Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of field of power units made up of an assembly of a plurality of battery cells. In particular, the present disclosure pertains to an energy block assembly formed of a plurality of battery cells and fuses interconnected to each other without the requirements of welding or soldering.

BACKGROUND
[0002] A battery pack is a set of any number of batteries or individual battery cells that may be configured in a series, parallel or a combination of both to deliver the desired voltage and current. Components of battery packs include the individual batteries or cells, and interconnects which provide electrical conductivity between them.
[0003] A battery cell typically features a protrusion at one end, cylindrical in shape, with a flat conductive base smaller in diameter than the cell itself, serving as a positive pole of the cell. At the opposite end, there is another flat conductive base, bounded by a protective casing, slightly smaller in diameter than the cell’s exterior but larger than the aforementioned cylindrical protrusion, often acting as a negative pole of the cell. Cylindrical battery cells are favoured in battery technology due to their balance between energy efficiency and power output, along with their cost-effectiveness in mass production. Nevertheless, their relatively low energy density necessitates large and expensive assemblies including copper bus bars, connecting wires, additional energy management electronic components and harnesses, which can introduce performance limitations due to imperfect electrical and thermal connections. Therefore, developing a simple, cost-effective assembly method with optimal electrical and thermal properties is crucial for advancements in electric power systems.
[0004] Modern batteries typically consist of numerous cells, often numbering in the hundreds or thousands, interconnected through conductive strips welded to cell terminals and separated by insulating materials. These cells are assembled into packs using adhesive tape, a laborious and costly process that lacks the flexibility for after-sales or maintenance services to replace faulty cells. More recently, alternative solutions have emerged, involving the mechanical and electrical connection of battery cells through flat plates with conductive tracks, typically made of copper, and secured together using mechanical elements like spacers to ensure firm contact and structural integrity.
[0005] For instance, in patent document FR 3073671 B1, an energy block is detailed, comprising an assembly of multiple battery cells without welding. This block incorporates lower and upper plates with metal contact areas, where the upper plate, constructed from an elastically deformable material, flexes axially in relation to the cell orientation due to spiral-shaped cut-outs. However, this design proves unsatisfactory because post-assembly, the geometry deviates from parallel alignment with the cell terminals’ surface, resulting in only point contact and elevated contact resistance. Additionally, this angled orientation reduces the available area for thermal conductivity. The patent document also proposes integrating fuse elements for each battery cell to enhance safety. While the fuse element configuration is functional, it significantly raises assembly costs and complexity, particularly impractical for modern energy storage devices housing thousands of cells.
[0006] Similarly, patent document EP2008354 outlines a battery block utilizing rapid blow fuse links to mitigate sustained arc formation risks. However, this approach necessitates precision robotic equipment for fuse link creation, proving not only time-intensive but also costly.
[0007] Hence, there exists a necessity within the field to address the drawbacks and limitations inherent in current solutions. This entails delivering a straightforward, dependable, and economical assembly for energy blocks, which facilitates optimal surface contact between electrically conductive portions of a plate and the terminals of battery cells, thereby enhancing their electrical and thermal connectivity. Moreover, such an assembly should ensure uniform stress distribution on the battery cells, even amidst dynamic conditions like impulse impacts. Furthermore, there is a desire to eliminate the need for additional fuse elements or fuse wire links for battery cells, as these significantly escalate costs, demand expensive manufacturing methods, and consume considerable time.
OBJECTS OF THE PRESENT DISCLOSURE
[0008] An object of the present disclosure is to provide a simple and reliable energy block assembly for facilitating optimal surface contact between electrically conductive portions of a plate and terminals of battery cells, to improve their electrical and thermal connectivity.
[0009] Another object of the present disclosure is to provide an energy block assembly configured to maintain uniform stress distribution on the battery cells, even amidst dynamic conditions.
[0010] Another object of the present disclosure is to provide a cost-efficient energy block assembly a cost-effective energy block assembly that eradicates the need for supplementary fuse elements or fuse wire links for the battery cells.

SUMMARY
[0011] Aspects of the present disclosure relates to an energy block assembly, which includes a plurality of battery cells, and at least one bus plate coupled to a cell terminal of at least one battery cell of the plurality of at least one battery cells. The at least one bus plate includes a base portion, a terminal connection portion, and a plurality of circular arc-shaped cut-out portions connecting the terminal connection portion to the base portion. The plurality of circular arc-shaped cut-out portions are arranged around the terminal connection portion to maintain a contact surface area of an electrical contact between the terminal connection portion and the cell terminal.
[0012] In an embodiment, each of the plurality of circular arc-shaped cut-out portions may be integrated with copper traces having pre-defined thickness to serve as a fuse for the cell terminal. The copper traces may be adapted to melt, when a current passing through the cell terminal exceeds a conducting capacity of the copper traces integrated to each of the plurality of circular arc-shaped cut-out portions, to prevent an overcurrent condition of the at least one battery cell. The pre-defined thickness of the copper traces for each of the plurality of circular arc-shaped cut-out portions may be selected based on an overcurrent capacity of the at least one battery cell.
[0013] In an embodiment, each of the plurality of circular arc-shaped cut-out portions may include a first end connected to the terminal connection portion and a second end connected to the base portion, the first end extending from the second end in the form of a circular arc.
[0014] In an embodiment, when the at least one bus plate is placed on the at least one battery cell, the plurality of circular arc-shaped cut-out portions wrap around the cell terminal.
[0015] In an embodiment, when the at least one bus plate is placed on the at least one battery cell, the plurality of circular arc-shaped cut-out portions deform the terminal connection portion to move out of plane from the base portion to maintain the contact surface area of the electrical contact between the terminal connection portion and the cell terminal.
[0016] In an embodiment, when the at least one bus plate is placed on the at least one battery cell, the plurality of circular arc-shaped cut-out portions exert a load on the terminal connection portion in an axial direction towards the cell terminal to increase the contact surface area of the electric contact between the terminal connection portion and the cell terminal.
[0017] In an embodiment, the cell terminal is any of a positive terminal or a negative terminal of the at least one battery cell.
[0018] In an embodiment, a number of the plurality of circular arc-shaped cut-out portions is greater than two.
[0019] In an embodiment, the energy block assembly provides a cost-friendly and reliable solution for forming a battery pack with integrated fuses without the requirement of welding or soldering. The energy block assembly utilizes three or more connections derived from circular arcs, i.e., circular arc-shaped cut-out portions, to ensure accurate application of perpendicular load application to the cell terminal. This enhances contact efficiency and minimizes resistance. Furthermore, the energy block assembly enlarges the contact surface area of the electrical contact between the terminal connection portion and the cell terminal, thereby significantly improving thermal conductivity and reducing contact resistance. In addition, the copper traces of specific thickness are incorporated into these arcs to act as internal fuses. This integration enhances safety and efficiency while concurrently reducing manufacturing expenses through the elimination of external fuse elements, and streamlining assembly time.
[0020] Various objects, features, aspects and advantages of the inventive 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 THE DRAWINGS
[0021] 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.
[0022] FIGs. 1A to 1C illustrate various representations of an energy block assembly, in accordance with an embodiment of the present invention;
[0023] FIG. 2 illustrates a plan view of a bus plate of the energy block assembly in accordance with an embodiment of the present invention;
[0024] FIGs. 3A to 3D illustrate various representations of the bus plate coupled to a battery cell of the energy block assembly, in accordance with an embodiment of the present invention; and
[0025] FIGs. 4A and 4B illustrate a plan view and a perspective view of multiple bus plates coupled to plurality of battery cells of the energy block assembly, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION
[0026] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such details as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosures as defined by the appended claims.
[0027] Embodiments explained herein relate to economical and reliable solution for producing an energy block assembly having a plurality of battery cells integrated with built-in fuses, while eliminating the need for welding or soldering. The energy block assembly utilizes multiple connections fashioned from circular arcs to ensure precise application of perpendicular force to a terminal connection portion towards a terminal of each of the battery cell to maintain continuous electrical contact with the terminal. This optimization enhances contact efficiency and reduces resistance. The energy block assembly increases the contact surface area between the terminal connection portion and the cell terminal, significantly improving thermal conductivity and diminishing contact resistance. Moreover, copper traces of defined thickness are integrated into these arcs to serve as internal fuses, enhancing safety and efficiency while simultaneously cutting manufacturing costs by eliminating the requirements of external fuse elements and reducing assembly time.
[0028] FIGs. 1A and 1B illustrate a perspective view and a front view of an energy block assembly 100, respectively. FIG. 1C shows a close-up view of the energy block assembly 100. The energy block assembly 100 (also referred to as “battery bank” hereinafter) includes a plurality of battery cells 102 that may be connected in series, parallel or a combination thereof. The battery cell 102 may be cylindrical in shape, and each of the battery cells 102 may include a positive terminal 104 and a negative terminal (not shown) on opposite axial ends thereof. The cell terminals are electrical contacts used to connect a load or charger to the battery cell 102. These terminals may have a wide variety of designs, sizes, and features. In an example, the positive terminal 104 may be in the form of a protrusion emanating outwards from on an axial end of the battery cell 102. The negative terminal may be in the form of a circular disc formed on the opposite axial end of the battery cell 102. The negative terminal may be flush with the opposite axial end of the battery cell 102.
[0029] The energy block assembly 100 also includes at least one bus plate 106 coupled to a cell terminal 104 of each of the battery cells 102. In an implementation, a number of the bus plates 106 may be equal to the number of battery cells 102, with each bus plate 106 fitted or coupled to the cell terminal 104 of each of the battery cells 102. Although FIGs. 1A to 1C depict the bus plates 106 coupled to the positive terminals 104 of the battery cells 102, the bus plates 106 are configured to be coupled to the negative terminals of the battery cells 102 in a similar manner. The bus plates 106 act as bus bars for high current power distribution. The bus plates 106 may be used to connect low voltage electrical equipment to the plurality of batteries 102. The energy block assembly 100 may also include a base plate 108 disposed at an axial end of the battery cells 102 opposite to the axial end at which the bus plates 106 are coupled. The base plate 108 may have a conductive surface that ensures connection with the negative terminal of the battery cells 102. In an implementation, the base plate 108 may have similar configuration as the plurality of bus plates 106.
[0030] FIG. 2 illustrates a plan view of the bus plate 106 of the energy block assembly 100. The bus plate 106 includes a base portion 202, a terminal connection portion 204, and a plurality of circular arc-shaped cut-out portions 206 connecting the terminal connection portion 204 to the base portion 202. The circular arc-shaped cut-out portions 206 are arranged around the terminal connection portion 204 to maintain a contact surface area of an electrical contact between the terminal connection portion 204 and the cell terminal 104. In an implementation, the cell terminal 104 may be any of the positive terminal or the negative terminal of the battery cell 102. The circular arc-shaped cut-out portions 206 may be formed of materials having high conductivity and heat resistance, such as copper or copper alloys.
[0031] Each of the circular arc-shaped cut-out portions 206 may be integrated with copper traces having pre-defined thickness to serve as an internal fuse for the cell terminal 104. The copper traces may be adapted to melt, when a current passing through the cell terminal 104 exceeds a conducting capacity of the copper traces integrated to the circular arc-shaped cut-out portions 206, to prevent an overcurrent condition of the corresponding battery cell 102. The pre-defined thickness of the copper traces for each of the circular arc-shaped cut-out portions 206 may be selected based on an overcurrent capacity of the battery cell 102. Each of the circular arc-shaped cut-out portions 206 may include a first end 208 connected to the terminal connection portion 204 and a second end 210 connected to the base portion 202. The first end 208 may extend from the second end 210 in the form of a circular arc.
[0032] The copper traces incorporated within the circular arc-shaped cut-out portions 206 are engineered with the pre-defined thickness, serving as integrated fuses. In instances of current overload surpassing the conducting capacity of the copper traces, the copper traces melt, thereby mitigating overcurrent situations and potential harm to the battery cells 102. Moreover, employing three or more circular arc-shaped cut-out portions 206 reduces the current required for the copper traces (internal fuse) to burn off, thereby enhancing safety of the energy block assembly 100.
[0033] Referring now to FIGs. 3A to 3D, where various representations of the bus plate 106 coupled to a battery cell 102 of the battery bank 100 are shown. When the bus plate 106 is placed on the battery cell 102, the circular arc-shaped cut-out portions 206 may wrap or encircle around the cell terminal 104 of the battery cell 102 to ensure even distribution of force over the cell terminal 104. Each circular arc-shaped cut-out portion 206 may extend along a significant portion of the cell’s circumference to maximize the contact area. Also, the circular arc-shaped cut-out portions 206 encircling the cell terminal 104 enable deforming of the terminal connection portion 204 to move out of plane from the base portion 202. The circular arc-shaped cut-out portions 206 may extend over a specific segment of the battery cell’s circumference, conforming precisely to its shape to achieve maximum surface contact between the terminal connection portion 204 and the cell terminal 104. The circular arc-shaped cut-out portions 206 may be uniformly spaced around the battery cell 102 to evenly distribute force and minimize the occurrence of localized stress points. This configuration of the bus plate 106 biases the terminal connection portion 204 to maintain a uniform contact surface area with the cell terminal 104.
[0034] The energy block assembly 100 adopts the circular arc-shaped cut-out portions 206 for each battery cell 102 to ensure consistent and perpendicular force application on the terminal contact portion 204 to maintain continuous surface contact of the terminal contact portion 204 with the cell terminal 104 of the battery cell 102, while eliminating angular force issues associated with conventional spiral-shaped connections, thereby ensuring sustained surface contact even during impulse impacts. Through the utilization of multiple circular arc-shaped cut-out portions 206, the contact surface area between the terminal contact portion 204 and the cell terminal 104 increases. This configuration not only enhances electrical connectivity but also improves thermal management by facilitating more efficient heat dissipation pathways from the cell terminal 104 of the battery cell 102. As a result, the increased surface area offered by the energy block assembly 100 substantially enhances thermal conductivity, and promotes improved heat distribution and dissipation, crucial in high-energy-density battery systems.
[0035] FIGs. 4A and 4B illustrate a plan view and a perspective view of multiple bus plates 106 coupled to the plurality of battery cells 102 of the battery bank 100. As shown, when the bus plate 106 is coupled to the battery cell 102, the circular arc-shaped cut-out portions 206 exert a load on the terminal connection portion 204 in the axial direction towards the cell terminal 104 to increase the contact surface area of the electric contact between the terminal connection portion 204 and the cell terminal 104. In an example, a number of the circular arc-shaped cut-out portions 206 may be greater than two. Through optimization of contact area and material properties, the battery bank 100 achieves lower electrical resistance and minimized voltage drop, and enhanced thermal conduction. Such enhancements collectively improve the efficiency, safety, and longevity of the battery bank 100. In an embodiment, design of the battery bank 100 is scalable to various sizes and shapes of battery cells, allowing for versatility in assembling energy blocks of different capacities and configurations. The circular arc-shaped cut-out portions 206 may be coupled to the battery cells using a method that guarantees robust mechanical stability while preserving electrical efficiency.
[0036] The battery bank 100 of the present disclosure surpasses the limitations of conventional techniques by introducing the bus plates 106 featuring an improved approach to deformable surfaces. Unlike conventional spiral arrangements, the battery bank 100 employs three or more connections based on circular arcs 206 to maintain the uniform electrical contact between the terminal contact portion 204 and the cell terminal 104 of the battery cell 102, by effectively biasing the terminal contact portion 204 in the direction of the cell terminal 104 at all times. This configuration improves contact efficiency and diminishes resistance of the cell terminal 104. Furthermore, this configuration increases the contact surface area, notably enhancing thermal conductivity, superior thermal handling capabilities, and reducing contact resistance. In addition, the battery bank 100 of the present disclosure integrates the copper traces with the pre-defined thickness on the circular arc-shaped cut-out portions 206 to function as built-in fuses to bolster safety and efficiency while simultaneously reducing manufacturing costs (due to the elimination of external fuse elements) and assembly time.
[0037] 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. , Claims:WE CLAIM:

1. An energy block assembly (100), comprising:
a plurality of battery cells (102); and
at least one bus plate (106) coupled to a cell terminal (104) of at least one battery cell (102) of the plurality of battery cells (102), the at least one bus plate (106) comprising a base portion (202), a terminal connection portion (204), and a plurality of circular arc-shaped cut-out portions (206) connecting the terminal connection portion (204) to the base portion (202), wherein the plurality of circular arc-shaped cut-out portions (206) are arranged around the terminal connection portion (204) to maintain a contact surface area of an electrical contact between the terminal connection portion (204) and the cell terminal (104).

2. The energy block system (100) as claimed in claim 1, wherein each of the plurality of circular arc-shaped cut-out portions (206) are integrated with copper traces having pre-defined thickness to serve as a fuse for the cell terminal (104).

3. The energy block system (100) as claimed in claim 2, wherein the copper traces are adapted to melt, when a current passing through the cell terminal (104) exceeds a conducting capacity of the copper traces integrated to each of the plurality of circular arc-shaped cut-out portions (206), to prevent an overcurrent condition of the at least one battery cell (102).

4. The energy block system (100) as claimed in claim 2, wherein the pre-defined thickness of the copper traces for each of the plurality of circular arc-shaped cut-out portions (206) is selected based on an overcurrent capacity of the at least one battery cell (102).

5. The energy block system (100) as claimed in claim 1, wherein each of the plurality of circular arc-shaped cut-out portions (206) comprises a first end (208) connected to the terminal connection portion (204) and a second end (210) connected to the base portion (202), the first end (208) extending from the second end (210) in the form of a circular arc.

6. The energy block system (100) as claimed in claim 1, wherein when the at least one bus plate (106) is placed on the at least one battery cell (102), the plurality of circular arc-shaped cut-out portions (206) wrap around the cell terminal (104).

7. The energy block system (100) as claimed in claim 1, wherein when the at least one bus plate (106) is placed on the at least one battery cell (102), the plurality of circular arc-shaped cut-out portions (206) deform the terminal connection portion (204) to move out of plane from the base portion (202) to maintain the contact surface area of the electrical contact between the terminal connection portion (204) and the cell terminal (104).

8. The energy block system (100) as claimed in claim 1, wherein when the at least one bus plate (106) is placed on the at least one battery cell (102), the plurality of circular arc-shaped cut-out portions (206) exert a load on the terminal connection portion (204) in an axial direction towards the cell terminal (104) to increase the contact surface area of the electric contact between the terminal connection portion (204) and the cell terminal (104).

9. The energy block system (100) as claimed in claim 1, wherein the cell terminal (104) is any of a positive terminal or a negative terminal of the at least one battery cell (102).

10. The energy block system (100) as claimed in claim 1, wherein a number of the plurality of circular arc-shaped cut-out portions (206) is greater than two.