DESC:TECHNICAL FIELD
[0001] The present subject matter is related, in general to a thermal propagation prevention system, and more particularly, but not exclusively to a thermal propagation prevention system in a battery pack.
BACKGROUND
[0002] Battery packs, such as Lithium-ion (Li-ion) battery pack or the like, are used to power electrical components in applications, such as electric vehicles, hybrid vehicles, mobile phones, laptops, medical equipment’s or the like. A battery pack has a plurality of cells in electrical connection with each other.
[0003] The battery pack are commonly used in various fields, for example, the battery pack serve as power sources for personal electronic devices like mobile phones, laptops, camera, electronic devices and the like. Further, the battery pack supplies possess desirable properties such as recharging capability, making them attractive as potential power sources for industries such as but not limited to automobile industry.
[0004] With the advancement in technology, an electric or hybrid electric vehicle makes use of plurality of power units to drive the vehicle. Typically, the plurality of power units is a battery pack to provide power to run a motor which in turn runs one or more wheels of the vehicle. The plurality of power units in such hybrid electric vehicles are prone to damage in high power applications due to increase in temperature as the usage increases.
[0005] When the battery pack is subjected to altitude changes and increase in temperature, there exists a difference between the internal pressure of the battery pack and the external pressure of the operating environment leading to damage caused to the sealing surface and resulting in battery failure. Battery heating is generally caused due to fire or explosion, chemical reactions, chemical risk due to toxic liquids and gases, or short circuits.
[0006] The increase in temperature of the battery pack leads to poor performance of the vehicle and causes thermal runaway, which creates an unsafe driving condition for a user. In battery technology, lithium-ion cells have attained significant popularity due to high energy density, high power density, excellent cycle performance and environmental friendliness. A better cooled battery pack ensures the welfare and safety of the user and as well as leads to an increase in durability and health of the plurality of cells of the battery pack.
[0007] Conventionally, to dissipate the heat generated in the plurality of cells of the battery pack and to overcome the thermal runaway issue, the battery pack includes liquid-filling materials, such as cooling liquid. However, use of such materials causes handling problems of the battery pack. In some conventional battery packs, for managing thermal issues in battery packs, have included the use of Phase Change Material (PCM) and other passive cooling techniques. The PCM absorbs the heat generated by the cells and changes its state from solid to liquid and dissipates the heat through the casing of the battery pack. However, the PCM solution is unable to dissipate heat instantly in cases where thermal runaway has been triggered. Further, PCM solutions have limitations in terms of weight, mechanical stability and their ability to contain the propagation of thermal runaway and flames. Furthermore, the integration of PCM can add significant weight to the battery pack, which is undesirable in applications where weight reduction is critical for overall efficiency and performance.
[0008] Recent advancements in battery technologies have led to the emergence of lighter weight alternatives, such as Lithium Ion Batteries (LiB). However, LiB presents challenges due to their unstable nature, necessitating sophisticated battery management systems to ensure safe and efficient operation. Internal combustion engines require a starting mechanism to initiate their operation, typically achieved by rotating the engine to the adequate speed for fuel injection and ignition to take over sustained operation. Traditionally, this has been accomplished using electrolytic batteries, such as Valve Regulated Lead-Acid (VRLA) batteries, which are known for their reliability but are relatively heavy.
[0009] Conventionally, starter systems for internal combustion engines involve the use of a separate starter relay connected to the battery via unprotected cables. This setup not only adds weight and cost but also raises safety concerns due to exposed wiring.
[00010] Moreover, one significant challenge with conventional multi-layer PBC (MLPCB) designs is the lack of provisions for protecting against overcurrent situations. In BMS applications, signal tracks within MLPCBs carry relatively low currents, primarily determined by their cross-sectional area. While this design efficiently transmits signals, it falls short in addressing potential overcurrent scenarios. In the absence of adequate protection mechanisms, instances of overcurrent due to short circuits, overloading, or mismatched loads can pose a severe risk to the battery pack's integrity and safety.
[00011] Another critical issue arises concerning water ingress into the battery system. Water entry can lead to electrical shorts and corrosion, compromising the functionality and safety of the BMS. Without appropriate safeguards in place, the presence of water within the battery module can exacerbate the risk of thermal runaway—a condition where excessive heat generation triggers ignition, potentially resulting in catastrophic damage to the battery pack and surrounding components.
