Description:DESCRIPTION
Technical field
[001] This disclosure relates generally to busbars, more particularly to thermal runaway mitigation busbars.
BACKGROUND
[002] With the rise in demand for portable electric appliances and gadgets, and automobiles that are cost-effective and eco-friendly, there is a growing need for batteries that have a long life and are safe to use over a period of time. In a battery pack, the terminals of adjacent cells are connected using busbars. During battery operation, short circuits may occur, such that high currents from one cell may flow into adjacent cells via busbars, leading to thermal runaway.
[003] Some conventional systems use fuses and other safety devices integrated with busbars to mitigate short circuit issues in battery packs. However, the problem may still persist due to the limitation of number of fuses that can be integrated into the battery packs. Moreover, assembling busbars along with the fuses or safety devices is a cumbersome process.
[004] Therefore, there is a requirement of busbars that efficiently mitigate thermal runaway in battery packs.
SUMMARY OF THE INVENTION
[005] In an embodiment, a battery is disclosed. The battery may include a first cell and a second cell. Further, the first cell may include a first terminal and the second cell may further include a second terminal. The battery may further include a first busbar coupled to the first terminal of the first cell. In an embodiment the first busbar may be a self-recoiling busbar, which may be configured to transition from a stressed position to a recoiled position. Further the battery may include a second busbar coupled to the second terminal of the second cell. In an embodiment, the second busbar may be a non-recoiling busbar. The battery may further include a thermosensitive connecting material configure to couple the first busbar and the second busbar through adhesion upon solidification. In an embodiment, the first busbar may be in the stressed position after the first busbar and the second busbar are coupled. The thermosensitive connecting material may further configure to decouple the first busbar and the second busbar upon liquefying, when the current temperature of the thermosensitive connecting material exceeds a predefined temperature. In an embodiment, the first busbar self-transitions to the recoiled state upon liquefication of the thermosensitive connecting material.
[006] In another embodiment, a vehicle (not shown) may be disclosed. The vehicle may include a battery. Further the vehicle may include a first cell and a second cell. Further the first cell may include a first terminal and the second cell may include a second terminal. The vehicle may further include a first busbar coupled to the first terminal. In an embodiment the first busbar may be a self-recoiling busbar. In an embodiment the first busbar may be configured to transition from a stressed position to a recoiled position. Further the vehicle may include a second busbar coupled to the second terminal. In an embodiment, the second busbar is a non-recoiling busbar. The vehicle may further include a thermosensitive connecting material configured to couple the first busbar and the second busbar through adhesion upon solidification. In an embodiment, the first busbar is in the stressed position after the first busbar and the second busbar are coupled. The thermosensitive connecting material may further configure to decouple the first busbar and the second busbar upon liquefying, when the current temperature of the thermosensitive connecting material exceeds a predefined temperature. In an embodiment, the first busbar self-transitions to the recoiled state upon liquefication of the thermosensitive connecting material.
[007] In yet another embodiment, a self-recoiling busbar may be disclosed. The self-recoiling busbar may include a stationary portion configured to be coupled to a first terminal of a first cell. The self-recoiling busbar may further include a recoiling portion configured to be coupled to a stationary busbar attached to a second terminal of a second cell through the connecting material. In an embodiment, the recoiling potion may be coupled to the stationary busbar through a connecting material. In an embodiment, the recoiling portion may be in a stressed position when coupled. Further the self-recoiling busbar may include a profile section connecting the stationary portion and the recoiling portion. In an embodiment the profile section may be configured to transition the self-recoiling busbar from the stressed position to a recoiled position upon decoupling of the recoiling portion from the stationary busbar.
[008] In another embodiment, a busbar assembly may be disclosed. The busbar assembly may include a first busbar coupled to a first terminal of a first cell. In an embodiment, the first busbar is a self-recoiling busbar. In an embodiment, the first busbar may configure to transition from a stressed position to a recoiled position. Further the busbar assembly may include a second busbar coupled to a second terminal of a second cell. In an embodiment, the second busbar may be a non-recoiling busbar. Further the busbar assembly may include a thermosensitive connecting material configured to couple the first busbar and the second busbar through adhesion upon solidification. In an embodiment, the first busbar is in the stressed position after the first busbar and the second busbar are coupled. The thermosensitive material may further configure to decouple the first busbar and the second busbar upon liquefying, when the current temperature of the thermosensitive connecting material exceeds a predefined temperature. In an embodiment, the first busbar self-transitions to the recoiled state upon liquefication of the thermosensitive connecting material.
BRIEF DESCRIPTION OF THE DRAWINGS
[009] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
[010] FIGs. 1A and 1B illustrate a stressed position and recoiled position of a self-recoiling busbar, in accordance with an embodiment of the present disclosure.
[011] FIGs. 2A and 2B illustrate a coupled state and a decoupled state of a busbar assembly, in accordance with an embodiment of the present disclosure.
