Description:FIELD OF THE INVENTION
[001] Present invention generally relates to an energy storage module of a vehicle, and more particularly relates to an interconnect member of the energy storage module.

BACKGROUND OF THE INVENTION
[002] Rechargeable battery technology has been finding its applications in mobility areas like automobiles or vehicles. Many attempts have been made in order to reduce costs associated with the components involved in the battery technology. Batteries typically comprise components like electrical connectors along with Battery Management System (BMS), which may be focused for reducing overall cost associated with the batteries. The existing batteries may employ metallic plates with bulky and complex structures, where the metallic plates may be used to connect with the terminals of the battery cells for energy or current transfer. The metallic plates may often include wires or fuses for protecting cells of the batteries in events of over current and/or thermal runaway. Such batteries may add-up cost and increase complexity in the overall structure.
[003] Further, in the existing designs of batteries, the batteries may need to have a particular cell configuration for achieving voltage and current requirements. The cell configuration may include arrangement of number of cells in series and parallel. To achieve the series and parallel cells configuration, the cells need to be connected in a certain way. In addition, there exists packaging constraints which may include, but not limited to, length, width and height of the battery that needs to be considered to obtain a desired cell configuration. The said constraints may further reduce a freedom of arrangement of the cells. Therefore, a separate interconnect member needs to be designed for each arrangement of cells that satisfies the cell arrangement and the cell configuration of the battery pack. This provides a lot of scope for development of different interconnector designs for different requirements. In addition to this, the interconnect member may sometimes need to be made of expensive metals for welding purposes. Therefore, an optimization on volume of the interconnect member may also be required. The existing designs in the interconnect members have too many separate parts, leading to difficulty in assembly.
[004] Thus, there is a need in the art to overcome the aforesaid problems by providing an interconnect member for a battery module that addresses these problems.

SUMMARY OF THE INVENTION
[005] In one aspect, the present invention is directed to an energy storage module. The energy storage module comprises a plurality of cells. The energy storage module further comprises a housing. The housing comprises an upper housing and a lower housing. The housing being configured to accommodate the plurality of cells in a predetermined array. The housing comprises a plurality of interconnect members disposed between the upper housing and the lower housing/ Each of the interconnect member is a planar structure comprising at least three column portions extending from a first end to a second end of the energy storage module, and a plurality of row portions being connected between the three column portions. Each row portion being disposed in a staggered manner with respect to one another and comprises a pair of tabs at ends of each row portion. The pair of tabs being configured to connect with a first group of cells in parallel and a second group of cells in parallel.
[006] In an embodiment, the pair of tabs comprises a first set of tabs. The first set of tabs being formed between the first column portion and the second column portion.
[007] In a further embodiment, the first set of tabs being configured to connect with the first group of cells in parallel.
[008] In a further embodiment, the pair of tabs comprises a second set of tabs. The second set of tabs being formed between the second column portion and the third column portion.
[009] In a further embodiment, the second set of tabs being configured to connect with the second group of cells in parallel.
[010] In a further embodiment, the row portion being disposed in between a two column portions forms a neck portion in the interconnect member. The neck portion being configured to prevent unintended flow of current.
[011] In a further embodiment, the second column portion of the interconnect member comprises at least one bent portion.
[012] In a further embodiment, the at least three column portions are configured to connect at least four columns of the cells of the energy storage module in a series manner.
[013] In another aspect, the present invention relates to an interconnect member for an energy storage module. The interconnect member being a planar structure comprises at least three column portions extending from a first end to a second end of the energy storage module. The interconnect member comprises a plurality of row portions being connected between the three column portions. Each row portion being disposed in a staggered manner with respect to one another and comprises a pair of tabs at ends of each row portion. The pair of tabs being configured to connect with a first group of cells in parallel and a second group of cells in parallel.

BRIEF DESCRIPTION OF THE DRAWINGS
[014] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a perspective view of an energy storage module comprising a plurality of interconnect members, in accordance with an embodiment of the present invention.
Figure 2 illustrates an exploded view of the energy storage module shown in Figure 1, in accordance with an embodiment of the present invention.
Figures 3a – 3c illustrate a perspective view of one of the interconnect members shown in Figures 1 and 2, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[015] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[016] The claimed invention achieves a battery module configuration with the cells in parallel are divided into two rows, while reducing the amount of material required to make an interconnect member.
[017] The present invention comprises an energy storage module having cell arrangement which is designed based on the space available and the required energy storage module.
[018] Present invention can find its application in a two-wheeled vehicle, three-wheeled vehicle, four-wheeled vehicle, all energy storage application, power backup, all electronics application with wireless mode.
[019] Present invention generally relates to an energy storage module of a vehicle, and more particularly relates to an interconnect member of the energy storage module.
[020] Figure 1 illustrates a perspective view of an energy storage module 100 having a plurality of interconnect members 106, in accordance with an embodiment of the present invention. In some embodiments, an energy storage unit (not shown) may comprise one or more components, including, but not limited to, a plurality of energy storage modules 100, a controller (not shown) or a Battery Management System (BMS) (not shown), fuses (not shown), a plurality of connectors (not shown) and sensors (not shown). The term “energy storage unit” as referred in the present disclosure is a “battery pack”, and the term “energy storage module” as referred in the present disclosure is a “battery module”. The term “battery module” is interchangeably used in place of the term “energy storage module” and more often with the “battery module” for brevity. The battery modules 100 are charged by an external electrical source and/or by a regenerative braking system in the vehicle, and the stored energy from the energy storage modules 100 may be utilized for supplying electrical energy to one or more electric and/or electrical components of the vehicle and/or for suppling electrical energy to a motor (not shown) for driving the vehicle. Thus, the application of the present invention may be found in vehicles, such as, but not limited to, internal combustion engine vehicles, electric vehicles, and hybrid vehicles. In some embodiments, the present invention may also find its applications apart from vehicles like any machine driven or operated by the energy of the battery pack. It may be understood that the term “vehicle” as used herein may include, but not limited to, a two-wheeled vehicle (scooter or bike or the like) or a three-wheeled vehicle or a four or multi wheeled vehicle.
[021] As illustrated in Figure 2, the energy storage module 100 comprise a plurality of cells 102. It is to be noted that the present invention is being illustrated using a single energy storage module 100 for the purposes of simplicity. An energy storage unit or the battery pack may typically comprise more than one energy storage modules 100.
[022] In some embodiments, the plurality of cells 102 of the energy storage module 100 may be made of, but not limited to, Lithium-ions. It may be contemplated that the plurality of cells 102 are not limited to only Lithium-ions, and the cells may be made of any other material known in the art. Thus, the scope of application of the present invention may not be limited to only the battery modules having the Lithium-ions.
[023] Referring again to Figure 1 in conjunction with Figure 2, the figures illustrate the energy storage module 100 in perspective view and exploded view, respectively. In an embodiment, the energy storage module 100 comprises the plurality of cells 102 (shown in Figure 2) which is accommodated inside a housing 104. The plurality of cells 102 is arranged inside the housing 104 in a predetermined array. In an embodiment, the housing 104 is designed such that the cells 102 that are to be connected in parallel are divided into two separate rows. As shown in Figure 2, the housing 104 comprises an upper housing 104A and a lower housing 104B. In some exemplary embodiments, the upper housing 104A and the lower housing 104B can be made of non-conducting material, such as, but not limited to, plastic. In some embodiments, the upper housing 104A and the lower housing 104B are provided with a plurality of mounting provisions 104C (shown in Figure 2). The mounting provision 104C may be a through hole or a blind hole with a flat bottom or a conical bottom. The mounting provisions 104C may be provided at an interior surface of the upper housing 104A and the lower housing 104B. In some embodiments, each of the mounting provision 104C may have a diameter which is substantially same as that of a diameter of the cell 102. In some exemplary embodiment, each cell of the plurality of cells 102 is in a cylindrical shape having a positive terminal (not shown) and a negative terminal (not shown). It is to be understood that the cell may have any other shape apart from the cylindrical shape and therefore, the illustrated embodiment of the cell being cylindrical shape should not be meant to be limiting the scope of the present invention.
[024] As shown in Figure 2, the upper housing 104A and the lower housing 104B may be joined to each other through one or more fastening mechanism. In the illustrated embodiment the upper housing 104A and the lower housing 104B are provided with fastening screws 104D for joining to form the housing 104. In some embodiments, the upper housing 104A may be joined or coupled with the lower housing 104B through yet another known mechanism like, a snap lock mechanism (not shown). Therefore, the joining mechanism of fastening screws 104D as illustrated in Figures 1 and 2 should not be meant to be limiting the scope of the present invention.
[025] Referring again to Figures 1 and 2, the upper housing 104A has an inner surface 104A1 and an outer surface 104A2, and the lower housing 104B has an inner surface 104B1 and an outer surface 104B2. The outer surfaces 104A1, 104B1 are configured to be placed with one or more components of the energy storage module 100 or the energy storage unit. In an embodiment, the energy storage module 100 further comprises a plurality of interconnect members 106. In the illustrated embodiment, the upper housing 104A is configured to be placed with three interconnect members 106. Similarly, as shown in Figure 2, the lower housing 104B is configured to be placed with three interconnect members 106. Further, the upper housing 104A and the lower housing 104B are configured to be placed with another interconnect member 106A at any one side-edge of the upper housing 104A and the lower housing 104B. Furthermore, in the illustrated embodiment, the plurality of interconnect members 106 is disposed on the upper housing 104A and the lower housing 104B. That is to say, the outer surfaces 104A1, 104B1 of the upper housing 104A and the lower housing 104B, respectively, are configured to support a plurality of interconnect members 106.
[026] Figures 3 and 4 illustrate perspective views of the interconnect member 106, in accordance with an embodiment of the present invention. Though the Figures 1 and 2 illustrate three interconnect members 106 on both the upper housing 104A and the lower housing 104B, the embodiment shown in Figures 3 and 4 are relating to one interconnect member 106 which is having similar construction as that of the remaining interconnect members 106. For sake of brevity, only one interconnect member 106 is explained in the present disclosure. In an embodiment, the interconnect member 106 is a planar structure and may be made of a conducting material, like a metal (nickel). The term “interconnect member” may also be referred as a “busbar”. The interconnect member 106 is configured to interconnect the plurality of cells 102 of the battery module 100. As illustrated in Figure 3a, the planar structure of the interconnect member 106 comprises at least three column portions 108A, 108B, 108C. The three column portions 108A, 108B, 108C are extended from a first end 110 (shown in Figure 1) to a second end 112 (shown in Figure 1) of the energy storage module 100. The illustrated embodiment in Figure 3a of the interconnect member 106 comprises three column portions 108A, 108B, 108C. However, it should be understood that the interconnect member 108 may be provided with additional column portions and thus, the number of column portions as disclosed in the present invention should not be meant to limit the scope of the present invention. The column portions 108A, 108C may further include one or more through holes 108F (shown in Figure 3a).
[027] In an embodiment, the second column portion 108B of the interconnect member 108 comprises at least one bent portion 108D (shown in Figure 3a). The second column portion 108B is slightly lengthier that lengths of the first column portion 108A and the second column portion 108B. In the illustrated embodiment, the bent portion 108D is substantially perpendicular to the column portions 108A, 108B, 108C. The bent portion 108D is used for voltage tapping of the battery unit. It may be understood that the bent portion 108D in the illustrated embodiment is provided on the column portion 108B (central column portion). However, the bent portion 108D may also be provided on any other two column portions 108A, 108C. Therefore, the illustrated exemplary embodiment of the bent portion 108D at the column portion 108B should not be meant to be limiting the scope of the present invention.
[028] As shown in Figure 3b, the interconnect member 106 further comprises a plurality of row portions 114. The plurality of row portions 114 is connected between the three column portions 108A, 108B, 108C. In an embodiment, each row portion 114 is disposed in a staggered manner with respect to one another. That is to say, the row portion 114 provided between the column portions 108A and 108B is placed or located below the row portion 114 provided between the column portions 108B and 108C. In the illustrated embodiment in Figure 3a, it may be noticed that a portion of a second-row portion 114-2 from top is placed just below a first-row portion 114-1 from the top of the interconnect member 106. Thus, the first-row portion 114-1 and the second-row portion 114-2 are disposed in a staggered manner. Similarly, the subsequent row portions 114 of the interconnect member 106 are disposed in same staggered manner.
[029] In an embodiment shown in Figures 3a and 3b, the interconnect member 106 comprises a pair of tabs 118 at ends 114A, 114B of each of the row portion 114. The pair of tabs 118 are configured to connect with a first group of cells in parallel and a second group of cells in parallel. The pair of tabs 118 are slightly bent interiorly from a planar surface of the column portions 118 and the row portions 114 through a connecting portion 118D. In an embodiment, the connecting portion 118A may be provided in a stepped manner or inclined manner.
[030] In an embodiment shown in Figure 3c, the pair of tabs 118 comprises a first set of tabs 118A. The first set of tabs 118A is formed between the first column portion 108A and the second column portion 108B. The first set of tabs 118A is configured to connect with the first group of cells in parallel.
[031] In an embodiment shown in Figure 3c, the pair of tabs 118 comprises a second set of tabs 118B. The second set of tabs 118B is formed between the second column portion 108B and the third column portion 108C. The second set of tabs 118B is configured to connect with the second group of cells in parallel.
[032] In an embodiment, the row portion 114 is disposed in between a two column portions 108 forms a neck portion 116 (shown in Figure 3b) in the interconnect member 106. In some embodiments, the neck portion 116 is a cut-out or a blank portion in the interconnect member 106. Thus, the neck portion 116 is configured to prevent unintended flow of current. In the illustrated embodiment, the neck portion 116 are in shape of square or rectangle.
[033] In an embodiment, the at least three column portions 108A, 180B, 108C are configured to connect at least four columns of the cells 102 of the energy storage module 100 in a series manner.
[034] In some embodiments, the energy storage module 100 comprises an interconnect member 106A at each diagonally opposite edges of the energy storage module 100. The interconnect member 106A comprises two column portions 108E (shown in Figure 2) and a plurality of row portions 114E (shown in Figure 2). Each row portion 114E of the interconnect member 106A comprises a pair of tabs.
[035] Advantageously, the present invention improves aesthetics, eases assembly, reduces cost, provides advantages of market attractiveness for the battery modules.
[036] The present invention having the new interconnect member design is designed for a battery pack where the cells that are to be connected in series are connected in two separate rows. The interconnector member design achieves the required battery configuration when the cells connected in parallel are distributed in two separate rows. Further, the present invention achieves the battery configuration where the cells in parallel are divided into two rows, while reducing the amount of material required to make the interconnect member. This is due to the fact that the interconnect member for the battery pack is designed based on the space available and the required battery configuration.
[037] In the present invention, the required configuration and cell arrangement in the battery pack is achieved by using the interconnect member which is having a quad-row interconnector. The key feature in the present invention is to provide the quad-row interconnector in the four rows of tabs, two of these rows are connected to one group of cells in parallel and the other two to another group of cells in parallel.
[038] In the present invention, the interconnect members are placed on the housing and welded to the cells. The cells in parallel are split into two separate rows. The cross-section areas (necks) between the group of cells in series where current is not intended to flow is reduced so as to save nickel material.
[039] The present invention provides advantages, like the ability to package cells which are in parallel in two separate rows which can help with space constraints on the battery pack.
[040] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

List of Reference Numerals and Characters:
100: Energy storage module
106, 106A: Interconnect member
102: Plurality of cells
104: Housing
104A: Upper housing
104B: Lower housing
104C: Mounting provisions
104D: Fastening screws
104A1: Inner surface of upper housing
104A2: Outer surface of upper housing
104B1: Inner surface of lower housing
104B2: Outer surface of lower housing
108A, 108B, 108C: Column portions
108D: Bent portion
108F: Through holes
110: First end of energy storage module
112: second end of energy storage module
114, 114E: Row portion
114A, 114B: Ends of row portion
114E: Row portion
114-1: First-row portion
114-2: Second-row portion
116: Neck portion
118: Tabs
118A: First set of tabs
118B: Second set of tabs
118D: Connecting portion
118E: Column portion

, Claims:1. An energy storage module (100), the energy storage module (100) comprising:
a plurality of cells (102);
a housing (104) comprising an upper housing (104A) and a lower housing (104B), the housing (104) being configured to accommodate the plurality of cells (102) in a predetermined array;
a plurality of interconnect members (106) disposed between the upper housing (104A) and the lower housing (104B), wherein each of the interconnect member (106) is a planar structure comprising:
at least three column portions (108A, 108B, 108C) extending from a first end (110) to a second end (112) of the energy storage module (100), and
a plurality of row portions (114) being connected between the three column portions (108A, 108B, 108C), each row portion (114) being disposed in a staggered manner with respect to one another and comprises a pair of tabs (118) at ends (114A, 114B) of each row portion (114), the pair of tabs (118) being configured to connect with a first group of cells in parallel and a second group of cells in parallel.

2. The energy storage module (100) as claimed in claim 1, wherein the pair of tabs (118) comprises a first set of tabs (118A), the first set of tabs (118A) being formed between the first column portion (108A) and the second column portion (108B).

3. The energy storage module (100) as claimed in claim 2, wherein the first set of tabs (118A) being configured to connect with the first group of cells in parallel.

4. The energy storage module (100) as claimed in claim 1, wherein the pair of tabs (118) comprises a second set of tabs (118B), the second set of tabs (118B) being formed between the second column portion (108B) and the third column portion (108C).

5. The energy storage module (100) as claimed in claim 4, wherein the second set of tabs (118B) being configured to connect with the second group of cells in parallel.

6. The energy storage module (100) as claimed in claim 1, wherein the row portion (114) being disposed in between a two column portions (108) forms a neck portion (116) in the interconnect member (106), the neck portion (116) being configured to prevent unintended flow of current.

7. The energy storage module (100) as claimed in claim 1, wherein the second column portion (108B) of the interconnect member (108) comprises at least one bent portion (108D).

8. The energy storage module (100) as claimed in claim 1, wherein the at least three column portions (108A, 180B, 108C) are configured to connect at least four columns of the cells (102) of the energy storage module (100) in a series manner.

9. An interconnect member (106) for an energy storage module (100), the interconnect member (106) being a planar structure comprising:
at least three column portions (108A, 108B, 108C) extending from a first end (110) to a second end (112) of the energy storage module (100), and
a plurality of row portions (114) being connected between the three column portions (108A, 108B, 108C), each row portion (114) being disposed in a staggered manner with respect to one another and comprises a pair of tabs (118) at ends (114A, 114B) of each row portion (114), the pair of tabs (118) being configured to connect with a first group of cells in parallel and a second group of cells in parallel.

10. The interconnect member (106) as claimed in claim 9, wherein the pair of tabs (118) comprises a first set of tabs (118A), the first set of tabs (118A) being formed between the first column portion (108A) and the second column portion (108B).

11. The interconnect member (106) as claimed in claim 10, wherein the first set of tabs (118A) being configured to connect with the first group of cells in parallel.

12. The interconnect member (106) as claimed in claim 9, wherein the pair of tabs (118) comprises a second set of tabs (118B), the second set of tabs (118B) being formed between the second column portion (108B) and the third column portion (108C).

13. The interconnect member (106) as claimed in claim 12, wherein the second set of tabs (118B) being configured to connect with the second group of cells in parallel.

14. The interconnect member (106) as claimed in claim 9, wherein the row portion (114) being disposed in between a two column portions (108) forms a neck portion (116) in the interconnect member (106), the neck portion (116) being configured to prevent unintended flow of current.

15. The interconnect member (106) as claimed in claim 9, wherein the second column portion (108B) of the interconnect member (108) comprises at least one bent portion (108D).

16. The interconnect member (106) as claimed in claim 9, wherein the at least three column portions (108A, 180B, 108C) are configured to connect at least four columns of the cells (102) of the energy storage module (100) in a series manner.