[00012] Furthermore, the previous MLPCB designs lack tracks that can serve as fuses to disconnect the battery module from the BMS during hazardous situations. Without this essential safety feature, the BMS remains susceptible to thermal runaway, wherein certain components may ignite, further escalating the risk of damage and endangering the entire battery system.
[00013] In essence, the limitations of prior art MLPCB designs highlight a pressing need for enhanced safety features within BMS. Addressing these challenges is crucial to safeguarding battery packs from potential hazards and ensuring the reliability of battery systems across various applications.
[00014] The above information as disclosed in this background section is only for enhancement of understanding of the background of the disclosure and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art.
[00015] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.
SUMMARY OF THE INVENTION
[00016] According to embodiments illustrated herein, the present invention provides a battery pack.
[00017] The battery pack comprises of a casing, a plurality of cells, a first material and a plurality of sheets. The plurality of cells are placed inside the casing of the battery pack. The first material is disposed on at least one end of the plurality of cells. The first material is configured to hold and support the plurality of cells. Each of the plurality of sheets comprises of a plurality of slots. The plurality of cells are configured to be placed in these plurality of slots, and the plurality of slots conform with a shape of the at least one end of the plurality of cells.
[00018] The battery pack further comprises a first circuit and a second circuit. The first circuit and the second circuit being part of a battery management system of the battery pack. The first circuit being configured to supply power to a plurality of low current devices, the plurality of low current devices being configured to power vehicle electrical systems. The second circuit being configured to supply power to a plurality of high current devices. Upon ignition key activation, the battery pack powers up the plurality of low current devices using the first circuit. When the user of the vehicle initiates a vehicle start request, a controller of the battery management system communicates with a Vehicle Control Unit (ECU) to activate the second circuit, to facilitate power supply to high current devices.
[00019] The battery pack further comprises a Printed Circuit Board, the printed circuit board comprises of a plurality of tracks, the plurality of tracks being configured to disconnect the power supply to electrical components, thereby ensuring critical safety features.
[00020] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[00021] The details are described with reference to an embodiment of a b battery pack along with the accompanying diagrams. The same numbers are used throughout the drawings to reference similar features and components.
[00022] Figure 1 exemplarily illustrates an exploded view of a battery pack in accordance with an embodiment of the present disclosure.
[00023] Figure 2 exemplarily illustrates a perspective view of an assembled battery pack in accordance with an embodiment of the present disclosure.
[00024] Figure 3 exemplarily illustrates a circuit view of a battery management system of the battery pack in accordance with an embodiment of the present disclosure.
[00025] Figure 4 exemplarily illustrates a perspective view of a print circuit board of the battery management system of the battery pack in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[00026] Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope and spirit being indicated by the following claims.
[00027] An objective of the present subject matter is to provide a mechanism which can withstand high operating temperatures and protect plurality of cells of the battery packs from heat propagation during thermal runaway, internal pressure raises as well as regulate the flow of gases during thermal runaway.
[00028] Further, the present subject matter also provides a thermal management mechanism to dissipate the high temperatures occurrences in the event of thermal runaway and protect the plurality of cells of battery pack from exploding and causing harm to the user.
[00029] An objective of the present subject matter is to design a Battery Management System (BMS) for a battery pack in vehicles that efficiently manages the discharge current path. This includes splitting the discharge current path into two units: one for low current applications powering vehicle electrical systems and another for high current applications such as electric start.
[00030] Another objective of the present subject matter is to ensure continuous power supply to the low current output of the BMS while implementing safeguards to disable the output only in the event of a detected short circuit. This is aimed at preserving the memory variables of the Vehicle Control Unit (ECU) and facilitating faster powering up of user-facing systems.
[00031] Additionally, an objective of the present subject matter is to ensure timely deactivation of the high current output path of the BMS, either upon successful engine start or based on a predetermined timer threshold. This objective aims to prevent unnecessary power consumption and enhance overall system efficiency.
[00032] Another objective includes integrating fuse tracks into the printed circuit board to allow for timely disconnection of the battery module from the BMS during hazardous conditions, such as overcurrent or water ingress events, thereby mitigating the risk of thermal runaway and ensuring the safety of the battery pack. Additionally, the objective encompasses optimizing the constructional details of the printed circuit board to facilitate efficient signal transmission while prioritizing safety considerations.