[012] FIGs. 3A and 3B illustrate an enabled state and disabled state of a battery, in accordance with an embodiment of the present disclosure.
[013] FIGs. 4A and 4B illustrate an enabled state and disabled state of a battery, in accordance with another embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE DRAWINGS
[014] The foregoing description has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which forms the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other devices, systems, assemblies, and mechanisms for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its device or system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
[015] The terms “including”, “comprises”, “comprising”, “comprising of” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a system or a device that includes a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[016] Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, the same numerals have been used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to FIGs. 1 – 4.
[017] Referring to FIGs. 1A and 1B, a stressed position 100a and a recoiled position 100b of a self-recoiling busbar 102 is disclosed, in accordance with an embodiment of the present disclosure. The self-recoiling busbar 102, as the name suggests, may transition between the recoiled position 100b and the stressed position 100a. The recoiled position 100b is the natural state of rest of the self-recoiling busbar 102 and the stressed position 100a is where the self-recoiling busbar 102 is under the impact of an external force. The self-recoiling busbar 102 may be made up of a conducting and durable material that has elastic properties enabling the self-recoiling busbar 102 to transition between the recoiled position 100b and the stressed position 100a. The material may be a metal or a composite material with desired properties. Examples of the material may include but are not limited to steel, titanium, copper, and certain alloys like spring steel.
[018] The self-recoiling busbar 102 may include a stationary portion 104, a recoiling portion 106, and a profile section 108 that connects the stationary portion 104 and the recoiling portion 106. At one end of the self-recoiling busbar 102, the stationary portion 104 may couple to a first terminal of a first cell (not shown in FIG.1A and 1B), through an alignment hole in the stationary portion 104. On the other end of the self-recoiling busbar 102, the recoiling portion 106 may couple to a stationary busbar (not shown in FIG.1A and 1B) using a thermosensitive connecting material. The stationary busbar may be a non-recoiling busbar. The thermosensitive material, for example, may be solder. Thermosensitive connecting material may liquify under high temperature and solidify in room temperature. This property of the thermosensitive connecting material may be used to couple the recoiling portion 106 to the stationary busbar by adhesion upon solidification. After coupling with the stationary busbar, the recoiling portion 106 may be in the stressed position 100a and once the coupling is removed (upon liquification of the thermosensitive connecting material) the recoiling portion 106 may be in the recoiled portion 100b.
[019] The transition of the self-recoiling bar 102 between the stressed position 100a and the recoiled position 100b is enabled by the profile section 108. The profile section 108 may include a curved structure that enables the recoiling action of the self-recoiling busbar 102. In some embodiments, the curved structure may be a C-shaped profile. To further elaborate on the profile section 108, it may be configured to transition the self-recoiling busbar 102 from the stressed position 100a to the recoiled position 100b upon decoupling of the recoiling portion 106 from the stationary busbar. The decoupling of the recoiling portion 106 from the stationary busbar may occur when the thermosensitive connecting material melts and liquefies. This may occur due to a rise in the temperature of the thermosensitive connecting material caused by current drain beyond a predetermined threshold from the first cell or the second cell. The decoupling of the self-recoiling busbar 102 from the stationary busbar may save one of the first cell and the second cell from being damaged from the affected cell. Upon liquification, the thermosensitive connecting material may disperse through the one or more holes 210 in either the self-recoiling busbar 102 or the stationary busbar.
[020] Now referring to FIGs. 2A and 2B, a coupled state 200a and a decoupled state 200b of a busbar assembly 202 is illustrated, in accordance with an embodiment of the present disclosure. The busbar assembly 202 may include the self-recoiling busbar 102 (first busbar) that may be coupled to a non-recoiling bar 204 (second busbar) using a thermosensitive connecting material 206. A layer of the thermosensitive connecting material 206 may be sandwiched between the self-recoiling busbar 102 and the non-recoiling busbar 204. The thermosensitive connecting material 206 may liquify at high temperature and solidify at room temperature.
[021] The thermosensitive connecting material 206 may be used to couple the self-recoiling busbar 102 and the non-recoiling busbar 204 through adhesion upon solidification. As discussed, the self-recoiling busbar 102 may be in the stressed position 100a after coupling with the non-recoiling busbar 204. The thermosensitive connecting material 206 may decouple the self-recoiling busbar 102 from the non-recoiling busbar 204 upon liquefying, when the current temperature of the thermosensitive connecting material 206 exceeds a predefined temperature. The temperature increase may occur as a result of current drain from one of a first cell or a second cell.
[022] To facilitate quick and easy dispersal of the thermosensitive connecting material 206 post liquefication, one or more of the self-recoiling busbars 102 and the non-recoiling bar 204 may include one or more holes 210. The quick dispersal of the liquified thermosensitive connecting material 206 may ensure immediate decoupling of the self-recoiling bar 102 and the non-recoiling bar 204 and prevent any damage to the first cell or the second cell in case of thermal runaway. Each of the self-recoiling bar 102 and the non-recoiling busbar 204 may include busbar alignment holes 208. The busbar alignment holes 208 of the self-recoiling busbar 102 may be used to couple the self-recoiling busbar 102 with a first terminal of a first cell. The stationary portion 104 may include the busbar alignment hole 208 through which the self-recoiling busbar 102 may be nailed down or attached to the first terminal. In a similar manner, the non-recoiling busbar 204 may include the busbar alignment hole 208 through which the non-recoiling busbar 204 may be nailed down or attached to a second terminal of a second cell.
