emission standards.
The purpose of these technologies is to enhance fuel economy and meet emission standards. Battery packs used with electric vehicles store large amounts of energy in a small space, producing high energy densities. These battery packs include an external housing that is designed for more than just environmental protection and packaging efficiency. The external housing also enhances safety and stability, particularly under a range of anticipated abnormal operating conditions.
As electric vehicles have gained prominence, special attention is given to preventing water, coolant, or any other fluid from entering a module chamber of the battery pack. It is crucial to protect the lean module of the battery pack from dust and water to ensure the battery pack's durability and safety.
However, a challenge arises when routing a high voltage busbar (an electrical conductor) from the bottom module pack (battery pack) to a top external mounted electrical and electronic (EE) box. This routing provision through a cooling plate of the battery pack can potentially lead to water leakage (in case of cooling plate brazing failure) into the module chamber through a cutout provided in the cooling plate for the routing provisioning.
Further, many concept design study approaches explore different design solutions to address this issue. However, none of the approaches is found feasible for packaging the electrical and electronic (EE) box inside the module chamber, due to limited space inside the module chamber and increased cost of the product due to more number of high-voltage connectors.
Therefore, there is a need in the art to provide a high-voltage busbar assembly (an electrical conductor) for routing through the cooling plate, while ensuring effective water ingress sealing against the battery pack and the electrical and electronic (EE) box.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a high-voltage busbar assembly to eliminate a potential risk of water entry or leakage or water entry from a cooling plate, or outside abuse condition, which could lead to water ingress into a module chamber and an electrical and electronic (EE) box, causing a short circuit inside a battery pack.
Another object of the present disclosure is to provide a high-voltage busbar assembly for routing through a cooling plate of a battery pack by ensuring effective ingress protection sealing against water and dust for both the battery pack and the electrical and electronic (EE) box assembled in the battery pack.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
This summary is provided to introduce concepts related to a high-voltage busbar assembly with ingress protection (IP) sealing to eliminate a potential risk of water leakage or entry into a battery pack of an electric automotive vehicle. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
According to a first embodiment, the present disclosure envisages a high-voltage busbar assembly for routing through a cooling plate (an electrical conductor) while ensuring effective ingress protection and dielectric sealing. The busbar is routed through a cooling plate from a bottom module to a top-mounted electrical and electronic (EE) box of a battery pack.
The busbar assembly includes a metallic holder made of aluminium having at least two legs for mounting on the battery pack, a circular base formed over the legs, and an extended metallic member protruding vertically from a top portion of the circular base, where a through-hole is formed starting from a base portion of the circular base to a top portion of the extended metallic member.
The busbar assembly further includes a circular busbar accommodated inside the through-hole by means of an insulating material structure, where the circular busbar has a top end extending from a top portion of the extended metallic member and a bottom end extending from the bottom portion of the circular base in an assembled condition.
The busbar assembly further includes a flexible busbar fixed with the bottom end of the circular busbar and extends at a right angle therefrom for establishing an electrical connection with the terminal of the battery pack. In an aspect, the circular busbar and the flexible busbar are metallic components for conducting current from the battery pack.
In an aspect, the through-hole is filled with an insulating material potting and has a circular diameter with a two-step configuration to hold a busbar holder. The busbar holder is adapted to accommodate a circular busbar inside the through-hole.
The busbar assembly further includes a first gasket arranged in a circular groove formed on a peripheral region of a top surface of the circular base. A metallic nut made of aluminium threaded over external threads of the extended metallic member to lock the cooling plate of the battery pack over the top surface of the circular base and the first gasket mounted thereon. A second gasket arranged in a circular groove formed on a top surface of shoulders of the metallic nut. The first gasket and the second gasket are O-rings.
The busbar assembly further includes a plastic nut threaded over external threads of the extended metallic member to lock a top plate of electrical and electronic (EE) box of the battery pack over the top surface of the shoulders of the metallic nut and have the second gasket mounted thereon. A plastic protection cap fitted over the top end of the circular busbar with positive locking.