[00033] As per an aspect of the present subject matter, a battery pack comprises of a casing, a plurality of cells, a first material and a plurality of sheets. The plurality of cells are placed inside the casing of the battery pack. The first material is disposed on at least one end of the plurality of cells. The first material is configured to hold and support the plurality of cells. Each of the plurality of sheets comprises of a plurality of slots. The plurality of cells are configured to be placed in these plurality of slots, and the plurality of slots conform with shape of the at least one end of the plurality of cells. With the implementations of the present subject matter, heat generated by the cells of the battery pack assemblies can be efficiently insulated from the other cells of the battery pack assemblies, thereby, the thermal runaway can be eliminated.
[00034] As per an aspect of the present subject matter, the battery pack further comprises a first circuit and a second circuit. The first circuit and the second circuit being part of a battery management system of the battery pack. The first circuit being configured to supply power to a plurality of low current devices, the plurality of low current devices being configured to power vehicle electrical systems. The second circuit being configured to supply power to a plurality of high current devices. Upon ignition key activation, the battery pack powers up the plurality of low current devices using the first circuit. When the user of the vehicle initiates a vehicle start request, a controller of the battery management system communicates with a Vehicle Control Unit (ECU) to activate the second circuit, to facilitate power supply to high current devices.
[00035] As per another aspect of the present subject matter, the battery pack further comprises a Printed Circuit Board, the printed circuit board comprises of a plurality of tracks, the plurality of tracks being configured to disconnect the power supply to electrical components, thereby ensuring critical safety features.
[00036] As per an aspect of the present subject matter, the plurality of sheets is stacked to cover a length of the plurality of cells. As per an aspect of the present subject matter, each of the plurality of sheets are made of a heat resistive material. A layer of silicate material is disposed between the each of the plurality of sheets.
[00037] As per an aspect of the present subject matter, the first material is a potting material. The potting material may be a polyurethane, an acrylic, an epoxy resin, a silicone material or a combination thereof. The potting material is disposed at a bottom portion of the battery pack.
[00038] As per an aspect of the present subject matter, the casing comprises of a top holding unit and a bottom holding unit. The top holding unit is configured to accommodate a first end of the plurality of cells. The bottom holding unit is placed opposite to the top holding unit and is configured to accommodate a second end of the plurality of cells. An enclosure created with the top holding unit and the bottom holding unit of the battery pack is configured to hold the plurality of cells. The plurality of sheets is stacked in the enclosure created with the top holding unit and the bottom holding unit of the battery pack. The perimeter of the enclosure conforms to the perimeter of the plurality of sheets. The first material is disposed on a bottom surface of the bottom holding unit.
[00039] As per an aspect of the present subject matter, the battery pack comprises a first member. The first member is configured to cover the plurality of cells from the first end.
[00040] As per an aspect of the present subject matter, the top holding unit and the bottom holding unit of the casing of the battery pack are attached by a fastening member.
[00041] As per an aspect of the present subject matter, the plurality of slots in the each of the plurality of sheets are uniformly placed. A plurality of hollow slots are formed by stacking the plurality of sheets and the plurality of slots. The hollow slots are configured to accommodate the plurality of cells.
[00042] As per an aspect of the present subject matter, stack of the plurality of sheets is compressed between the top holding unit and the bottom holding unit of each cell holder of the at least one cell holder. Each of the plurality of sheets can be compressed in thickness ranging from 25% to 50% of initial thickness of the plurality of sheets.
[00043] As per an aspect of the present subject matter, the casing comprises of a plurality of heat dissipating fins. The plurality of heat dissipating fins are disposed on an outer surface of the casing of the battery pack.
[00044] As per an aspect of the present subject matter, a Phase Change Material (PCM) is disposed between the plurality of sheets.
[00045] As per an aspect of the present subject matter, the first material is disposed on at least one end of the plurality of cells which is a negative terminal of the plurality of cells. The first material enables a heat dissipation through the negative terminal of the plurality of cells.
[00046] As per an aspect of the present subject matter, the first material is disposed on at least one end of the plurality of cells which is a negative terminal of the plurality of cells. The first material enables a heat dissipation through the negative terminal of the plurality of cells.
[00047] As per an aspect of the present subject matter, the first material is disposed on at least one end of the plurality of cells which is a negative terminal of the plurality of cells. The first material enables a heat dissipation through the negative terminal of the plurality of cells.
