Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of battery pack reworking. In particular, the present disclosure relates to a simple, compact, and efficient system for conducting electric current from an isolated energy storage module in an energy storage module pack.

BACKGROUND
[0002] Battery packs play a vital role in various industries, providing portable power solutions for a myriad of applications ranging from consumer electronics to electric vehicles. A battery pack typically consists of an arrangement of smaller units known as battery cells (or energy storage modules). These cells are interconnected in specific series and parallel configurations to yield desired voltage and current outputs. Both mechanical and electrical systems are employed within the battery pack to ensure proper cell alignment and connectivity.
[0003] The mechanical system within the battery pack serves to securely hold each cell in place, preventing displacement or damage during operation or handling. The electrical interconnect system facilitates the flow of current from the cells to the electrical assembly like Printed Circuit Board (PCB) by establishing connections to the positive and negative terminals of each cell. Conventionally, these connections have been made using various welding processes such as laser welding, spot welding, resistance welding, or wire bonding. The connections made between the cells through any of the welding processes may result in damage to the interconnects or the terminals of the cells and frequent occurrence of feeder sparks during production due to the presence of epoxy or foreign materials on the terminal of cells or the interconnects, making the cells isolated and non-functional within the battery pack. The number of battery packs damaged per day in a manufacturing plant is a considerable number which can be reworked to make them functional and reduce losses to the manufacturing plants. The manufacturing plants are scraping the damaged battery packs due to the non-availability of simple, cost-effective methods to perform reworking on the damaged battery packs.
[0004] Despite the advancements in the manufacturing processes of battery packs, there exists a significant challenge related to the reliability and maintenance of these systems. If any connection within the pack, whether in series or parallel configuration, becomes compromised or broken, the overall functionality of the pack is compromised due to the non-availability of an efficient and a cost-effective method to repair or fix the isolated cells in the battery pack. Moreover, in such instances, traditional repair or rework methods often prove to be complex, time-consuming, and expensive.
[0005] Some conventional methods for establishing connections within battery packs involve the use of soldered wires. However, this approach poses limitations, where there exists a risk of thermal damage to the battery cells due to the high temperatures associated with soldering. While interconnects are typically welded to the cells using methods that mitigate thermal risks, the soldering process poses a significant challenge during repair or rework scenarios.
[0006] Furthermore, the potential for damage to the battery cells during the rework process also poses a significant concern. The use of soldering techniques, particularly at high temperatures, can inadvertently lead to thermal damage or degradation of the cells. As a result, the rework process becomes inherently risky and undesirable, often necessitating the replacement or disposal of the entire battery pack.
[0007] Additionally, the existing rework process for repairing broken connections within battery packs is not only cumbersome but also presents a considerable risk affecting the performance of the cells.
[0008] There is, therefore, a well-established need in the art to overcome the above-mentioned problems by providing a simple, compact, and efficient system for conducting electric current from an isolated energy storage module in an energy storage module pack.

OBJECTS OF THE PRESENT DISCLOSURE
[0009] A general object of the present disclosure is to overcome the problems associated with existing battery packs for reworking, by providing a simple, compact, efficient, and cost-effective system for conducting electric current from an isolated energy storage module in an energy storage module pack.
[0010] Another object of the present disclosure is to provide a system that can be bent at any angle to be easily coupled between the isolated energy storage module and an electrical assembly in the energy storage module pack.
[0011] Yet another object of the present disclosure is to provide a system that can be easily manufactured in-house to fix the isolated energy storage module in the energy storage module pack.

SUMMARY
[0012] Aspects of the present disclosure pertain to the field of battery pack reworking. In particular, the present disclosure relates to a simple, compact, and efficient system for conducting electric current from an isolated energy storage module in an energy storage module pack.
[0013] In an aspect, the present disclosure relates to a system for conducting electric current from an isolated energy storage module in an energy storage module pack, including one or more electrical feeders. The one or more electrical feeders are electrically coupled between the isolated energy storage module and an electrical assembly in at least one orientation of a plurality of orientations. The one or more electrical feeders conduct electric current from the isolated energy storage module to the electrical assembly in the energy storage module pack. The one or more electrical feeders are adapted to be bent in a plurality of angles. The bending of the one or more electrical feeders facilitates the electrical coupling between the isolated energy storage module and the electrical assembly.