The top end of the circular busbar having an internal threads for busbar extension mounting inside the electrical and electronic (EE) box.
According to a second embodiment, the present disclosure further envisages a busbar assembly that includes a metallic holder made of aluminium that has at least two legs for mounted near an electric terminal on the battery pack and a circular base formed over the legs, where a first through-hole is formed starting from a base portion of the circular base to a top portion of the circular base.
The busbar assembly further includes an extended metallic member threaded over the internal threads of the first through-hole of the circular base to extend vertically from the top portion of the circular base. A pair of circular busbars with an insulating material structure is accommodated inside a second through-hole which is formed starting from a base portion to a top portion of the extended metallic member, where each of the circular busbars has a top end extending from a top portion of the extended metallic member and a bottom end extending from the bottom portion of the extended metallic member in an assembled condition.
The busbar assembly further includes a pair of flexible busbars fixed with bottom ends of the respective circular busbars, where each of the flexible busbars is extended opposite to each other at a right angle from the respective circular busbars to establish an electrical connection with the terminal of the battery pack.
The busbar assembly further includes a first gasket mounted in a circular groove which is formed on a peripheral region of a top surface of the circular base.
The busbar assembly further includes a first metallic nut made of aluminium threaded over external threads of the extended metallic member to lock the cooling plate of the battery pack over the top surface of the circular base and the first gasket mounted thereon. A second metallic nut is threaded over the external threads of the extended metallic member and above the first metallic nut to lock the rotational movement of the first metallic nut and provide a housing to accommodate the top plate. A second gasket mounted in a circular groove formed on a top surface of shoulders of the second metallic nut and a plastic nut threaded over the external threads of the extended metallic member to lock a top plate of electrical and electronic (EE) box of the battery pack over a top surface of shoulders of the second metallic nut having the second gasket mounted thereon.
In an aspect, a plastic protection cap fitted over the top end of each of the circular busbars with positive locking.
In an aspect, the insulating material structure is an insulating material separator fitted in the second through-hole of the extended metallic member.
In an aspect, the insulating material separator has a segment to accommodate a pair of circular busbars.
In an aspect, the circular busbars and the flexible busbars are metallic components for conducting current from the battery pack.
According to a third embodiment, the present disclosure further envisages a busbar assembly that includes a plastic holder that has an L-shaped base surface having mounting holes for mounting near a terminal, on a vertical wall of the battery pack.
The busbar assembly further includes a flexible busbar fabricated inside the plastic holder in such a way that one connection end of the flexible busbar establishes a connection with the terminal of the battery pack and another connection end of the flexible busbar is fabricated as a link plate on top surface of the plastic holder and an insulating material structure integrated on a circular busbar, the link plate with the plastic holder having a bottom weld nut for circular busbar mounting, where the circular busbar has external thread tappings for busbar bolted joint connection with the link plate. The insulating material formed with a circular groove on a peripheral region of the lower surface of shoulders to arrange a gasket in between the insulating material and a cooling plate of the battery pack.
In an aspect, the insulating material structure is a plastic nut moulded together into the circular busbar.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A high-voltage busbar assembly for routing through a cooling plate with ingress protection (IP) sealing of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1A illustrates an exploded view of a battery pack with an electrical and electronic (EE) box;
Figure 1B illustrates an assembled view of the battery pack with the electrical and electronic (EE) box;
Figure 2A illustrates a high-voltage busbar assembly in accordance with a first embodiment of the present disclosure;
Figure 2B illustrates an exploded view of different components of the high-voltage busbar assembly in accordance with the first embodiment of the present disclosure;
Figure 2C illustrates an assembled view of the high-voltage busbar assembly in accordance with the first embodiment of the present disclosure;
Figure 3A illustrates a high-voltage busbar assembly in accordance with a second embodiment of the present disclosure;
Figure 3B illustrates an exploded view of different components of the high-voltage busbar assembly in accordance with the second embodiment of the present disclosure;
Figure 3C illustrates an assembled view of the high-voltage busbar assembly in accordance with the second embodiment of the present disclosure;
Figure 4A illustrates a high-voltage busbar assembly in accordance with a third embodiment of the present disclosure;
Figure 4B illustrates an exploded view of different components of the high-voltage busbar assembly in accordance with the third embodiment of the present disclosure; and
Figure 4C illustrates an assembled view of the high-voltage busbar assembly in accordance with the third embodiment of the present disclosure.