[00048] As per an aspect of the present subject matter, the first material is disposed on at least one end of the plurality of cells which is a negative terminal of the plurality of cells. The first material enables a heat dissipation through the negative terminal of the plurality of cells.
[00049] As per an aspect of the present subject matter, the battery management system of the battery pack comprises a controller, the controller being configured to detect an activation of the ignition key of the vehicle. Upon detection of the ignition key activation, the controller activates the second circuit of the battery management system. This aspect ensures optimizing the overall performance and efficiency of the starting process.
[00050] Additionally, in another aspect of the present subject matter, the battery management system includes controlling a first circuit output configuration and a second circuit output configuration, wherein output of first circuit is dedicated to powering the low current devices, and the output of second circuit is dedicated to high current devices to handle the high power requirements of the starter motor during engine startup. This dual-output configuration allows for efficient allocation of power resources, ensuring that essential vehicle systems are continuously powered while providing the necessary boost for engine starting operations.
[00051] Furthermore, in yet another aspect of the present subject matter, the battery management system is equipped with a switching circuitry comprising of the first circuit and the second circuit, selectively activates the high power output path only when an electric start request is detected. This selective activation mechanism minimizes power consumption and reduces the risk of overloading the battery during normal vehicle operation, thereby extending the lifespan of the battery pack and enhancing its overall reliability.
[00052] As per an aspect of the present subject matter, the controller monitors a plurality of parameters associated with the battery pack, and disconnect the second circuit if in the event of the plurality of parameters being an abnormal operating conditions, thereby preventing damage to the battery pack and ensuring the safety of the vehicle and its occupants.
[00053] As per an aspect of the present subject matter, the printed circuit board comprising a plurality of fuse tracks, the plurality of fuse tracks being
[00054] Additionally, the integration of the switching circuitry within the battery management system eliminates the need for additional external relay or switching components, simplifying the overall system architecture and reducing the overall cost and complexity of the electric start system. This aspect not only streamlines the manufacturing process but also enhances the robustness and reliability of the electric start mechanism, contributing to a more seamless and efficient vehicle starting experience.
[00055] The present subject matter is described using a battery pack which is used in a vehicle, whereas the claimed subject matter can be used in any other type of application employing above-mentioned battery pack, with required changes and without deviating from the scope of invention. Further, it is intended that the disclosure and examples given herein be considered as exemplary only.
[00056] The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the invention(s)” unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but not limited to”, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.
[00057] The embodiments of the present invention will now be described in detail with reference to battery pack with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[00058] Figure 1 exemplarily illustrates an exploded view of a battery pack in accordance with an embodiment of the present disclosure. Figure 2 exemplarily illustrates a perspective view of an assembled battery pack in accordance with an embodiment of the present disclosure. For brevity, figure 1 and figure 2 are explained together.
[00059] A battery pack (100) comprises of a casing (102), a plurality of cells (104), a first material (106), a plurality of sheets (108). The plurality of cells (104) is placed inside the casing (102). The first material (106) is disposed on at least one end of the plurality of cells (104). The first material (106) is configured to hold the plurality of cells (104). Each of the plurality of sheets (108) comprising plurality of slots (110). The plurality of cells (104) are configured in the plurality of slots (110). The plurality of slots (110) conforms with shape of the at least one end of the plurality of cells (104). Each sheet within the plurality of sheets (108) is positioned sequentially atop the other, ensuring that the plurality of slots (110) on each individual sheet run parallel to one another. Furthermore, the plurality of slots (110) conform with shape of the plurality of cells (104) in the battery pack (100).
[00060] The plurality of sheets (108) is stacked to cover a length of the plurality of cells (104). Each of the plurality of sheets (108) are made of a heat resistive material. A layer of silicate material is disposed between the each of the plurality of sheets (108). Each sheet of the plurality of sheets (108) is made from thermally insulating materials such as, but not limited to, Mica, to manage heat effectively or prevent propagation of the heat between adjacent cells within the battery pack. The selection of these materials helps to prevent the unnecessary transfer of heat between adjacent battery cells and ensures that temperature fluctuations are kept under control. Further, each sheet of the plurality of sheets (108) comprising a coating of heat resistive material. The incorporation of the heat-resistant material on each sheet provides an additional layer of protection against heat accumulation and propagation, accordingly, enhancing the overall thermal containment capabilities of the battery pack. The layer of silicate serves as an effective insulator, contributing to the overall thermal resistance of the battery pack and further minimizing heat transfer. The combination of thermally insulating materials, heat-resistant coatings, and silicate layers between the plurality of sheets (108) collectively strengthens the thermal management capabilities of the battery pack and accordingly ensuring the safety and reliable performance of the battery pack under various operating conditions and collectively minimize the likelihood of thermal events, contributing to enhanced operational safety.