[0014] In an embodiment, a first interconnect may be electrically coupled between a first terminal of the isolated energy storage module and the electrical assembly. The first interconnect may be configured to conduct electric current from the first terminal of the isolated energy storage module to the electrical assembly. In another embodiment, the one or more electrical feeders may be configured to conduct electric current in an event of breakage of the first interconnect. The one or more electrical feeders may conduct electric current from the first terminal of the isolated energy storage module to the electrical assembly or to a second interconnect electrically coupled between an adjacent energy storage module and the electrical assembly. In an embodiment, the first terminal may be a positive terminal or a negative terminal of the isolated energy storage module.
[0015] In an embodiment, the first electrical feeder of the one or more electrical feeders may include a top end and a bottom end. The top end may be electrically coupled to the electrical assembly. The bottom end may be adapted to be slit to facilitate the electrical coupling. The electrical coupling may couple the first electrical feeder to the first interconnect or the first terminal of the isolated energy storage module.
[0016] In an embodiment, in a first orientation of the plurality of orientations, the top end of the first electrical feeder may be configured on the electrical assembly. The bottom end of the first electrical feeder may be configured on the broken first interconnect. The broken first interconnect may be electrically coupled to the isolated energy storage module.
[0017] In an embodiment, in a second orientation of the plurality of orientations, the top end of the first electrical feeder may be configured on the electrical assembly. The bottom end of the first electrical feeder may be configured on the first terminal of the isolated energy storage module.
[0018] In an embodiment, a second electrical feeder of the one or more electrical feeders may include a first end and a second end. The second end may be adapted to be slit to facilitate electrical coupling. The electrical coupling may couple the second electrical feeder to a second interconnect. The second interconnect may be electrically coupled to the adjacent energy storage module or to a second terminal. The second terminal may pertain to the adjacent energy storage module. The first end and the second end may be slit to facilitate electrical coupling. The electrical coupling may couple the second electrical feeder to a first interconnect or the isolated energy storage module. The second terminal may be a positive terminal or a negative terminal of the adjacent energy storage module.
[0019] In an embodiment, the system may include a polyimide film. The polyimide film may be operatively coupled to the second electrical feeder. The polyimide film may be configured between the first end and the second end of the second electrical feeder. The polyimide film may electrically insulate a portion between the first end and the second end when positioned on the electrical assembly. The polyimide film may resist high temperatures the other energy storage modules. The polyimide film may be a Kapton tape.
[0020] In an embodiment, in a third orientation of the plurality of orientations, the second end of the second electrical feeder may be configured on the second interconnect. The first end of the second electrical feeder may be configured on the broken first interconnect. The broken first interconnect may be coupled to the isolated energy storage module. The insulated portion between the first end and the second end of the second electrical feeder may remain on top of the electrical assembly.
[0021] In an embodiment, in a fourth orientation of the plurality of orientations, the second end of the second electrical feeder may be configured on the second interconnect. The first end of the second electrical feeder may be configured on the isolated energy storage module. The insulated portion between the first end and the second end of the second electrical feeder may remain on top of the electrical assembly.
[0022] In an embodiment, the first electrical feeder and the second electrical feeder of the one or more electrical feeders may be configured to conduct electric current from the isolated energy storage module to the electrical assembly in a fifth orientation of the plurality of orientations. The fifth orientation may be any of the plurality of orientations.
[0023] Various objects, features, aspects, and advantages of the subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF DRAWINGS
[0024] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.
[0025] FIG. 1A illustrates a schematic view of a first electrical feeder of the proposed system, in accordance with an embodiment of the present disclosure.
[0026] FIG. 1B illustrates a schematic view of a second electrical feeder of the proposed system, in accordance with an embodiment of the present disclosure.
[0027] FIGs. 2A and 2B illustrate a block view and a schematic view of the first electrical feeder in a first orientation, respectively, in accordance with embodiments of the present disclosure.
[0028] FIGs. 3A and 3B illustrate a block view and a schematic view of the first electrical feeder in a second orientation, respectively, in accordance with embodiments of the present disclosure.
[0029] FIGs. 4A and 4B illustrates a block view and a schematic view of the second electrical feeder in a third orientation, respectively, in accordance with embodiments of the present disclosure.
[0030] FIGs. 5A and 5B illustrate a block view and a schematic view of the second electrical feeder in a fourth orientation, respectively, in accordance with embodiments of the present disclosure.