REFERENCE NUMERALS
200, 300, 400 - Busbar Assembly
100 - Battery Pack
101 - Cooling Plate
102 - Bottom Plate
103 - Electrical and Electronic (EE) Box
104 – Module Chamber
105 - Top Plate
201 - Metallic Holder
201L1, 201L2 – Legs of Metallic Holder
201C - Circular Base of Metallic Holder
201C-CG - Circular Groove of Peripheral Region of Circular Base
201C-TS - Top Surface of Circular Base
201C-B - Bottom Portion of Circular Base
201C-T - Top Portion of Circular Base
201E - Extended Metallic Member
201E-T Top Portion of Extended Member
201E-B - Bottom Portion of Extended Member
201-TH - Through-hole
202 - Circular Busbar
202-T - Top End of Circular Busbar
202-TS - Top Surface of Circular Busbar
202-B - Bottom End of Circular Busbar
202-I - Insulating Material Structure
202I-S - Lower Surface of Shoulders of Insulating Material Structure
202I-C - Circular Groove of Peripheral Region of Lower Surface of Shoulders
203 - Flexible Busbar
203F-OC - One Connection
203F-AC - Another Connection
204 - Gasket
204A - First Gasket
204B - Second Gasket
205 - Metallic Nut
205-T - Shoulders
205-TS - Top Surface of Shoulders of Metallic Nut
205-CG - Circular Groove of shoulders
206 - Plastic Nut
207 - Plastic Protection Cap
208 - Busbar Holder
209 – Fastening Means
301-TH - First Through-Hole
302-TH - Second Through-Hole
303A, 303B - Pair of Circular Busbar
303-T – Top End of Circular Busbar
304A, 304B - Pair of Flexible Busbar
305 - First Metallic Nut
306 - Second Metallic Nut
306-T - Shoulders of Second Metallic Nut
306-TS - Top Surface of shoulders of Second Metallic Nut
306-CG - Circular Groove of Top Surface of shoulders of Second Metallic Nut
307 - Segment
401 - Plastic Holder
402 - L-Shaped Base Surface Mounting Holes
403 - Link Plate
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Battery packs used with electric vehicles store large amounts of energy in a small space, producing high energy densities. These battery packs include an external housing that is designed for more than just environmental protection and packaging efficiency. The external housing also enhances safety and stability, particularly under a range of anticipated abnormal operating conditions.
As electric vehicles have gained prominence, special attention is given to preventing water, coolant, or any other fluid from entering a module chamber of the battery pack. It is crucial to protect the lean module of the battery pack from dust and water to ensure the battery pack's durability and safety.
However, a challenge arises when routing a high voltage busbar (an electrical conductor) from the bottom module pack (battery pack) to a top external mounted electrical and electronic (EE) box. This routing provision through a cooling plate of the battery pack can potentially lead to water leakage (in case of cooling plate brazing failure) into the module chamber through a cutout provided in the cooling plate for the routing provisioning.
Further, many concept design study approaches have explored different design solutions to address this issue. However, none of the approaches is found feasible for packaging the electrical and electronic (EE) box inside the module chamber, due to limited space inside the module chamber and increased cost of the product due to more number of high-voltage connectors.
To overcome the above-mentioned drawbacks, the present disclosure envisages a high-voltage busbar assembly (an electrical conductor) for routing through a cooling plate while ensuring effective ingress protection sealing against water and dust ingress for both a battery pack and an electrical and electronic (EE) box.
Figures 1A and 1B illustrate a typical assembly of a battery pack 100. The battery pack 100 includes a module chamber 104 sandwiched between a bottom plate 102 and a top plate 105. Further, in between the module chamber 104 and the top plate 105, a cooling plate 101 is fixed for radiating the heat from cells present in the module chamber 104. On the top surface of the top plate 105 and in the region of terminals of the battery pack 100, an electrical and electronic (EE) box 103 is mounted.