[00061] The first material (106) is a potting material (106). The potting material (106) is a polyurethane, an acrylic, an epoxy resin, a silicone material or a combination thereof. The potting material (106) is disposed at a bottom portion of the battery pack (100). The potting material provides support to the plurality of cells (104) and ensures that the cells are tightly and securely disposed in the battery pack. The at least one end of the plurality of cells (104) where the potting material is disposed may be a negative terminal of the plurality of cells (104) which enables a heat dissipation through the negative terminal of the plurality of cells (104). The potting material at the bottom of the cells, specifically at the negative terminal, serves a dual purpose. It provides structural integrity to the cells as well as facilitates heat dissipation. This structural support enhances the overall robustness of the battery pack while ensuring that the cells are securely held in place, even under challenging conditions such as physical impact. The incorporation of potting material at the negative terminal aids in efficient heat dissipation, contributing to the maintenance of a nominal temperature range within the battery cells. This is crucial for preventing overheating during charging or discharging processes, thereby extending the lifespan of the battery and improving overall performance.
[00062] The first material (106) is disposed on a bottom surface of the bottom holding unit (102b). This helps in creating a base of the battery pack, as well as maintaining its centre of gravity.
[00063] The plurality of slots (104) in each of the plurality of sheets (108) are uniformly placed. This creates a plurality of hollow slots (110a) by stacking the plurality of sheets (108) and their plurality of slots (110). The hollow slots (110a) are configured to accommodate the plurality of cells (104). The hollow slots hold the cells in place securely, thereby eliminating the need for a separate cell holder. The hollow slots ensure that the cells are not freely movable inside the battery pack.
[00064] The stack of the plurality of sheets (108) is disposed between the top holding unit (102a) and the bottom holding unit (102b) of the casing. Each of the plurality of sheets (108) can be compressed in thickness ranging from 25% to 50% of initial thickness of the plurality of sheets (108). This deliberate compression not only bolsters the structural integrity of the assembly but also contributes to the enhanced thermal management and safety features of the battery pack. The controlled compression within this range optimizes the interaction between the plurality of sheets, influencing factors such as heat transfer, thermal insulation, and the overall structural integrity of the battery pack, thereby contributing to enhanced performance.
[00065] In an aspect, the casing comprises a plurality of heat dissipating fins. The plurality of heat dissipating fins is disposed on an outer surface of the casing of the battery pack (100).
[00066] In an embodiment, the Phase Change Material (PCM) is disposed between the plurality of sheets (108). In another embodiment, the PCM along with the silicate layer is disposed between the plurality of sheets (108). The Phase Change Material (PCM) will further contribute to the overall thermal resistance of the battery pack and further minimizing heat transfer. The combination of the stacked sheets and optional integration of PCM offers a balanced approach to cooling. It allows for efficient heat dissipation while also absorbing and releasing heat when necessary, contributing to temperature regulation.
[00067] In an aspect, the casing (102) of the battery pack (100) comprises of a top holding unit (102a) and a bottom holding unit (102b). The top holding unit (102a) is configured to accommodate a first end (104a) of the plurality of cells (104). The bottom holding unit (102b) is placed opposite to the top holding unit (102a) and is configured to accommodate a second end (104b) of the plurality of cells (104). Between the top holding unit and the bottom holding unit, an enclosure is created with the top holding unit (102a) and the bottom holding unit (102b) of the battery pack (100) is configured to hold the plurality of cells (104). The plurality of sheets (108) are stacked in the enclosure created between the top holding unit (302) and the bottom holding unit (304) of the battery pack (100). The perimeter of the enclosure conforming to the perimeter of the plurality of sheets (108). Therefore, the plurality of sheets (108) cover the entire enclosure within the casing, thereby increasing structural support.