[023] Referring to FIGs.3A and 3B, an enabled state 300a and a disabled state 300b of a battery 306 is illustrated, in accordance with an embodiment of the present disclosure. The battery 306 may include a first cell 302 and a second cell 304. The first cell 302 and the second cell 304 may be arranged in any pattern. The first cell 302 may include a first terminal 308 and the second cell 304 may include a second terminal 310. In an embodiment, the battery may be implemented in any vehicle including but not limited to a passenger vehicle, a utility vehicle, commercial vehicles, and any other vehicle. The battery may include plurality of cells and plurality of terminals, and the battery may be encapsulated within a housing or an enclosure. Examples of such batteries may include, but are not limited to Lead acid batteries, SLI batteries, deep cycle batteries, VRLA batteries (valve- Regulated Lead-Acid batteries), Lithium-ion batteries, sodium ion batteries, etc.
[024] Further the battery 306 may include the self-recoiling busbar 102 (a first busbar) coupled to the first terminal 308 of the first cell 302. The battery 306 may further include the non-recoiling busbar 204 (a second busbar) coupled to the second terminal 310 of the second cell 304. The self-recoiling busbar 102 and the non-recoiling busbar 204 may be coupled through the thermosensitive connecting material 206 through adhesion upon solidification. Once coupled, the self-recoiling busbar 102 is in the stressed position 100a. A layer of the thermosensitive connecting material 206 may be sandwiched between the self-recoiling busbar 102 and the non-recoiling busbar 204.
[025] Further, when there is a current drain out of one of the first cell 302 or the second cell 304, it may cause sudden increase in temperature causing thermal runaway via the self-recoiling busbar 102 and the non-recoiling busbar 204. The increased temperature may cause the thermosensitive connecting material 206 to liquify. The liquification of the thermosensitive connecting material 206 may transition the self-recoiling busbar 102 from the stressed position 100a to the recoiled position 100b, after removal of the binding force caused by the solidified thermosensitive connecting material 206. This may result in decoupling of the self-recoiling busbar 102 from the non-recoiling busbar 204, thereby breaking the coupling between the self-recoiling busbar 102 and the non-recoiling busbar 204.
[026] Now referring to FIGs. 4A and 4A an enabled state 400a and a disabled state 400b of a battery 402, in accordance with another embodiment of the present disclosure. This embodiment may include a busbar panel 404 that may further include a base 406 (that may be rectangular) and a plurality of self-recoiling busbars 102 protruding from corners of the base 406 (as depicted in FIGs. 4A and 4B).The base 406 may have a rectangular or square shape as per the required implementations on the battery 402. Each of the plurality of self-recoiling busbars 102 are configured to couple via the thermosensitive connecting material 206 with the non-recoiling busbar 204 attached to terminals of respective battery cells. It may be noted that the busbar panel 404 may be implemented on various cell organization patterns in a battery.
[027] The invention thus provides a self-recoiling busbar that enables thermal runaway mitigation in batteries. The self-recoiling busbar acts as a fuse connecting two cells in a battery that immediately detects excess current drain. This is enabled by the ability of the self-recoiling busbar to transition from a stressed state (where connection between cells is intact) to a recoiled state (where connection between cells is broken) to stop the thermal runaway between adjacent cells. This prevents the battery from getting damaged. The ability of the self-recoiling bar to transition between the two states is enabled by use of a thermosensitive connecting material that couples self-recoiling busbar with a non-recoiling busbar in the stressed state. As the thermosensitive connecting material melts due to excessive heat (cause by current drain for example), the self-recoiling busbar with the non-recoiling busbar are decoupled, thus breaking the connection between the adjacent cells. The self-recoiling busbar is thermal runaway mitigation busbar that is easy to install, cost-effective, and does not require design changes in current battery implementations.
[028] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.” Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
[029] 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.
, Claims:CLAIMS
I/We Claim:
1. A battery (306) comprising:
a first cell (302) comprising a first terminal (308);
a second cell (304) comprising a second terminal (310);
a first busbar (102) coupled to the first terminal (308), wherein the first busbar (102) is a self-recoiling busbar (102), and wherein the first busbar (102) is configured to transition from a stressed position (100a) to a recoiled position (100b);
a second busbar (204) coupled to the second terminal (310), wherein the second busbar (204) is a non-recoiling busbar; and
a thermosensitive connecting material (206) configured to:
couple the first busbar (102) and the second busbar (204) through adhesion upon solidification, wherein the first busbar (102) is in the stressed position (100a) after the first busbar (102) and the second busbar (204) are coupled; and
decouple the first busbar (102) and the second busbar (204) upon liquefying, when the current temperature of the thermosensitive connecting material (206) exceeds a predefined temperature, wherein the first busbar (102) self-transitions to the recoiled position (100b) upon liquefication of the thermosensitive connecting material (206).

2. The battery (306) as claimed in claim 1, wherein the thermosensitive connecting material (206) is sandwiched between the first busbar (102) and the second busbar (204).

3. The battery (306) as claimed in claim 1, wherein the thermosensitive connecting material (206) is solder.

4. The battery (306) as claimed in claim 1, wherein the current temperature of the thermosensitive connecting material (206) exceeds the predefined temperature in response to current drain from at least one of the first cell (302) and the second cell (304).

5. The battery (306) as claimed in claim 1, wherein at least one of the first busbar 102 and the second busbar 204 comprises at least one hole 210 configured to allow dispersal of thermosensitive connecting material (206) upon liquefication.

6. A vehicle comprising:
a battery (306) comprising;
a first cell (302) comprising a first terminal (308);
a second cell (304) comprising a second terminal (310);
a first busbar (102) coupled to the first terminal (308), wherein the first bus (102) bar is a self-recoiling bus bar, and wherein the first busbar (102) is configured to transition from a stressed position (100a) to a recoiled position (100b);
a second busbar (204) coupled to the second terminal (310), wherein the second busbar (204) is a non-recoiling busbar; and
a thermosensitive connecting material (206) configured to:
couple the first busbar (102) and the second busbar (204) through adhesion upon solidification, wherein the first busbar (102) is in the stressed position (100a) after the first busbar (102) and the second busbar (204) are coupled; and
decouple the first busbar (102) and the second busbar (204) upon liquefying, when the current temperature of the thermosensitive connecting material (206) exceeds a predefined temperature, wherein the first busbar (102) self-transitions to the recoiled position (100b) upon liquefication of the thermosensitive connecting material (206).

7. The vehicle as claimed in claim 6, wherein the thermosensitive connecting material (206) is sandwiched between the first busbar (102) and the second busbar (204).

8. A self-recoiling busbar (102) comprising:
a stationary portion (104) configured to be coupled to a first terminal (308) of a first cell (302);
a recoiling portion (106) configured to be coupled to a stationary busbar attached to a second terminal (310) of a second cell (304), wherein the recoiling portion (106) is coupled to the stationary busbar through a thermosensitive connecting material (206), and wherein the recoiling portion (106) is in a stressed position (100a) when coupled;
a profile section (108) connecting the stationary portion (104) and the recoiling portion (106), wherein the profile section (108) is configured to:
transition the self-recoiling busbar (102) from the stressed position (100a) to a recoiled position (100b) upon decoupling of the recoiling portion (106) from the stationary busbar.

9. The self-recoiling busbar (102) as claimed in claim 8, wherein the self-recoiling busbar (102) comprises a busbar alignment hole (208) configured to couple the stationary portion (104) with the first terminal (308).

10. The self-recoiling busbar (102) as claimed in claim 11, wherein the profile section 108 is c-shaped section configured to enable the transition of the self-recoiling busbar (102) between the stressed position (100a) and the recoiled position (100b).

11. A busbar assembly (202) comprising:
a first busbar (102) coupled to a first terminal (308) of a first cell (302), wherein the first busbar (102) is a self-recoiling busbar, and wherein the first busbar (102) is configured to transition from a stressed position (100a) to a recoiled position (100b);
a second busbar (204) coupled to a second terminal (310) of a second cell (304), wherein the second busbar (204) is a non-recoiling busbar; and
a thermosensitive connecting material (206) configured to:
couple the first busbar (102) and the second busbar (204) through adhesion upon solidification, wherein the first busbar (102) is in the stressed position (100a) after the first busbar (102) and the second busbar (204) are coupled; and
decouple the first busbar (102) and the second busbar (204) upon liquefying, when the current temperature of the thermosensitive connecting material (206) exceeds a predefined temperature, wherein the first busbar (102) self-transitions to the recoiled position (100b) upon liquefication of the thermosensitive connecting material (206).