Further, an electrical busbar connection between the battery pack 100 and EE box 103 is routed through a cutout of the cooling plate 101. In such a configuration, any leakage on the cooling plate 101 or other water entry may lead to water entry inside the module chamber 104, and electrical and electronic EE box 103 leading to a short circuit. To overcome this issue, a busbar assembly is proposed in the present disclosure, which will ensure ingress protection to the battery pack 100 and the EE box 103 while being routed through cooling plate 101.
Figures 2A-2C illustrate different views of different components of a high-voltage busbar assembly 200 in accordance with a first embodiment of the present disclosure. The busbar assembly 200 is routed through the cooling plate 101 from a bottom plate 102 to the top-mounted electrical and electronic (EE) box 103 of the battery pack 100. The busbar assembly 200 includes a metallic holder 201 made of aluminium having at least two legs 201L1, 201L2 for mounting near an electric terminal on the battery pack 100 through a fastening means 209, a circular base 201C formed over the legs 201L1, 201L2, and an extended metallic member 201E protruding vertically from a top portion 201C-T of the circular base 201C. In an aspect, a through-hole 201-TH is formed starting from a base portion 201C-B of the circular base 201C to a top portion 201E-T of the extended metallic member 201E.
Further, a circular busbar 202 is accommodated inside the through-hole 201-TH by means of an insulating material structure 202-I. The circular busbar 202 has a top end 202-T extending from a top portion 201E-T of the extended metallic member 201E and a bottom end 202-B extending from the bottom portion 201C-B of the circular base 201C in an assembled condition.
In an aspect, the through-hole 201-TH is filled with an insulating material potting and has a circular diameter with a two-step configuration to hold a busbar holder 208. The busbar holder 208 accommodates a circular busbar 202 inside the through-hole 201-TH.
Yet further, a flexible busbar 203 is fixed with the bottom end 202-B of the circular busbar 202 and extends at a right angle therefrom for establishing an electrical connection with the terminal of the battery pack 100. In an aspect, the circular busbar 202 and the flexible busbar 203 are metallic components for conducting current from the battery pack 100.
Yet further, a first gasket 204A is arranged in a circular groove 201C-CG formed on a peripheral region of a top surface 201C-TS of the circular base 201C. On external threads of the extended metallic member 201E, a metallic nut 205 made of aluminium is threaded to lock the cooling plate 101 of the battery pack 100 over the top surface 201C-TS of the circular base 201C and have the first gasket 204A mounted thereon.
Yet further, a second gasket 204B is arranged in a circular groove 205-CG formed on a top surface 205-TS of shoulders 205-T of the metallic nut 205. In an aspect, the first gasket 204A and the second gasket 204B are O-rings.
On external threads of the extended metallic member 201E, a plastic nut 206 is threaded to lock a top plate 105 of the battery pack 100 over the top surface 205-TS of the shoulders 205-T of the metallic nut 205 and have the second gasket 204B mounted thereon.
In an aspect, a plastic protection cap 207 is fitted over the top end 202-T of the circular busbar 202 with positive locking.
Figures 3A-3C illustrate different views of a high-voltage busbar assembly 300 in accordance with a second embodiment of the present disclosure. The busbar assembly 300 is routed through the cooling plate 101 from the module chamber 104 to the top-mounted electrical and electronic (EE) box 103. The busbar assembly 300 includes a metallic holder 201 made of aluminium having at least two legs 201L1, 201L2 for mounting near a terminal on the battery pack 100, a circular base 201C formed over the legs 201L1, 201L2. In an aspect, a first through-hole 301-TH is formed starting from a base portion 201C-B of the circular base 201C to a top portion 201C-T of the circular base 201C.
Yet further, an extended metallic member 201E is threaded over internal threads of the first through-hole 301-TH of the circular base 201C to extend vertically from the top portion 201C-T of the circular base 201C.