[00068] The top holding unit (102a) and the bottom holding unit (102b) of the casing (102) of the battery pack (100) are attached by a fastening member (102c). In an embodiment, the bottom holding unit and the top holding unit comprises of mounting lugs which conform with each other. The fastening member is inserted through these mounting lugs, thereby securely fastening and attaching the top holding unit with the bottom holding unit.
[00069] In an embodiment, the battery pack (100) comprises of a first member (not shown) which covers the plurality of cells (104) from the first end (104a). The first member (102d) provides a base for a plurality of electrical components that are to be disposed in the battery pack. In an embodiment, the first end (104a) is a positive terminal of the plurality of cells (104). The potting material (106) is disposed on the negative terminal of the plurality of cells, which is on the bottom surface of the bottom holding unit.
[00070] Figure 3 exemplarily illustrates a circuit view of a battery management system of the battery pack in accordance with an embodiment of the present disclosure.
[00071] The system comprises a battery pack (100) with positive and negative output terminals. The positive output terminal of the battery is connected to a starter relay (not labelled), and an ignition key (304) in parallel. The starter relay serves as a controllable switching element for activating the starter motor (312). The output of the starter relay is connected to the starter motor. Additionally, the ignition key is connected to all vehicle electrical loads, including the Engine Control Unit (ECU) (306), for system wakeup. A fuse (302) is depicted to safeguard against overcurrent conditions. The negative terminal of the battery is connected to the grounding line of the vehicle, completing the electrical circuit. The battery pack features positive and negative output terminals. Internally, cells configured in series and parallel are connected to a Battery Management System (BMS, 314). The BMS (314) manages the battery operation and ensures safe and efficient performance. The electric start mechanism remains unchanged from the conventional system. The proposed solution involves splitting the Battery Management System (BMS, 314) into two output paths, as depicted in the drawings. First circuit (314a) is configured to power vehicle electrical loads with low current demands, while second circuit (314b) is designated for the high-power demand loads. A switching circuitry within the BMS selectively activates output 2 only during an ignition key activation. The output of the second terminal is directly connected to the starter motor, eliminating the need for intermediate switching circuitry. The depiction of the BMS unit with an integrated switching element is shown, although alternate configurations are possible. The present subject matter offers enhanced safety, efficiency, and reliability by incorporating a split BMS (314) design and eliminating the need for additional switching elements. Through careful management of power distribution and activation, the system ensures optimal performance during engine startup while minimizing complexity and cost.
[00072] Figure 4 exemplarily illustrates a perspective view of a print circuit board of the battery management system of the battery pack in accordance with an embodiment of the present disclosure.
[00073] In an aspect, the print circuit board (200) contains signal tracks responsible for transmitting signals from interconnectors to the Battery Management System (BMS, 314). However, the print circuit board lacks tracks that can serve as fuses to disconnect the module from the BMS. This design limitation can lead to safety hazards such as thermal runaway in the event of overcurrent or water ingress. The absence of fuse tracks (202) increases the risk of certain components on the BMS igniting, potentially resulting in catastrophic situations. The print circuit board (200) retains the function of transmitting signals from interconnectors to the Battery Management System (BMS). However, significant improvements have been made to enhance safety and reliability. Fuse tracks (202) are incorporated into the MLPCB design to address the previous design limitation. These fuse tracks serve as safety mechanisms by disconnecting the module from the BMS in the event of overcurrent or water ingress. Additionally, the cross-sectional area of the tracks is reduced by approximately 33% to increase resistance in an embodiment. This reduction in cross-sectional area allows the tracks to effectively act as fuses that will blow in the event of a catastrophic situation, thereby disconnecting the battery module from the BMS and preventing further risks.
[00074] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[00075] The present claimed invention solves the technical problem of thermal propagation. More specifically, by employing a stack of thermally insulating sheets, each coated with a layer of heat-resistant material, the invention effectively curtails the spread of thermal runaway and the potential for flame propagation.
[00076] Further, incorporation of the stacked sheets not only enhances the overall robustness of the assembly but also contributes to the longevity and resilience of the battery pack.
[00077] This mechanical stability fortifies the pack against various external stresses and operational conditions, guaranteeing sustained performance over time. The stack of sheets allows for tailored thermal management strategies to suit specific requirements. This adaptability ensures efficient heat dissipation while also accommodating the absorption and release of heat as needed, resulting in optimized temperature regulation.
[00078] Furthermore, one of the problems pertaining to weight of the battery pack, is appropriately addressed by the elimination of PCM and the adoption of the stack of sheets. This reduction in weight and bulkiness contributes to improved overall efficiency and extended operational range in case of electronic vehicles.
[00079] In light of the above mentioned advantages and the technical advancements provided by the disclosed method and system, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the configuration itself as the claimed steps provide a technical solution to a technical problem.
[00080] A description of an embodiment with several components in communication with another does not imply that all such components are required, On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention.
[00081] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[00082] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[00083] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
Reference Numerals:
100 – battery pack
102 – casing
102a – top holding unit
102b – bottom holding unit
102c – fastening member
102d – first member
104 – plurality of cells
104a – first end
104b - second end
106 – first material
108 - plurality of sheets
110 – plurality of slots
110a – hollow slots
314 – battery management system
302 – fuse
304 – ignition key
306 – vehicle control unit
308 – vehicle loads
312 - motor ,CLAIMS:WE CLAIM:

1. A battery pack (100), the battery pack (100) comprising:
a casing (102);
a plurality of cells (104), the plurality of cells (104) being placed inside the casing (102);
a first material (106), the first material (106) being disposed on at least one end of the plurality of cells (104), the first material (106) being configured to hold the plurality of cells (104); and
a plurality of sheets (108), each of the plurality of sheets (108) comprising plurality of slots (110),
wherein the plurality of cells (104) being configured to be placed in the plurality of slots (110), and the plurality of slots (110) conforming with a shape of the at least one end of the plurality of cells (104).

2. The battery pack (100) as claimed in claim 1, wherein the plurality of sheets (108) being stacked to cover a length of the plurality of cells (104).

3. The battery pack (100) as claimed in claim 1 comprising the plurality of sheets (108) being made of a heat resistive material, wherein a layer of silicate material being disposed between each of the plurality of sheets (108).

4. The battery pack (100) as claimed in claim 1 comprising the first material (106) being a potting material (106) disposed at a bottom portion of the battery pack (100), wherein the potting material (106) being a polyurethane, an acrylic, an epoxy resin, a silicone material or a combination thereof.

5. The battery pack (100) as claimed in claim 1, wherein the casing (102) comprising:
a top holding unit (102a) configured to accommodate the first end (104a) of the plurality of cells (104); and
a bottom holding unit (102b) placed opposite to the top holding unit (102a) and being configured to accommodate a second end (104b) of the plurality of cells (104),
an enclosure created with the top holding unit (102a) and the bottom holding unit (102b) of the battery pack (100) is configured to hold the plurality of cells (104),
the plurality of sheets (108) being stacked in the enclosure created between the top holding unit (102a) and the bottom holding unit (102b),
a perimeter of the enclosure being conformed to a perimeter of the plurality of sheets (108), and
the first material (106) being disposed on a bottom surface of the bottom holding unit (102b).

6. The battery pack (100) as claimed in claim 1 comprising a first member (102d) being configured to cover the plurality of cells (104) from the first end (104a).

7. The battery pack (100) as claimed in claim 5, wherein the top holding unit (102a) and the bottom holding unit (102b) being attached by a fastening member (102c).

8. The battery pack (100) as claimed in claim 1, wherein the plurality of slots (104) being uniformly disposed, wherein a plurality of hollow slots (110a) are formed by stacking the plurality of sheets (108) and the plurality of slots (110); and the plurality of hollow slots (110a) are configured to accommodate the plurality of cells (104).

9. The battery pack (100) as claimed in claim 5, wherein a stack of the plurality of sheets (108) being disposed between the top holding unit (102a) and the bottom holding unit (102b), and each of the plurality of sheets (108) configured to be compressed in thickness ranging from 25% to 50% of initial thickness of the plurality of sheets (108).

10. The battery pack (100) as claimed in claim 1, wherein the casing comprises a plurality of heat dissipating fins disposed on an outer surface of the casing of the battery pack (100).

11. The battery pack (100) as claimed in claim 1, wherein a Phase Change Material (PCM) being disposed between the plurality of sheets (108).
12. The battery pack (100) as claimed in claim 1, wherein the at least one end of the plurality of cells (104) being a negative terminal of the plurality of cells (104), and the first material (106) enabling a heat dissipation through the negative terminal of the plurality of cells (104).