[0031] FIG. 6 illustrates a schematic view elaborating a method of in-house preparation of the second electrical feeder, in accordance with an embodiment of the present disclosure.
[0032] FIG. 7 illustrates a flowchart of an example method of in-house preparation of the electrical feeders, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0033] For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.
[0034] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the present disclosure and are not intended to be restrictive thereof.
[0035] Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more…” or “one or more elements is required.
[0036] Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.
[0037] Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
[0038] Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure. The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.
[0039] In conventional systems and methods, a plurality of battery cells are often spot welded to join allied components of battery packs in manufacturing plants, where spot welding may be considered as a reliable method. A few reasons for opting spot welding process by the manufacturing plants may include high-speed production, which can be crucial in manufacturing environments where large quantities of batteries need to be assembled in a short span of time; strong bond, where the spot welding creates a strong bond between the battery components, that ensures secure connectivity even under stress or vibration; and cost-effectiveness, where the spot welding equipment can be relatively cost-effective and can be easily operated by any industrial worker compared to other joining methods. The conventional methods may aid to keep manufacturing costs down, but they often damage the battery packs.
[0040] The major drawback upon opting for welding process by the manufacturing plants can be high temperatures generated during the welding process and the presence of foreign particles on the battery cells which may result in a short circuit of one or more battery cells within the battery pack. The battery where in most of the cases is a lithium-ion battery that can be sensitive to heat are more prone to such incidents. In some instances, the heat produced during the welding operation may melt an interconnect that connects the battery cells to the Printed Circuit Board (PCB) or Laminated Busbar (LAMBUS). The disconnected or isolated battery cells may be non-functional and may remain isolated. The battery pack based on whether connected in series or parallel or combination of both may either become non-functional completely or function with reduced voltage.
[0041] Embodiments explained herein relate to a simple, compact, and efficient system for conducting electric current from an isolated energy storage module in an energy storage module pack. The above disconnected or isolated battery cells may be fixed in-house or within the manufacturing plant using the proposed system to conduct the electric current from an isolated energy storage module (battery cell) in an energy storage module pack (battery pack).
[0042] Referring to FIGs. 1A to 7, in an aspect, the proposed system (collectively designated as 100 herein) for conducting electric current from an isolated energy storage module 102 in an energy storage module pack is described.
[0043] In an embodiment, the energy storage module pack (hereinafter interchangeably referred to as “battery pack”) may be made up of a combination of energy storage modules 102 (hereinafter interchangeably referred to as “battery cell” or “cell” or “cells”). The battery cells within the battery pack may be arranged in a series or parallel or a combination of series and parallel configuration, which can generate electric current with a specific voltage to an electrical assembly 104 (hereinafter referred to as “PCB” or “LAMBUS”). The above arrangement may include one or more mechanical and one or more electrical systems inside the battery pack which connect the cells together. The mechanical system may firmly hold each battery cell in a particular position in a series or parallel or a combination of series and parallel configuration. One or more electrical feeders may be electrically coupled between the isolated battery cells 102 and the electrical assembly 104. The electrical coupling may be enabled through welding, using laser, spot, resistance, wire bonding, etc. The battery cells 102 may define a positive and a negative terminal. In an embodiment, the energy storage modules 102 may also be capacitors.
[0044] In an embodiment, the system 100 to conduct the electric current from an isolated energy storage module 102 in an energy storage module pack includes one or more electrical feeders. The one or more electrical feeders can be electrically coupled between the isolated energy storage module 102 and the electrical assembly 104 in at least one orientation of a plurality of orientations as shown in FIGs. 2A to 5B. The electrical feeders can conduct electric current from the isolated energy storage module 102 to the electrical assembly 104 or to the adjacent energy storage module 110 within the energy storage module pack, which may be functional, and conduct electric current to the electrical assembly 104. The electrical feeders are bent in a plurality of angles such that the size, number of bends, and angle of the bend of the electrical feeder may vary on a case-to-case basis, based on the distance between the isolated battery cell 102 and the PCB or LAMBUS or the adjacent energy storage module 110. The bending of the electrical feeders may easily facilitate the electrical coupling between the isolated energy storage module 102 and the electrical assembly 104 to conduct electric current.
[0045] In an embodiment, a fully functional battery pack or the energy storage module pack has a first interconnect 106 that can be electrically coupled between a first terminal 102-1 of the isolated energy storage module 102 and the electrical assembly 104. The first interconnect 106 may conduct electric current from the first terminal 102-1 of the isolated energy storage module 102 to the electrical assembly 104. In any event of damage of the first interconnect 106 can result in disconnection of the cell 102 from the electrical assembly 104 making the battery pack non-functional or semi-functional with limited voltage based on the arrangement of cells within the battery pack. In such a case, the proposed system 100 can facilitate a quick rework within the manufacturing plant. The disconnected cell 102 can be connected to the electrical assembly 104 to conduct electric current in an event of breakage of the first interconnect 106 due to generation of one or more feeder sparks during welding performed in-house or manufacturing plant. The feeder sparks may be generated due to presence of epoxy, flux, dust, PCM, insulation sheet, and any foreign particles. In an embodiment, the first terminal 102-1 may be a positive terminal or a negative terminal of the isolated energy storage module 102.
[0046] The one or more electrical feeders may conduct electric current from the first terminal 102-1 of the isolated energy storage module 102 to the electrical assembly 104 or to a second interconnect 108 electrically coupled between an adjacent energy storage module 110 and the electrical assembly 104. In an exemplary embodiment, the electrical coupling can be through a welded coupling where the welding can be selected from a group comprising laser welding, spot welding, resistance welding, wire bonding, etc.
[0047] In an exemplary embodiment, the electrical coupling can be through a spring contact where spring-loading can be configured on both ends of one or more electrical feeders between the isolated battery cell 102 and the electrical assembly 104, thereby facilitating a secure and a resilient electrical connection. The spring contact can exert sufficient pressure to maintain reliable conductivity while accommodating slight variations in cell position or dimension.
[0048] In an exemplary embodiment, the electrical coupling can be through a press-fit connector. The press-fit connectors can be configured to fit snugly into corresponding receptacles on the isolated battery cell 102 and the electrical assembly 104 to provide a reliable electrical connection without the need for soldering or welding. The electrical feeders can be equipped with these connectors to establish a seamless electrical pathway.
[0049] In another exemplary embodiment, the electrical coupling can be through conductive adhesives. The conductive adhesives can be applied between the ends of the one or more electrical feeders, the isolated battery cell 102, and the electrical assembly 104. Conductive adhesives can create a strong and conductive bond without the need for traditional soldering or welding processes. These adhesives may typically contain metal particles or conductive polymers that may facilitate electrical conduction while providing mechanical strength.
[0050] In another exemplary embodiment, the electrical coupling can be through crimp connectors. The crimp connectors can be configured on the ends of the electrical feeders to allow for a quick and secure attachment to both the isolated battery cell 102 and the electrical assembly 104. The crimp connectors may utilize mechanical compression to establish a gas-tight and electrically conductive connection, offering a reliable alternative to soldering or welding processes.
[0051] In another exemplary embodiment, the electrical coupling can be through an ultrasonic bonding. The ultrasonic bonding may join the electrical feeders to the isolated battery cell 102 and the electrical assembly 104. Ultrasonic bonding may provide a low-temperature and a non-invasive method for creating strong and durable electrical connections. The ultrasonic bonding may utilize high-frequency vibrations to generate localized heat, effectively bonding the materials together without causing thermal damage.
[0052] In another exemplary embodiment, the electrical coupling can be through a conductive tape. The conductive tape can be applied along the length of the electrical feeders and adhering it to both the isolated battery cell 102 and the electrical assembly 104 can establish a reliable electrical connection. The conductive tapes may feature a layer of conductive material such as copper or aluminum to provide a simple yet effective means of transmitting electrical current.
[0053] In another exemplary embodiment, the electrical coupling can be through a compression contact. The compression contact may be configured to exert pressure on contact pads located on the isolated battery cell 102 and the electrical assembly 104, creating a secure and a low-resistance electrical connection. The compression contacts can be spring-loaded or mechanically actuated to ensure proper contact pressure is maintained.
[0054] In an embodiment, a first electrical feeder 112 of the one or more electrical feeders, as shown in FIG. 1A, may include a top end 112-1 and a bottom end 112-2. The top end 112-1 may be electrically coupled to the electrical assembly 104. The bottom end 112-2 may be adapted to be slit to facilitate the electrical coupling. The electrical coupling may couple the first electrical feeder 112 to the first interconnect 106 or the first terminal 102-1 of the isolated energy storage module 102. In an exemplary embodiment, the first electrical feeder 112 of the one or more electrical feeders may be a Z-type electrical feeder, as shown in FIG.1A.
[0055] Referring to FIGs. 2A and 2B, the proposed system 100 connected via a first orientation 200 of the plurality of orientations is shown, such that the top end 112-1 of the first electrical feeder 112 may be configured on the electrical assembly 104. Further, the bottom end 112-2 of the first electrical feeder 112 may be configured on the broken first interconnect 106. The broken first interconnect 106 may be electrically coupled to the isolated energy storage module 102.
[0056] Referring to FIGs. 3A and 3B, the proposed system 100 connected via a second orientation 300 of the plurality of orientations is shown, such that the top end 112-1 of the first electrical feeder 112 may be configured on the electrical assembly 104. Further, the bottom end 112-2 of the first electrical feeder 112 may be configured on the first terminal 102-1 of the isolated energy storage module 102.
[0057] Yet in another embodiment, a second electrical feeder 114 of the one or more electrical feeders, as shown in FIG. 1B, may include a first end 114-1 and a second end 114-2. The first end 114-1 may be adapted to be slit as shown in FIG. 1B to facilitate electrical coupling. The electrical coupling may couple the second electrical feeder 114 to a second interconnect 108. The second interconnect 108 may be electrically coupled to the adjacent energy storage module 110 or to a second terminal 110-1. The second terminal 110-1 may pertain to the adjacent energy storage module 110. The first end 114-1 and the second end 114-2 may be slit, as shown in FIG. 1B, to facilitate electrical coupling. The electrical coupling may couple the second electrical feeder 114 to the first interconnect 106 or the isolated energy storage module 102. The second terminal 110-1 may be a positive terminal or a negative terminal of the adjacent energy storage module 110. In an exemplary embodiment, the second electrical feeder 114 of the one or more electrical feeders may be a jumper type electrical feeder, as shown in FIG. 1B.
[0058] In an embodiment, the system 100 may include a polyimide film 116. The polyimide film 116 may be operatively coupled to the second electrical feeder 114. The polyimide film 116 may be configured between the first end 114-1 and the second end 114-2 of the second electrical feeder 114. The polyimide film 116 may electrically insulate a portion between the first end 114-1 and the second end 114-2 when positioned on the electrical assembly 104. The polyimide film 116 may resist high temperatures from other energy storage modules. In some embodiments, the polyimide film 116 may be a Kapton tape.
[0059] Referring to FIGs. 4A and 4B, the proposed system 100 connected via a third orientation 400 of the plurality of orientations is shown, such that the second end 114-2 of the second electrical feeder 114 may be configured on the second interconnect 108. Further, the first end 114-1 of the second electrical feeder 114 may be configured on the broken first interconnect 106. The broken first interconnect 106 may be coupled to the isolated energy storage module 102. The insulated portion between the first end 114-1 and the second end 114-2 of the second electrical feeder 114 may remain on top of the electrical assembly 104.
[0060] Referring to FIGs. 5A and 5B, the proposed system 100 connected via a fourth orientation 500 of the plurality of orientations is shown, such that the second end 114-2 of the second electrical feeder 114 may be configured on the second interconnect 108. Further, the first end 114-1 of the second electrical feeder 114 may be configured on the isolated energy storage module 102. The insulated portion between the first end 114-1 and the second end 114-2 of the second electrical feeder 114 may remain on top of the electrical assembly 104.
[0061] In an embodiment, the first electrical feeder 112 and the second electrical feeder 114 of the one or more electrical feeders may be configured to conduct electric current from the isolated energy storage module 102 to the electrical assembly 104 in a fifth orientation of the plurality of orientations. The fifth orientation may be any of the plurality of orientations.
[0062] Referring to FIG. 6, a method of instantly preparing the second electrical feeder 114 which can be a jumper-type electrical feeder within the manufacturing plant is disclosed. A readily available strip can be electrically conductive, available within the manufacturing plant. The strip can be cut into a desired shape and size as required for a particular battery pack as shown in block 602. A polyimide film 116 can be wound in the middle of the strip as shown in block 604, for electrical and thermal insulation, leaving the ends 114-1 and 114-2 such that the ends 114-1 and 114-2 can be later bent in one or more angles. The number of layers wound can be optional as shown in block 606. In most cases, the polyimide film 116 can be a Kapton tape. An electrical tape can be wound around the polyimide film 116 on the strip for additional insulation as shown in block 608. The ends 114-1 and 114-2 of the strip can be bent forming a z-shape as shown in blocks 610 and 612 for ease of coupling them to the electrical assembly 104 (PCB or LAMBUS) and the isolated battery cell 102. Moreover, the first end 114-1 may be coupled to the electrical assembly 104 can be slit for ease of coupling. The second end 114-2 may be coupled to the isolated battery cell 102 and can be slit for ease of coupling.
[0063] Referring to FIG. 7, a flowchart 700 describing reworking of the non-functional battery pack in-house or in manufacturing plant is disclosed. In block 702, the non-functional battery packs which comprise several other components to be assembled within the pack are sent to the spot welding station located within the manufacturing plant, as described in block 704, where the welding operation may be carried out. During said welding process, a feeder spark may be generated due to presence of epoxy, flux, dust, or due to other reasons like PCM, insulation sheet, and any foreign particles. The feeder spark may disconnect or isolate one or more cells within the battery pack, making the battery pack un-usable.
[0064] In block 706, the battery pack may be inspected to check if each cell within the battery pack is functional. Upon detection of any cell isolated from the electrical assembly 104, that said battery pack may be sent to a rework area as shown in block 708. In the other case, upon detecting the battery pack to be functional, that said battery pack may be sent to the production line as shown in block 702. Moreover, the rework area may be located within the manufacturing plant. Further in block 708, the faulty or the non-functional battery pack upon reaching the rework area, the first electrical feeder 112 (Z-type feeder) or the second electrical feeder 114 (Jumper-type feeder) may be used by a worker to fix the isolated cells such that the non-functional battery pack may be functional like a new battery pack conducting the required electric current with desired voltage, as shown in block 708. The ends of the first electrical feeder 112 (Z-type feeder) or the second electrical feeder 114 (Jumper-type feeder) are either soldered/spot welded to their respective joints in the rework area. In an embodiment, one end of the first electrical feeder 112 may be soldered and connected to the electrical assembly 104, and the other end of the first electrical feeder 112 may be positioned above the isolated energy storage holder 102 or the broken first interconnect 106 and left unconnected. Additionally, one end of the second electrical feeder 114 may be positioned above the isolated energy storage holder 102 or the broken first interconnect 106 and left unconnected, and the other end of the second electrical feeder 114 may be positioned on the second interconnect 108 electrically coupled to an adjacent energy storage module 110 and left unconnected. The ends of the first electrical feeder 112 (Z-type feeder) or the second electrical feeder 114 (Jumper-type feeder) that are left unconnected are then taken to the spot welding station shown in block 704 and welded. The battery pack may then be sent to the glue application station as shown in block 710 such that the reworked battery pack may be glued with hot glue on the welded and/or soldered joints as shown in block 710. Further, the reworked battery pack is sent back to the production line as per block 702 upon application of glue. The hot glue may be applied on the welded joints due to mechanical stability, as the welding alone may not provide sufficient mechanical stability to the components, especially when PCB is subjected to mechanical stress or vibration and the applying of glue may secure the components in place, reducing the risk of becoming loose or detached over time, improved electrical performance, as the application of glue may minimize the risk of electrical short circuits by providing insulation and maintaining consistent spacing between them; enhanced heat dissipation, as there exist a few types of glues, which may have the properties of thermal conductivity aiding in dissipating heat from electronic components to prevent overheating and enhancing the performance of the battery; and manufacturing process compatibility, as the application of glue may be integrated into the PCB. The manufacturing process may be an efficient and cost-effective method for reworking the battery pack and restoring it back to normal.
[0065] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0066] The present disclosure overcomes the problems associated with existing battery pack reworking, by providing a simple, compact, efficient, and cost-effective solution for conducting electric current from an isolated energy storage module in an energy storage module pack.
[0067] The present disclosure provides a system that can be bent at any angle to be easily coupled between the isolated energy storage module and the electrical assembly in the energy storage module pack.
[0068] The present disclosure provides a system that can be easily manufactured in-house to fix the isolated energy storage module in the energy storage module pack.
, Claims:1. A system (100) for conducting electric current from an isolated energy storage module (102) in an energy storage module pack, the system (100) comprising:
one or more electrical feeders electrically coupled between the isolated energy storage module (102) and an electrical assembly (104), in at least one orientation of a plurality of orientations, to conduct electric current from the isolated energy storage module (102) to the electrical assembly (104) in the energy storage module pack,
wherein the one or more electrical feeders are adapted to be bent in a plurality of angles, facilitating the electrical coupling of the one or more electrical feeders between the isolated energy storage module (102) and the electrical assembly (104).
2. The system (100) as claimed in claim 1, comprising a first interconnect (106) electrically coupled between a first terminal (102-1) of the isolated energy storage module (102) and the electrical assembly (104), wherein the first interconnect (106) is configured to conduct electric current from the first terminal (102-1) of the isolated energy storage module (102) to the electrical assembly (104) such that, in an event of breakage of the first interconnect (106), the one or more electrical feeders are configured to conduct electric current from the first terminal (102-1) of the isolated energy storage module (102) to the electrical assembly (104) or to a second interconnect (108) electrically coupled between an adjacent energy storage module (110) and the electrical assembly (104).
3. The system (100) as claimed in claim 2, wherein the first terminal (102-1) is a positive terminal or a negative terminal of the isolated energy storage module (102).
4. The system (100) as claimed in claim 2, wherein a first electrical feeder (112) of the one or more electrical feeders comprises a top end (112-1) and a bottom end (112-2), wherein the top end (112-1) is electrically coupled to the electrical assembly (104) and the bottom end (112-2) is adapted to be slit to facilitate electrical coupling of the first electrical feeder (112) to the first interconnect (106) or the first terminal (102-1) of the isolated energy storage module (102).
5. The system (100) as claimed in claim 4, wherein the first electrical feeder (112), in a first orientation of the plurality of orientations, is configured on the electrical assembly (104) from the top end (112-1), and on the broken first interconnect (106) coupled to the isolated energy storage module (102) from the bottom end (112-2).
6. The system (100) as claimed in claim 4, wherein the first electrical feeder (112), in a second orientation of the plurality of orientations, is configured on the electrical assembly (104) from the top end (112-1) and on the first terminal (102-1) of the isolated energy storage module (102) from the bottom end (112-2).
7. The system (100) as claimed in claim 1, wherein a second electrical feeder (114) of the one or more electrical feeders comprises a first end (114-1) and a second end (114-2), wherein the second end (114-2) is adapted to be slit to facilitate electrical coupling of the second electrical feeder (114) to a second interconnect (108) electrically coupled to an adjacent energy storage module (110) or to a second terminal (110-1) of the adjacent energy storage module (110), and wherein the first end (114-1) is adapted to be slit to facilitate electrical coupling of the second electrical feeder (114) to a first interconnect (106) or the isolated energy storage module (102).
8. The system (100) as claimed in claim 7, wherein the second terminal (110-1) is a positive terminal or a negative terminal of the adjacent energy storage module (110).
9. The system (100) as claimed in claim 7, comprising a polyimide film (116) operatively coupled to the second electrical feeder (114), and configured between the first end (114-1) and the second end (114-2) of the second electrical feeder (114), to electrically insulate a portion between the first end (114-1) and the second end (114-2) on the electrical assembly (104) and to resist high temperatures from the electrical insulation from other energy storage modules, wherein the polyimide film (116) is a Kapton tape.
10. The system (100) as claimed in claim 9, wherein the second electrical feeder (114), in a third orientation of the plurality of orientations, is configured on the second interconnect (108) from the second end (114-2) and on a broken first interconnect (106) coupled to the isolated energy storage module (102) from the first end (114-1) such that the insulated portion between the first end (114-1) and the second end (114-2) remains on top of the electrical assembly (104).
11. The system (100) as claimed in claim 9, wherein the second electrical feeder (114), in a fourth orientation of the plurality of orientations, is configured on the second interconnect (108) from the second end (114-2) and on the isolated energy storage module (102) from the first end (114-1) such that the insulated portion between the first end (114-1) and the second end (114-2) remains on top of the electrical assembly (104).
12. The system (100) as claimed in claim 1, wherein a first electrical feeder (112) and a second electrical feeder (114) of the one or more electrical feeders, in a fifth orientation of the plurality of orientations, are configured to be electrically coupled in any of the plurality of orientations to conduct electric current from the isolated energy storage module (102) to the electrical assembly (104).