Yet further, a pair of circular busbars 303A, 303B, with an insulating material structure 202-I, accommodated inside a second through-hole 302-TH formed starting from a base portion 201E-B to a top portion 201E-T of the extended metallic member 201E. In an aspect, each of the circular busbars 303A, 303B has a top end 303-T extending from a top portion 201E-T of the extended metallic member 201E and a bottom end 303-B extending from the bottom portion 201E-B of the extended metallic member 201E in an assembled condition.
Yet further, the insulating material structure 202-I is an insulating material separator fitted in the second through-hole 302-TH of the extended metallic member 201E. In an aspect, the insulating material separator has a segment 307 to accommodate a pair of circular busbars 303A, 303B.
Yet further, a pair of flexible busbars 304A, 304B are fixed with the bottom ends of the respective circular busbars 303A, 303B. In an aspect, each of the flexible busbars 304A, 304B are extended opposite to each other at a right angle from the respective circular busbars 303A, 303B for establishing an electrical connection with the terminal of the battery pack 100. In an aspect, the circular busbars 303A, 303B and the flexible busbars 304A, 304B are metallic components for conducting current from the battery pack 100.
Yet further, a first gasket 204A is mounted in a circular groove 201C-CG formed on a peripheral region of a top surface 201C-TS of the circular base 201C. On external threads of the extended metallic member 201E, a first metallic nut 305 is threaded to lock the cooling plate 101 of the battery pack 100 over the top surface 201C-TS of the circular base 201C and have the first gasket 204A mounted thereon.
On external threads of the extended metallic member 201E and above the first metallic nut 305, a second metallic nut 306 is threaded to lock the rotational movement of the first metallic nut 305. In an aspect, the first metallic nut 305 and the second metallic nut 306 are made of aluminium.
Yet further, a second gasket 204B is mounted in a circular groove 306-CG formed on a top surface 306-TS of shoulders 306-T of the second metallic nut 306. In an aspect, the first gasket 204A and the second gasket 204B are O-rings.
On external threads of the extended metallic member 201E, a plastic nut 206 is threaded to lock the top plate 105 of the battery pack 100 over a top surface of shoulders 306-T of the second metallic nut 306 and has the second gasket 204B mounted thereon.
In an aspect, a plastic protection cap 207 is fitted over the top end 303-T of each of the circular busbars 303A, 303B with positive locking.
Figures 4A-4B illustrate different views of a high-voltage busbar assembly 400 in accordance with a third embodiment of the present disclosure. The busbar assembly 400 is routed through the cooling plate 101 from the module chamber 104 to a top-mounted electrical and electronic (EE) box 103 of the battery pack 100. The busbar assembly 400 includes a plastic holder 401 having an L-shaped base surface having mounting holes 402 for mounting, near an electric terminal, on a vertical wall of the battery pack 100.
Yet further, a flexible busbar 203 is fabricated inside the plastic holder 401 in such a way that one connection end 203F-OC of the flexible busbar 203 establishes an electric connection with the terminal of the battery pack 100 and another connection end 203F-AC of the flexible busbar 203 is fabricated as a link plate 403 on top surface of the plastic holder 401.
Yet further, an insulating material structure 202-I is integrated into a circular busbar 202. The circular busbar 202 has external threads for mounting with the link plate 403 having a bottom weld nut and the top surface 202-TS of the circular busbar 202 has internal thread tappings for busbar bolted joint connection inside the electrical and electronic (EE) box 103, and the insulating material 202-I is formed with a circular groove 202I-C on a peripheral region of the lower surface of shoulders 202I-S to arrange a gasket 204 in between the insulating material 202-I and the cooling plate 101 of the battery pack 100.
In an aspect, a plastic protection cap 207 is fitted over the top end 202-T of the circular busbar 202 with positive locking. In an aspect, the gasket 204 is an O-ring.
In an aspect, the insulating material structure 202-I is a plastic nut integrated into the circular busbar 202 and the circular busbar 202.
In an aspect, the circular busbar 202 and the flexible busbar 203 are metallic components for conducting current from the battery pack 100.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a high-voltage busbar assembly with ingress protection sealing:
• helps to eliminate a potential risk of water leakage or entry onto the cooling plate and external abuse, which could lead to water entering the battery pack and the EE box, causing a short circuit inside the battery module; and
• provides an effective ingress protection sealing of the battery pack of the electric automotive vehicle; and
• helps to protect the battey pack of the electric automotive vehicle from dust and water and ensures the battery pack's durability and safety.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A high-voltage busbar assembly (200) for routing through a cooling plate (101) from a module chamber (104) to a top-mounted electrical and electronic box (103) of a battery pack (100), said busbar assembly (200) comprises;
a holder (201) having at least two legs (201L1, 201L2) for mounting on the battery pack (100) through fastening means (209), a base (201C) formed over the legs (201L1, 201L2), and an extended member (201E) protruding vertically from a top portion (201C-T) of the circular base (201C), wherein a through-hole (201-TH) is formed starting from a base portion (201C-B) of the base (201C) to a top portion (201E-T) of the extended member (201E);
a first busbar (202) accommodated inside the through-hole (201-TH) by means of an insulating material structure (202-I), wherein the first busbar (202) has a top end (202-T) extending from a top portion (201E-T) of the extended member (201E) and has a bottom end (202-B) extending from the bottom portion (201C-B) of the base (201C) in an assembled condition;
a second busbar (203) fixed with the bottom end (202-B) of the first busbar (202) and extending angularly therefrom for establishing an electrical connection with the terminal of the battery pack (100);
a first gasket (204A) arranged in a first groove (201C-CG) formed on a peripheral region of a top surface (201C-TS) of the base (201C);
a first nut (205) threaded over external threads of the extended member (201E) so as to lock the cooling plate (101) of the battery pack (100) over the top surface (201C-TS) of the base (201C) having the first gasket (204A) mounted thereon;
a second gasket (204B) arranged in a second groove (205-CG) formed on a top surface (205-TS) of shoulders (205-T) of the first nut (205); and
a second nut (206) threaded over external threads of the extended member (201E) so as to lock a top plate (105) of the battery pack (100) over the top surface (205-TS) of the shoulders (205-T) of the first nut (205) having the second gasket (204B) mounted thereon.
2. The high-voltage busbar assembly (200) as claimed in claim 1, wherein the holder (201) is metallic, the base (201C) is circular, the first groove (201C-CG) is circular, the extended member (201E) is metallic, the first busbar (202) is circular , the second busbar (203) is flexible, the first nut (205) is metallic, the second groove (205-CG) is circular and the second nut (206) is plastic.
3. The high-voltage busbar assembly (200) as claimed in claim 2, comprises a plastic protection cap (207) fitted over the top end (202-T) of the circular busbar (202) with positive locking.
4. The high-voltage busbar assembly (200) as claimed in claim 2, comprises a busbar holder (208) to accommodate the circular busbar (202) inside the through-hole (201-TH) and through-hole (201-TH) has a circular diameter with a two-step configuration to hold the busbar holder (208).
5. The high-voltage busbar assembly (200) as claimed in claim 2, wherein the insulating material structure (202-I) is an insulating material potting filled in the through-hole (201-TH).
6. The high-voltage busbar assembly (200) as claimed in claim 2, wherein the circular busbar (202) and the flexible busbar (203) are metallic components for conducting current from the battery pack (100).
7. A high-voltage busbar assembly (300) for routing through a cooling plate (101) from a module chamber (104) to a top-mounted electrical and electronic box (103) of a battery pack (100), said busbar assembly (300) comprises,
a metallic holder (201) having at least two legs (201L1, 201L2) for mounting near an electric terminal on the battery pack (100) and a circular base (201C) formed over the legs (201L1, 201L2), wherein a first through-hole (301-TH) being formed starting from a base portion (201C-B) of the circular base (201C) to a top portion (201C-T) of the circular base (201C);
an extended metallic member (201E) threaded over internal threads of the the first through-hole (301-TH) of the circular base (201C) to extend vertically from the top portion (201C-T) of the circular base (201C);
a pair of circular busbars (303A, 303B), with an insulating material structure (202-I), accommodated inside a second through-hole (302-TH) formed starting from a base portion (201E-B) to a top portion (201E-T) of the extended metallic member (201E), wherein each of the circular busbars (303A, 303B) having a top end (303-T) extending from a top portion (201E-T) of the extended metallic member (201E) and having a bottom end (303-B) extending from the bottom portion (201E-B) of the extended metallic member (201E) in an assembled condition;
a pair of flexible busbars (304A, 304B) fixed with bottom ends of the respective circular busbars (303A, 303B), wherein each of the flexible busbars (304A, 304B) extends opposite to each other at a right angle from the respective circular busbars (303A, 303B) for establishing an electrical connection with the terminal of the battery pack (100);
a first gasket (204A) mounted in a circular groove (201C-CG) formed on a peripheral region of a top surface (201C-TS) of the circular base (201C);
a first metallic nut (305) threaded over external threads of the extended metallic member (201E) so as to lock the cooling plate (101) of the battery pack (100) over the top surface (201C-TS) of the circular base (201C) having the first gasket (204A) mounted thereon;
a second metallic nut (306) threaded over the external threads of the extended metallic member (201E) and above the first metallic nut (305) so as to lock the rotational movement of the first metallic nut (305);
a second gasket (204B) mounted in a circular groove (306-CG) formed on a top surface (306-TS) of shoulders (306-T) of the second metallic nut (306); and
a plastic nut (206) threaded over external threads of the extended metallic member (201E) so as to lock a top plate (105) of the battery pack (100) over a top surface of shoulders (306-T) of the second metallic nut (306) having the second gasket (204B) mounted thereon.
8. The high-voltage busbar assembly (300) as claimed in claim 7, comprises a plastic protection cap (207) fitted over the top end (303-T) of each of the circular busbars (303A, 303B) with positive locking.
9. The high-voltage busbar assembly (300) as claimed in claim 7, wherein the insulating material structure (202-I) is an insulating material separator fitted in the second through-hole (302-TH) of the extended metallic member (201E) and the insulating material separator has a segment (307) to accommodate a pair of circular busbars (303A, 303B).
10. The high-voltage busbar assembly (300) as claimed in claim 7, wherein the circular busbars (303A, 303B) and the flexible busbars (304A, 304B) are metallic components for conducting current from the battery pack (100).
11. A high-voltage busbar assembly (400) for routing through a cooling plate (101) from a module chamber (104) to a top-mounted electrical and electronic box (103) of a battery pack (100), said busbar assembly (400) comprises,
a plastic holder (401) having an L-shaped base surface having mounting holes (402) for mounting, near a terminal, on a vertical wall of the battery pack (100);
a flexible busbar (203) fabricated inside the plastic holder (401) in such a way that one connection end (203F-OC) of the flexible busbar (203) establishes a connection with the terminal of the battery pack (100) and another connection end (203F-AC) of the flexible busbar (203) is fabricated as a link plate (403) on the top surface of the plastic holder (401); and
an insulating material structure (202-I) integrated on a circular busbar (202), wherein the circular busbar (202) having external threads for mounting with the link plate (403) having a bottom weld nut, wherein a top surface 202-TS of the circular busbar 202 having an internal thread tappings for busbar bolted joint connection inside the electrical and electronic (EE) box 103, and wherein the insulating material (202-I) being formed with a circular groove (202I-C) on a peripheral region of lower surface of shoulders (202I-S) so as to arrange a gasket (204) in between the insulating material (202-I) and the cooling plate (101) of the battery pack (100).
12. The high-voltage busbar assembly (400) as claimed in claim 11, comprises a plastic protection cap (207) fitted over the top end (202-T) of the circular busbar (202) with positive locking.
13. The high-voltage busbar assembly (400) as claimed in claim 11, wherein the insulating material structure (202-I) is a plastic nut integrated on the circular busbar (202).
14. The high-voltage busbar assembly (400) as claimed in claim 11, wherein the circular busbar (202) and the flexible busbar (203) are metallic components for conducting current from the battery pack (100).

Dated this 14th day of August 2023.

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

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI