Description:MODULAR BATTERY PACK
Field of the Invention
[0001] The present disclosure generally relates to user-repairable energy storage systems. Further, the present disclosure particularly relates to a modular battery pack enabling individual cell replacement.
Background
[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Electric vehicles (EVs) have gained significant traction in recent years due to their potential to reduce greenhouse gas emissions, lower dependency on fossil fuels, and provide sustainable transportation solutions. The demand for EVs has led to advancements in energy storage systems, particularly lithium-ion battery packs, which serve as the primary energy source for powering electric drivetrains. Lithium-ion battery packs are also widely used in energy storage systems (ESS) for renewable energy applications and home grid setups, owing to their high energy density, long cycle life, and relatively compact size. Despite their advantages, conventional battery pack designs used in such applications are associated with significant limitations, particularly in the context of construction, maintenance, and monitoring.
[0004] A common method employed in conventional lithium-ion battery packs is the use of spot-welding techniques to connect individual cells in a series and/or parallel arrangement. Spot welding involves fusing metal tabs to the terminals of the cells to create electrical connections. While this technique allows for the integration of multiple cells into a compact and rigid structure, it introduces several drawbacks. One of the primary issues is the lack of flexibility for repair or replacement of individual cells. Spot-welded connections are permanent, which makes isolating or replacing a defective cell difficult without damaging adjacent cells or connections. As a result, even when a single cell becomes defective, the entire battery pack often needs to be replaced, leading to increased costs and wastage. Such limitations are particularly challenging for non-technical users, as repairing spot-welded connections typically requires specialized tools and expertise.
[0005] Additionally, the high temperatures involved in the spot-welding process can cause thermal damage to the battery cells, potentially affecting their performance and longevity. This process also introduces the risk of uneven weld quality, where inconsistent weld strength or improper alignment can result in unreliable electrical connections. Such inconsistencies can compromise the durability and safety of the battery pack during operation.
[0006] Another critical limitation associated with spot-welded battery packs is the challenge of monitoring and measuring electrical parameters, such as voltage, current, and internal resistance, for each individual cell. Since cells are permanently connected through spot welding, it becomes difficult to access individual cell terminals without dismantling the welded connections. This limitation affects the ability to perform detailed diagnostics or monitor the state of charge (SOC) and state of health (SOH) of individual cells. Accurate measurement of these parameters is essential for identifying underperforming or defective cells and ensuring the overall performance and safety of the battery pack. However, the lack of accessibility to individual cells in spot-welded designs hinders the implementation of effective monitoring and maintenance strategies.
[0007] Furthermore, the serial arrangement of cells in conventional battery packs requires each cell to be individually checked during the manufacturing process to ensure proper functioning and uniformity. This process is labor-intensive and time-consuming, particularly for large battery packs comprising numerous cells. The inability to isolate and independently replace or monitor individual cells adds to the operational and maintenance complexities of spot-welded battery packs, making them less user-friendly and cost-efficient.
[0008] In light of the above discussion, there exists an urgent need for solutions that overcome the problems associated with conventional systems and/or techniques for constructing, maintaining, and monitoring battery packs. Such solutions should address the challenges posed by spot-welding techniques, including the difficulties in replacing defective cells, the risk of thermal damage, and the limitations in measuring electrical parameters for individual cells.
Summary
[0009] The following presents a simplified summary of various aspects of this disclosure in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements nor delineate the scope of such aspects. Its purpose is to present some concepts of this disclosure in a simplified form as a prelude to the more detailed description that is presented later.
[00010] The following paragraphs provide additional support for the claims of the subject application.
[00011] The present disclosure provides a modular battery pack comprising a lower section comprising multiple receptacles, each receptacle housing a first portion of a battery cell. Each receptacle comprises a spring-biased connector to exert consistent compressive force against the first portion of the battery cell. An upper section comprises multiple recesses, each recess housing a second portion of the battery cell. The upper section is aligned with the lower section such that the recesses are positioned in correspondence with the receptacles. Each recess comprises a resilient engagement unit maintaining stable contact with the second portion of the battery cell. Each resilient engagement unit and each spring-biased connector is associated with an identification code. A first sensing unit measures, individually for each battery cell, a state of charge and a state of health of each battery cell, with the measurements being tagged with the identification code. A second sensing unit detects a condition of the battery pack, selected from a thermal runaway, a gas leakage event, or a temperature. A control circuit coupled to the first sensing unit and the second sensing unit analyses the detected condition to initiate a pre-alert notification and identify a fault in any battery cell.
[00012] Moreover, the spring-biased connector comprises a hollow core spring forming a fluid pathway to enable the flow of a cooling medium to dissipate heat from the battery cell. The hollow core spring is fluidically coupled to a coolant reservoir. Furthermore, the receptacle comprises an auto-eject unit comprising a cam-driven plunger positioned beneath the spring-biased connector. The cam-driven plunger exerts an upward force upon receiving a fault signal from the control circuit, thereby displacing the battery cell from contact with the spring-biased connector.
[00013] Further, the spring-biased connector comprises a rotatable abrasive disk positioned at the interface between the spring and the battery cell. The abrasive disk removes debris and oxidation from the contact surface. Furthermore, at least one of the receptacle and recess comprises an encapsulated phase-change material layer positioned circumferentially around the battery cell. At least one of the spring-biased connector and resilient engagement unit is associated with a shear pin severing a physical connection and an electrical connection upon detecting an impact force exceeding a predefined threshold.
[00014] Moreover, each spring-biased connector and resilient engagement unit comprises a dual-contact pivoting unit, rotatably mounted to match the polarity of the battery cell. Furthermore, the lower section comprises a thermally conductive layer disposed beneath each receptacle to dissipate heat generated by the first portion of the battery cell during operation, thereby maintaining an optimal temperature range for each battery cell housed in the modular battery pack.
[00015] Furthermore, the resilient engagement unit comprises a multi-point contact structure to enable uniform pressure distribution across the second portion of the battery cell. Such a configuration minimizes the risk of mechanical stress and ensures stable electrical connectivity during operation. Additionally, each resilient engagement unit dynamically adjusts its pressure based on the thermal expansion of the second portion of the battery cell, thereby maintaining consistent contact and preventing damage to the battery cell.
[00016] Moreover, the upper section and the lower section further comprise alignment guides to precisely align the recesses and receptacles during assembly. Such alignment guides minimize assembly errors and enable accurate positioning of each battery cell.
Brief Description of the Drawings
[00017] The features and advantages of the present disclosure would be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
[00018] FIG. 1 illustrates a modular battery pack (100), in accordance with the embodiments of the present disclosure.
[00019] FIG. 2 illustrates an operational diagram of a modular battery pack (100) in accordance with the embodiments of the present disclosure.
[00020] FIG. 3 illustrates a system architecture for a modular battery pack (100), in accordance with the embodiments of the present disclosure.
[00021] FIG. 4 illustrates a user interface of a monitoring system for the modular battery pack (100), showcasing real-time information regarding operational and environmental parameters, in accordance with the embodiments of the present disclosure.
Detailed Description
[00022] In the following detailed description of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to claim those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims and equivalents thereof.
[00023] The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[00024] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00025] As used herein, the term "lower section" refers to a structural component of a system designed to provide a base or foundational layer for housing individual battery cells. Such a lower section is constructed with multiple cavities, pockets, or compartments, each shaped and dimensioned to accommodate a portion of the battery cell, typically the base or lower end. The cavities may be formed of materials such as polymer composites, metals, or reinforced thermoplastics, depending on the intended application and operating environment. Each cavity, referred to as a receptacle, may include additional features to enhance the secure positioning of the battery cell, such as integrated ribs, grooves, or clamping mechanisms. The lower section supports the physical integrity of the battery pack and may include properties like thermal insulation or conductive paths for heat dissipation. Examples of similar foundational structures in related applications include battery trays in electric vehicles or mounting bases in energy storage systems. The lower section further serves as a platform for integrating additional components such as connectors, sensors, or cooling elements, providing a versatile base for modular design.
[00026] As used herein, the term "receptacle" refers to a compartment or enclosure within the lower section designed to hold and secure a portion of a battery cell. Such a receptacle typically features precise dimensions and structural characteristics tailored to match the size and geometry of the battery cell. Each receptacle may include support features such as ribs, clamps, or spring-loaded mechanisms to apply mechanical force and maintain a secure connection with the housed battery cell. Receptacles may be fabricated from heat-resistant polymers, metal alloys, or other materials suitable for mechanical stress and thermal conditions. Examples of receptacles include holders in consumer electronics, battery modules in electric vehicles, or cell compartments in power tools. The receptacle provides stability and alignment for the battery cell while enabling integration with electrical and thermal management systems.
[00027] As used herein, the term "spring-biased connector" refers to a mechanical element comprising a spring mechanism that exerts consistent compressive force to establish and maintain electrical contact with a battery cell. Such a connector typically includes a conductive spring fabricated from materials like copper alloys, beryllium copper, or stainless steel, which provide both elasticity and electrical conductivity etc. The connector applies uniform force to ensure a stable connection and mitigate potential issues such as resistance fluctuations or contact degradation due to vibrations or thermal expansion. Spring-biased connectors are widely used in various applications, including electronic circuit boards, battery terminals, and electrical interconnects.
[00028] As used herein, the term "upper section" refers to a structural component positioned above the lower section and aligned to house a second portion of a battery cell. Such an upper section comprises multiple recesses, each designed to correspond to a receptacle in the lower section. Recesses may be formed of materials such as thermoplastics, composite materials, or lightweight metals, providing a stable enclosure for the upper portion of the battery cell. The upper section may include integrated features like clamps, engagement units, or thermal barriers for securing the battery cell and facilitating electrical and thermal management. Similar upper housing structures can be observed in battery enclosures for portable electronic devices, electric vehicles, or renewable energy storage units.
[00029] As used herein, the term "resilient engagement unit" refers to a mechanical component that provides flexible and stable contact with a battery cell. Such an engagement unit is designed to accommodate variations in cell dimensions or alignment while maintaining consistent mechanical and electrical contact. The unit typically includes materials such as elastomers, conductive polymers, or metallic springs, depending on the specific application. Examples of resilient engagement units include terminal connectors in rechargeable battery systems or compression pads in battery modules.
[00030] As used herein, the term "first sensing unit" refers to a device or assembly configured to measure individual parameters of a battery cell, such as state of charge or state of health. Such a sensing unit comprises sensors capable of detecting electrical, thermal, or chemical properties of the battery cell. Examples of sensors include voltmeters for voltage measurement, ammeters for current detection, or temperature sensors like thermocouples and RTDs. The first sensing unit may also include microcontrollers or analog-to-digital converters for processing and transmitting the measured data.
[00031] As used herein, the term "second sensing unit" refers to a device or assembly configured to detect overall conditions of a battery pack, such as thermal runaway, gas leakage, or temperature changes. Such a sensing unit comprises specialized sensors like gas sensors for detecting leaks, thermal sensors for identifying heat-related issues, or pressure sensors for monitoring internal pack pressure. Examples of sensing units include NDIR sensors for gas detection, thermistors for temperature measurement, or piezoelectric sensors for impact monitoring.
[00032] As used herein, the term "control circuit" refers to an electronic assembly comprising components such as microprocessors, integrated circuits, or controllers designed to process input signals from sensing units. Such a circuit performs data analysis, fault detection, and initiation of alerts based on the measured parameters. Control circuits are commonly found in battery management systems for electric vehicles, renewable energy storage systems, or industrial equipment.
[00033] FIG. 1 illustrates a modular battery pack (100), in accordance with the embodiments of the present disclosure. The modular battery pack (100) comprises a lower section (102) having multiple receptacles (104), each receptacle (104) being dimensioned and shaped to house a first portion of a battery cell. Each receptacle (104) incorporates a spring-biased connector (106) that applies a consistent compressive force against the first portion of the battery cell, thereby maintaining a stable physical and electrical connection. The spring-biased connector (106) comprises a conductive material, such as copper or its alloys, which provides both the mechanical elasticity and electrical conductivity necessary for efficient operation. The spring mechanism ensures that a uniform force is applied to the contact points, compensating for any thermal expansion or vibrations during operation. The receptacles (104) within the lower section (102) are constructed from materials capable of withstanding operational stresses, such as reinforced polymers, lightweight metals, or thermoplastics. The structural arrangement of the receptacles (104) within the lower section (102) enables the secure positioning of each battery cell while permitting quick assembly and disassembly. The lower section (102) also integrates structural reinforcements and thermal management features, such as conductive pathways or insulative coatings, to ensure the mechanical stability and thermal balance of the modular battery pack (100).
[00034] The modular battery pack (100) further comprises an upper section (108) having multiple recesses (110), each recess (110) being dimensioned to house a second portion of the battery cell. The upper section (108) is aligned with the lower section (102) in such a way that the recesses (110) of the upper section (108) correspond to the receptacles (104) of the lower section (102), thereby enabling precise positioning of the battery cells. Each recess (110) comprises a resilient engagement unit (112), which maintains stable contact with the second portion of the battery cell. The resilient engagement unit (112) accommodates any variations in the dimensions or alignment of the battery cells, thereby ensuring consistent mechanical and electrical contact. The engagement unit (112) is made from flexible and conductive materials, such as elastomers with conductive properties or metallic springs, that can adapt to changes in cell geometry caused by operational conditions such as thermal expansion. The upper section (108) is fabricated from lightweight and durable materials, such as reinforced polymers or aluminium alloys, and may include alignment features to facilitate assembly with the lower section (102). The alignment of the recesses (110) with the receptacles (104) allows the modular battery pack (100) to achieve a compact and organized configuration.
[00035] The modular battery pack (100) includes a first sensing unit (114) that is coupled to each spring-biased connector (106) and each resilient engagement unit (112). The first sensing unit (114) measures parameters of each battery cell individually, such as the state of charge (SOC) and the state of health (SOH). The measurements obtained by the first sensing unit (114) are tagged with an identification code associated with the corresponding spring-biased connector (106) and resilient engagement unit (112). The first sensing unit (114) comprises various sensors and measuring devices, including voltage sensors, current sensors, and impedance measurement devices, which provide real-time monitoring of each battery cell's operational status. The first sensing unit (114) further includes processing electronics to compile, store, and transmit the measured data for further analysis. The identification code associated with each spring-biased connector (106) and resilient engagement unit (112) ensures that the measurements are uniquely linked to the specific battery cell, thereby enabling precise fault detection and maintenance.
[00036] The modular battery pack (100) further includes a second sensing unit (116) that detects at least one condition of the modular battery pack (100), such as thermal runaway, a gas leakage event, or temperature variations. The second sensing unit (116) comprises specialized sensors, including temperature sensors, gas detection sensors, and thermal runaway detectors. The temperature sensors may include thermocouples or resistance temperature detectors (RTDs), while the gas detection sensors may include infrared or electrochemical gas sensors. The second sensing unit (116) provides comprehensive monitoring of the overall safety and environmental conditions of the modular battery pack (100). The detected conditions are transmitted to a control circuit (118) for further analysis.
[00037] The modular battery pack (100) incorporates a control circuit (118) that is coupled to the first sensing unit (114) and the second sensing unit (116). The control circuit (118) analyzes the data received from the first sensing unit (114) and the second sensing unit (116) to detect any abnormalities or faults in the battery cells or the modular battery pack (100) as a whole. The control circuit (118) is configured to initiate a pre-alert notification if a potential fault or hazardous condition is detected. The control circuit (118) comprises electronic components, such as microprocessors, memory modules, and communication interfaces, that process the data and execute the necessary safety protocols. The pre-alert notification generated by the control circuit (118) can be transmitted to an external monitoring system or a user interface, enabling timely intervention and maintenance. The identification codes tagged to the data measured by the first sensing unit (114) allow the control circuit (118) to pinpoint the specific battery cell associated with the fault, thereby facilitating targeted troubleshooting and replacement.
[00038] In an embodiment, the spring-biased connector (106) comprises a hollow core spring that forms a fluid pathway allowing a cooling medium to flow through the hollow core. The hollow core spring is fluidically coupled to a coolant reservoir, which serves as the source for the cooling medium. The hollow core spring is fabricated from materials that exhibit both elasticity and thermal conductivity, such as beryllium copper or stainless steel, to facilitate heat dissipation while maintaining mechanical resilience. The fluid pathway within the hollow core spring is designed to allow a continuous flow of the cooling medium, which may include liquids such as water, ethylene glycol, or dielectric coolants, depending on the application. The cooling medium absorbs heat generated by the battery cell during operation, preventing overheating and maintaining optimal temperature levels. The coupling between the hollow core spring and the coolant reservoir may involve connectors, seals, or fittings that prevent leakage while enabling the consistent flow of the cooling medium. The spring-biased nature of the connector ensures that the fluid pathway remains intact even under mechanical vibrations or thermal expansion conditions. The fluid pathway may also be connected to a pump or a closed-loop cooling system to enhance the circulation of the cooling medium. Similar cooling mechanisms are widely used in applications such as thermal management systems for electric vehicles or industrial battery systems. The integration of a hollow core spring into the modular battery pack (100) provides an effective means of managing heat generated by the battery cell during operation.
[00039] In an embodiment, the receptacle (104) comprises an auto-eject unit that includes a cam-driven plunger positioned beneath the spring-biased connector (106). The cam-driven plunger is constructed to exert an upward force upon receiving a fault signal from the control circuit (118). The fault signal is generated when abnormal conditions, such as overvoltage, overheating, or a short circuit, are detected in the corresponding battery cell. The upward force exerted by the cam-driven plunger displaces the battery cell from its contact with the spring-biased connector (106), effectively disconnecting the faulty cell from the electrical circuit. The cam-driven plunger may include mechanical components such as a spring-loaded cam mechanism, which stores and releases mechanical energy to produce the desired upward motion. The plunger is fabricated from materials such as high-strength alloys or polymers to withstand repetitive actuation without deforming. The fault signal from the control circuit (118) may be transmitted to the auto-eject unit via wired or wireless connections. The auto-eject unit is designed to operate autonomously, minimizing human intervention and allowing for rapid fault isolation. Such a mechanism is particularly relevant for applications involving high-capacity battery packs, where the removal of a single faulty cell is critical to maintaining the overall performance and safety of the system. Similar ejector mechanisms are commonly employed in modular energy storage systems and consumer electronics.
[00040] In an embodiment, the spring-biased connector (106) further includes a rotatable abrasive disk positioned at the interface between the spring and the battery cell. The abrasive disk is constructed to remove debris, oxidation, or other contaminants from the contact surface of the battery cell and the connector. The abrasive disk is fabricated from materials such as aluminium oxide or silicon carbide, which provide the necessary abrasiveness to clean the contact surfaces without causing significant wear. The disk is mounted on a rotatable axis, which is driven by a small motor, spring mechanism, or manual operation. The rotational motion of the abrasive disk ensures uniform cleaning of the contact surfaces during each operation. The cleaning process prevents the accumulation of contaminants that can increase electrical resistance and compromise the performance of the battery cell connection. The abrasive disk is positioned in such a way that it does not interfere with the normal operation of the spring-biased connector (106). The cleaning process may be activated periodically or in response to a predefined condition, such as a decrease in electrical conductivity detected by the first sensing unit (114). The incorporation of the abrasive disk into the modular battery pack (100) provides a practical solution to maintaining consistent electrical performance and prolonging the lifespan of the battery cells.
[00041] In an embodiment, at least one of the receptacle (104) and the recess (110) comprises an encapsulated phase-change material (PCM) layer positioned circumferentially around the battery cell. The encapsulated PCM layer is designed to absorb and release thermal energy, thereby regulating the temperature of the battery cell during operation. The PCM is a material that undergoes a phase transition, such as melting or solidifying, at a specific temperature range. Examples of PCM materials include paraffin waxes, fatty acids, and salt hydrates, which are selected based on the desired thermal properties and operating conditions. The encapsulation of the PCM within a protective layer, such as a polymeric shell or metallic casing, prevents leakage and degradation of the material. The PCM layer is integrated into the structural design of the receptacle (104) or the recess (110) to maximize thermal contact with the battery cell. The heat absorbed by the PCM during the melting process prevents the battery cell from overheating, while the heat released during solidification maintains the temperature within the optimal range during low-temperature conditions. The incorporation of an encapsulated PCM layer is commonly used in thermal management systems for energy storage devices, electronic components, and building materials.
[00042] In an embodiment, at least one of the spring-biased connector (106) and the resilient engagement unit (112) is associated with a shear pin that severs both the physical and electrical connections upon detecting an impact force exceeding a predefined threshold. The shear pin is a mechanical safety device fabricated from materials such as alloys or composites that are engineered to fracture at a specific load. The impact force may result from external shocks, such as collisions or drops, which could otherwise compromise the safety of the modular battery pack (100). The fracture of the shear pin isolates the affected component, preventing further damage to the battery cell or surrounding elements. The detection of the impact force may be achieved using sensors integrated into the system, such as piezoelectric sensors, accelerometers, or pressure sensors. Upon detecting an impact, the control circuit (118) signals the shear pin to sever the connection. The severing of the shear pin may be accompanied by a visual or audible alert, indicating the need for replacement or repair. The use of shear pins is widely implemented in mechanical systems, including automotive safety devices, industrial machinery, and energy storage systems, to enhance the reliability and safety of the system.
[00043] In an embodiment, each of the spring-biased connector (106) and the resilient engagement unit (112) comprises a dual-contact pivoting unit that is rotatably mounted to match the polarity of the battery cell. The dual-contact pivoting unit includes two electrically conductive arms or surfaces that pivot to align with the positive and negative terminals of the battery cell. The pivoting mechanism allows the dual-contact unit to accommodate variations in the orientation or alignment of the battery cell while maintaining stable electrical contact. The electrically conductive arms may be fabricated from materials such as copper, brass, or other conductive alloys to ensure efficient current transfer. The pivoting mechanism may involve mechanica

thermally conductive layers is a common practice in electronic devices, energy storage systems, and industrial equipment.
[00045] In an embodiment, the resilient engagement unit (112) comprises a multi-point contact structure that distributes pressure uniformly across the second portion of the battery cell. The multi-point contact structure includes multiple contact points, such as pins, springs, or conductive pads, which apply even mechanical force to the surface of the battery cell. The uniform pressure distribution reduces the risk of mechanical stress, such as deformation or cracking, which could compromise the structural integrity or electrical performance of the battery cell. The contact points are fabricated from conductive and flexible materials, such as gold-plated copper or conductive elastomers, to ensure stable electrical connectivity. The use of multi-point contact structures is widely observed in applications such as battery terminals, electronic connectors, and power distribution systems.
[00046] In an embodiment, each resilient engagement unit (112) dynamically adjusts its pressure based on the thermal expansion of the second portion of the battery cell. The dynamic adjustment mechanism involves materials or components, such as thermally responsive springs, shape-memory alloys, or elastomers, which expand or contract in response to temperature changes. The adjustment compensates for dimensional changes in the battery cell caused by thermal expansion or contraction during charging, discharging, or environmental variations. The dynamic pressure adjustment ensures consistent mechanical and electrical contact without overloading the battery cell. Such mechanisms are used in thermal and mechanical management systems for energy storage devices, electronic equipment, and industrial machinery.
[00047] In an embodiment, the upper section (108) and the lower section (102) further comprise alignment guides designed to align the recesses (110) and receptacles (104) during assembly. The alignment guides may include features such as grooves, ridges, or pins that interlock the upper and lower sections. The guides are fabricated from materials such as polymers, metals, or composites that provide dimensional stability and durability. The alignment guides prevent assembly errors, such as misalignment or displacement, ensuring accurate positioning of each battery cell. Similar alignment mechanisms are widely used in modular assembly systems, electronic enclosures, and energy storage systems.
[00048] In an embodiment, the modular battery pack (100) may incorporate a series connection of cells, wherein 32700 – LiFePO4 3.2V 6000mAh cells may be utilized. Both terminals of individual cells may be connected to the controller board (not shown). Traces on the PCB of the controller board may establish a series arrangement of the individual cells, forming the battery. Such an arrangement may facilitate a uniform layout of the cells, wherein all cells may face the same side up, thereby potentially encapsulating the wiring complexity from the user. The series connection may eliminate the need for external wiring, enabling a simpler and more organized design. The uniform layout and internal wiring design may reduce the possibility of misconnection during installation or maintenance, potentially improving user accessibility and convenience.
[00049] In an embodiment, the modular battery pack (100) may include an external off-the-shelf battery management system (BMS) connected directly to the controller board (not shown). The BMS may be coupled to the series line of the battery through the controller board, potentially eliminating the need for a smart BMS. This arrangement may reduce the overall cost of the system while enhancing repairability. If a specific component within the BMS becomes faulty, the external BMS may be replaced independently without requiring the replacement of the entire controller board. The use of an external BMS may allow for straightforward maintenance and modular design flexibility, which may provide advantages in terms of system longevity and cost-effectiveness.
[00050] In an embodiment, the state of charge (SOC) of the modular battery pack (100) may be determined using the voltage method. In this method, the battery voltage may be converted to an equivalent SOC value using a predefined discharge curve (voltage vs SOC). The voltage measurement may be achieved through voltage divider circuits comprising two power resistors (not shown) positioned on the controller board (not shown). The voltage of the series-connected cells may be measured, and individual cell voltage may be calculated based on differences between series voltages. For example, if the series 1 voltage measures 3.2V and the series 2 voltage measures 6.4V, the voltage of the first cell may be the series 1 voltage (3.2V), and the voltage of the second cell may be the difference between series 2 and series 1 voltages (6.4V - 3.2V = 3.2V). Such an approach may provide detailed SOC data for individual cells, which may support accurate diagnostics and battery monitoring.
[00051] In an embodiment, the state of health (SOH) of the modular battery pack (100) may be calculated using internal resistance (iR) measurement. A load resistor may be connected using a MOSFET (not shown) for a few seconds to obtain loaded voltage readings. The open-circuit voltage (V(open circuit)) may be measured without any load connected, representing the cell voltage in a no-load condition. The loaded voltage (V(load)) may be measured by connecting a power resistor in parallel with the cells. The current may then be calculated as V(load) divided by the resistance of the power resistor. Internal resistance (iR) may be determined as the voltage drop after the load is applied divided by the current. The calculated iR may be used to assess the SOH of individual cells, enabling the evaluation of overall battery health and performance.
[00052] In an embodiment, the modular battery pack (100) may include sensors configured to measure battery temperature and gas concentrations for safety purposes. The battery temperature may be monitored continuously, and an alert message may be sent to a user application if the temperature exceeds 50°C. Additionally, sensors may measure concentrations of gases such as hydrogen and carbon monoxide (CO) to detect potential risks. The data collected from temperature and gas sensors may be used to predict explosion risks, with pre-alert notifications being provided to users. Such safety monitoring may assist in mitigating hazardous situations and reducing the likelihood of accidents.
[00053] In an embodiment, the modular battery pack (100) may predict faulty cells by analyzing battery voltage and internal resistance data. Abnormalities in voltage levels or increased internal resistance values for individual cells may indicate faulty cells. Notifications identifying the unique address of defective cells may be sent to the user via a mobile application or, in the case of electric vehicles, displayed on the vehicle dashboard. This feature may allow the replacement of specific defective cells without requiring the replacement of the entire battery pack.
[00054] In an embodiment, the modular battery pack (100) may include a unique user-accessible casing design. The casing design may provide individual compartments for each cell, with each compartment corresponding to a unique cell address. This design may allow users to replace individual cells without requiring technical expertise or special tools. Unlike traditional battery packs with spot-welded cells, which may be challenging to repair, the modular casing may offer easier maintenance. Such a design may allow the battery pack to remain operational even when a single cell is defective, reducing downtime and replacement costs.
[00055] In an embodiment, the modular battery pack (100) may monitor and collect SOC and SOH data for individual cells, which may assist in diagnostics and fault prediction. Each cell may be assigned a unique identifier (ID) for tracking and monitoring purposes. Notifications regarding defective cells or hazardous conditions such as thermal runaway, gas leaks, or high temperatures may be sent to a mobile app or a vehicle dashboard. If hazardous conditions persist without intervention, the system may initiate a safety shutdown to prevent accidents, potentially improving user safety and system reliability.
[00056] In an embodiment, the modular battery pack (100) may employ a connection mechanism allowing different types of cells to be used within the battery pack. This mechanism may provide flexibility in accommodating various cell types while maintaining compatibility with the system architecture. Such a connection mechanism may enable seamless integration or removal of cells, enhancing the adaptability and scalability of the battery pack for applications such as electric vehicles and stationary energy storage systems.
[00057] In an embodiment, the receptacle (104) and the recess (110) of the modular battery pack (100) comprise an adjustable mechanism that enables expansion or contraction to accommodate battery cells of varying diameters. The adjustable mechanism facilitates adaptability to different battery cell sizes, enhancing the modularity and usability of the battery pack (100). The adjustable mechanism includes a threaded collar, which is disposed around an inner wall of the receptacle (104) and the recess (110). The threaded collar is configured to move along a threaded path when rotated. Such movement of the threaded collar alters the effective diameter of the receptacle (104) and the recess (110). This ensures that battery cells of different diameters are securely positioned within the respective receptacles (104) and recesses (110). Additionally, the adjustable mechanism reduces the need for manufacturing separate receptacles and recesses for various battery cell sizes, thereby improving the scalability and cost-effectiveness of the battery pack (100). The adjustable mechanism further ensures consistent mechanical and electrical contact between the battery cells and the corresponding spring-biased connectors (106) and resilient engagement units (112). This adaptability also enhances the operational safety of the battery pack (100) by preventing improper positioning of battery cells, which could otherwise lead to faults or hazards.
[00058] In an embodiment, the adjustable mechanism of the receptacle (104) and the recess (110) comprises a locking assembly coupled to the threaded collar. The locking assembly ensures that the receptacle (104) and the recess (110) maintain the desired diameter once adjusted. The locking assembly comprises a clamp or detent structure configured to engage with the threaded collar to prevent unintentional movement or rotation of the threaded collar after adjustment. Such a locking feature enhances the reliability of the battery pack (100) by preventing loosening or misalignment of the receptacles (104) and recesses (110), especially during operational vibrations or external shocks. The locking assembly further ensures uniform clamping pressure on the battery cells, providing stable contact between the battery cells and the spring-biased connectors (106) and resilient engagement units (112). The locking assembly can be designed to enable tool-free operation for ease of use, such as through the inclusion of a quick-release lever or a snap-fit mechanism. This feature ensures that users can efficiently secure the receptacle (104) and the recess (110) at the desired diameter without requiring specialised tools or equipment. By maintaining the desired adjustment of the receptacle (104) and the recess (110), the locking assembly improves the longevity and durability of the battery pack (100) under various operational conditions. Additionally, the locking assembly enhances user safety by reducing the likelihood of accidental battery displacement or improper engagement.
[00059] The lower section (102) and upper section (108) improve modularity and assembly precision. The alignment between receptacles (104) and recesses (110) allows for accurate positioning of each battery cell, reducing potential misalignment that could lead to mechanical stress or electrical inefficiency. The combination of spring-biased connectors (106) and resilient engagement units (112) stabilizes electrical connections by applying consistent compressive forces and accommodating variations in battery dimensions, minimizing contact degradation during operation.
[00060] The incorporation of the hollow core spring within the spring-biased connector (106), forming a fluid pathway, introduces an active cooling mechanism that dissipates heat generated by the battery cell. The coupling with a coolant reservoir provides an efficient thermal management solution, preventing overheating and thermal runaway conditions. This configuration improves the lifespan and reliability of battery cells by maintaining optimal operating temperatures during high-power or continuous usage scenarios. The fluid pathway also allows for integration with existing cooling systems, enhancing scalability.
[00061] The receptacle (104) includes an auto-eject unit with a cam-driven plunger positioned beneath the spring-biased connector (106), facilitating automatic fault isolation by ejecting faulty battery cells upon receiving a fault signal from the control circuit (118). This mechanism minimizes downtime and prevents damage propagation by physically disconnecting the affected cell from the system. The upward force generated by the plunger ensures reliable disconnection without causing mechanical stress to adjacent cells.
[00062] The spring-biased connector (106) further comprises a rotatable abrasive disk at the interface with the battery cell, designed to remove debris and oxidation from the contact surface. The abrasive disk rotates during predefined intervals or upon detecting a drop in electrical conductivity, ensuring stable electrical connections. Fabricated from abrasive materials like silicon carbide or aluminium oxide, the disk maintains the integrity of the contact surface, reducing maintenance requirements.
[00063] At least one of the receptacle (104) or the recess (110) includes an encapsulated phase-change material (PCM) layer positioned circumferentially around the battery cell. The PCM absorbs and releases thermal energy during phase transitions, regulating the temperature of the battery cell. This configuration mitigates risks associated with overheating or temperature fluctuations, maintaining consistent performance. The encapsulated PCM layer prevents leakage and degradation, extending operational life.
[00064] At least one of the spring-biased connector (106) or resilient engagement unit (112) is associated with a shear pin that severs physical and electrical connections upon detecting an impact force exceeding a predefined threshold. This safety feature isolates affected cells during mechanical shocks or collisions, protecting the rest of the system. The shear pin operates in conjunction with sensors monitoring impact forces, ensuring timely disconnection.
[00065] Each of the spring-biased connector (106) and resilient engagement unit (112) includes a dual-contact pivoting unit that adjusts to match the polarity of the battery cell. This pivoting mechanism accommodates variations in alignment while maintaining reliable electrical connections. The dual-contact design reduces contact failure risks, ensuring redundancy and stable current transfer.
[00066] The lower section (102) incorporates a thermally conductive layer beneath each receptacle (104), facilitating heat dissipation from the first portion of the battery cell. Constructed from materials such as copper or graphite composites, the layer transfers heat away from the cell, preventing thermal hotspots and maintaining operational safety during extended use.
[00067] The resilient engagement unit (112) includes a multi-point contact structure that uniformly distributes pressure across the second portion of the battery cell. This minimizes mechanical stress, such as deformation or cracking, while ensuring stable electrical connectivity. The multi-point design adapts to variations in cell surface geometry, maintaining performance under dynamic conditions.
[00068] Each resilient engagement unit (112) dynamically adjusts pressure based on the thermal expansion of the battery cell. The adjustment mechanism, using thermally responsive materials or shape-memory alloys, compensates for dimensional changes during operation. This feature prevents over-compression or disconnection, extending battery cell durability.
[00069] The upper section (108) and lower section (102) include alignment guides to align the recesses (110) and receptacles (104) during assembly. The guides, including grooves or interlocking features, reduce assembly errors and ensure accurate positioning of each battery cell, optimizing system reliability.
[00070] FIG. 2 illustrates an operational diagram of a modular battery pack (100) in accordance with the embodiments of the present disclosure. The modular battery pack (100) comprises an upper section (108) and a lower section (102), each designed with specific components to ensure seamless functionality. The upper section (108) includes recesses (110) configured to interact with resilient engagement units (112), which generate an identification code corresponding to the specific battery module. The lower section (102) features receptacles (104) coupled with spring-biased connectors (106) that facilitate secure electrical and mechanical connections. The identification code generated by the resilient engagement unit (112) and the spring-biased connector (106) enables accurate tracking and tagging of the battery module.
[00071] The modular battery pack (100) further includes a first sensing unit (114) configured to measure the state of charge and state of health of the battery cells. These measurements are tagged with the identification code for precise monitoring and diagnostics. A second sensing unit (116) is employed to detect critical conditions such as thermal runaway, gas leakage, and temperature variations within the battery module. The detected data is analyzed by a control circuit (118), which processes the inputs from both sensing units. Based on the analysis, the control circuit (118) initiates pre-alert notifications and identifies faults in the battery cells, enabling proactive maintenance and safety interventions. The diagram illustrates the interconnectivity and logical flow between the components, emphasizing the modular battery pack's operational efficiency and safety management capabilities.
[00072] FIG. 3 illustrates a system architecture for a modular battery pack (100), in accordance with the embodiments of the present disclosure. The system comprises a swappable cell holder housing multiple battery cells (Cell 1 to Cell n) that are monitored and managed to ensure optimal performance and safety. The swappable cell holder interacts with a main processor, which receives key parameters such as voltage, internal resistance (iR), thermal conditions, current, and gas levels from the cells. These parameters are processed by the main processor to evaluate critical metrics, including state of charge (SOC) and state of health (SOH). The main processor is further integrated with an off-the-shelf battery management system (BMS) to provide functionalities such as cell balancing and charge/discharge protection, maintaining the operational stability of the battery pack.
[00073] The main processor also employs predictive algorithms to identify potential cell failures and battery explosion risks. These predictions, along with SOC and SOH data, are communicated via a CAN bus or mobile/web applications for real-time monitoring and diagnostics. The integration with external interfaces enables users to access actionable insights regarding battery performance and safety. The system architecture ensures effective energy management, fault detection, and proactive safety measures, making it suitable for modular and swappable battery applications.
[00074] In an embodiment, the adjustable mechanism incorporated into each receptacle (104) and each recess (110) of the modular battery pack (100) enables expansion or contraction to accommodate battery cells of varying diameters. The inclusion of the threaded collar provides precise control over the dimensions of the receptacles (104) and recesses (110). This mechanism enhances the adaptability of the battery pack (100) by allowing it to securely house battery cells of different sizes without requiring physical modification or additional components. The ability to adjust the receptacle (104) and recess (110) diameter improves the efficiency of assembly and reduces downtime associated with reconfiguring the battery pack (100) for different cell specifications. Furthermore, the consistent and customized engagement achieved through the adjustable mechanism ensures stable mechanical and electrical connections with the spring-biased connectors (106) and resilient engagement units (112), thereby enhancing the overall reliability and operational performance of the battery pack (100).
[00075] In an embodiment, the locking assembly integrated with the threaded collar enhances the operational stability and safety of the battery pack (100). By securing the threaded collar in the desired position, the locking assembly prevents unintended adjustments or loosening during operation, which could compromise the fit or connection of the battery cells. This feature ensures that the receptacles (104) and recesses (110) maintain the adjusted diameter under various environmental conditions, such as vibrations or shocks. The locking assembly also promotes uniform clamping pressure across the battery cells, ensuring consistent contact and reducing the likelihood of electrical faults. By maintaining the alignment and stability of the battery cells within the adjustable receptacles (104) and recesses (110), the locking assembly contributes to the durability and longevity of the battery pack (100). Additionally, the locking assembly simplifies user interactions by enabling secure adjustments without specialized tools, further enhancing the operational efficiency and usability of the system.
[00076] FIG. 4 illustrates a user interface of a monitoring system for the modular battery pack (100), showcasing real-time information regarding operational and environmental parameters, in accordance with the embodiments of the present disclosure. The interface displays voltage readings for individual battery cells, providing detailed monitoring of the voltage levels associated with each receptacle (104) and recess (110). It also includes information on the State of Charge (SOC) and State of Health (SOH) of the battery pack (100), as measured by the first sensing unit (114), allowing users to assess the battery’s performance and longevity. Environmental parameters monitored by the second sensing unit (116), such as the temperature and hazardous gas levels, are displayed to ensure safe operating conditions. Additionally, the interface presents alert messages with corresponding timestamps, generated by the control circuit (118), to inform users of detected conditions such as thermal runaway, gas leakage events, or other anomalies. The interface provides a comprehensive and real-time overview of the battery pack's status, facilitating effective monitoring and management to enhance its safety, reliability, and operational efficiency.
[00077] Example embodiments herein have been described above with reference to block diagrams and flowchart illustrations of methods and apparatuses. It will be understood that each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by various means including hardware, software, firmware, and a combination thereof. For example, in one embodiment, each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations can be implemented by computer program instructions. These computer program instructions may be loaded onto a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions which execute on the computer or other programmable data processing apparatus create means for implementing the functions specified in the flowchart block or blocks.
[00078] Throughout the present disclosure, the term ‘processing means’ or ‘microprocessor’ or ‘processor’ or ‘processors’ includes, but is not limited to, a general purpose processor (such as, for example, a complex instruction set computing (CISC) microprocessor, a reduced instruction set computing (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, a microprocessor implementing other types of instruction sets, or a microprocessor implementing a combination of types of instruction sets) or a specialized processor (such as, for example, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), or a network processor).
[00079] The term “non-transitory storage device” or “storage” or “memory,” as used herein relates to a random access memory, read only memory and variants thereof, in which a computer can store data or software for any duration.
[00080] Operations in accordance with a variety of aspects of the disclosure is described above would not have to be performed in the precise order described. Rather, various steps can be handled in reverse order or simultaneously or not at all.
[00081] While several implementations have been described and illustrated herein, a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein may be utilized, and each of such variations and/or modifications is deemed to be within the scope of the implementations described herein. More generally, all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific implementations described herein. It is, therefore, to be understood that the foregoing implementations are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, implementations may be practiced otherwise than as specifically described and claimed. Implementations of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

Claims
I/We Claim:
1. A modular battery pack (100) comprising:
a lower section (102) comprising multiple receptacles (104), each receptacle (104) configured to house a first portion of a battery cell, wherein the each receptacle (104) comprising a spring-biased connector (106) to exert consistent compressive force against the first portion of the battery cell;
an upper section (108) comprising multiple recesses (110), each recess (110) configured to house a second portion of the battery cell, such upper section (108) being aligned with the lower section (102) such that the recesses (110) of the upper section (108) are positioned in correspondence with the receptacles (104) of the lower section (102), wherein each recess (110) comprising a resilient engagement unit (112) configured to maintain stable contact with the second portion of the battery cell, wherein the resilient engagement unit (112) and the spring-biased connector (106) is associated with an identification code;
a first sensing unit (114) coupled with each spring-biased connector (106) and resilient engagement unit (112) to measure, individually of each battery cell, a state of charge (SOC) and state of health (SOH) of each battery cell, wherein the measured SOC and SOH is tagged with the identification code;
a second sensing unit (116) is configured to detect at least on condition of the battery pack, wherein the condition is selected from a thermal runaway, a gas leakage event, and a temperature; and
a control circuit (118) coupled to the first sensing unit (114) and second sensing unit (116) analyze the detected condition to initiate a pre-alert notification and identify a fault of any of the battery cell.
2. The modular battery pack (100) of claim 1, wherein the spring-biased connector (106) comprising a hollow core spring forming a fluid pathway to allow a cooling medium to flow therethrough to dissipate heat from the battery cell, wherein the hollow core spring is being fluidically coupled to an coolant reservoir.
3. The modular battery pack (100) of claim 1, wherein the receptacle (104) comprises an auto-eject unit comprising a cam-driven plunger positioned beneath the spring-biased connector (106), said cam-driven plunger being configured to exert an upward force upon receiving a fault signal from the control circuit (118), such upward force displacing the battery cell from contact of the spring-biased connector (106).
4. The modular battery pack (100) of claim 1, wherein the spring-biased connector (106) comprising a rotatable abrasive disk positioned at the interface between the spring and the battery cell, said abrasive disk is configured to remove debris and oxidation from the contact surface.
5. The modular battery pack (100) of claim 1, wherein at least one of receptacle (104) and recess (110) comprising an encapsulated phase-change material (PCM) layer positioned circumferentially around the battery cell
6. The modular battery pack (100) of claim 1, wherein the at least one of spring-biased connector (106) and resilient engagement unit (112) is associated with a shear pin to sever a physical connection and an electrical connection upon detecting an impact force exceeding a predefined threshold.
7. The modular battery pack (100) of claim 1, wherein the each of spring-biased connector (106) and resilient engagement unit (112) comprises a dual-contact pivoting unit, wherein the said dual-contact pivoting unit being rotatably mounted to match the polarity of the battery cell
8. The modular battery pack (100) as claimed in claim 1, wherein said lower section (102) further comprises a thermally conductive layer disposed beneath each receptacle (104), said thermally conductive layer being configured to dissipate heat generated by the first portion of the battery cell during operation, thereby maintaining an optimal temperature range for each battery cell housed in said modular battery pack (100).
9. The modular battery pack (100) as claimed in claim 1, wherein said resilient engagement unit (112) comprises a multi-point contact structure configured to ensure uniform pressure distribution across the second portion of the battery cell, such configuration minimizing the risk of mechanical stress and ensuring stable electrical connectivity during operation.
10. The modular battery pack (100) as recited in claim 1, wherein each receptacle (104) and each recess (110) comprise an adjustable mechanism configured to expand or contract to accommodate battery cells of varying diameters, wherein the adjustable mechanism comprises:
a threaded collar disposed around an inner wall of the receptacle (104) and the recess (110), wherein rotation of the threaded collar adjusts the diameter of the receptacle (104) and the recess (110); and
a locking assembly coupled to the threaded collar to secure the receptacle (104) and the recess (110) at a desired diameter.

MODULAR BATTERY PACK
Abstract
The present disclosure provides a modular battery pack comprising a lower section comprising multiple receptacles, each receptacle housing a first portion of a battery cell. Each receptacle comprises a spring-biased connector to exert consistent compressive force against the first portion of the battery cell. An upper section comprises multiple recesses, each recess housing a second portion of the battery cell, with the upper section aligned with the lower section such that the recesses correspond to the receptacles. Each recess comprises a resilient engagement unit maintaining stable contact with the second portion of the battery cell. A first sensing unit measures, individually for each battery cell, a state of charge and state of health, tagged with an identification code. A second sensing unit detects conditions of the battery pack, including thermal runaway, gas leakage, or temperature. A control circuit analyses detected conditions to initiate pre-alert notifications and identify faults in the battery cells, enabling user repairability by individual cell replacement.
Fig. 1

, Claims:Claims
I/We Claim:
1. A modular battery pack (100) comprising:
a lower section (102) comprising multiple receptacles (104), each receptacle (104) configured to house a first portion of a battery cell, wherein the each receptacle (104) comprising a spring-biased connector (106) to exert consistent compressive force against the first portion of the battery cell;
an upper section (108) comprising multiple recesses (110), each recess (110) configured to house a second portion of the battery cell, such upper section (108) being aligned with the lower section (102) such that the recesses (110) of the upper section (108) are positioned in correspondence with the receptacles (104) of the lower section (102), wherein each recess (110) comprising a resilient engagement unit (112) configured to maintain stable contact with the second portion of the battery cell, wherein the resilient engagement unit (112) and the spring-biased connector (106) is associated with an identification code;
a first sensing unit (114) coupled with each spring-biased connector (106) and resilient engagement unit (112) to measure, individually of each battery cell, a state of charge (SOC) and state of health (SOH) of each battery cell, wherein the measured SOC and SOH is tagged with the identification code;
a second sensing unit (116) is configured to detect at least on condition of the battery pack, wherein the condition is selected from a thermal runaway, a gas leakage event, and a temperature; and
a control circuit (118) coupled to the first sensing unit (114) and second sensing unit (116) analyze the detected condition to initiate a pre-alert notification and identify a fault of any of the battery cell.
2. The modular battery pack (100) of claim 1, wherein the spring-biased connector (106) comprising a hollow core spring forming a fluid pathway to allow a cooling medium to flow therethrough to dissipate heat from the battery cell, wherein the hollow core spring is being fluidically coupled to an coolant reservoir.
3. The modular battery pack (100) of claim 1, wherein the receptacle (104) comprises an auto-eject unit comprising a cam-driven plunger positioned beneath the spring-biased connector (106), said cam-driven plunger being configured to exert an upward force upon receiving a fault signal from the control circuit (118), such upward force displacing the battery cell from contact of the spring-biased connector (106).
4. The modular battery pack (100) of claim 1, wherein the spring-biased connector (106) comprising a rotatable abrasive disk positioned at the interface between the spring and the battery cell, said abrasive disk is configured to remove debris and oxidation from the contact surface.
5. The modular battery pack (100) of claim 1, wherein at least one of receptacle (104) and recess (110) comprising an encapsulated phase-change material (PCM) layer positioned circumferentially around the battery cell
6. The modular battery pack (100) of claim 1, wherein the at least one of spring-biased connector (106) and resilient engagement unit (112) is associated with a shear pin to sever a physical connection and an electrical connection upon detecting an impact force exceeding a predefined threshold.
7. The modular battery pack (100) of claim 1, wherein the each of spring-biased connector (106) and resilient engagement unit (112) comprises a dual-contact pivoting unit, wherein the said dual-contact pivoting unit being rotatably mounted to match the polarity of the battery cell
8. The modular battery pack (100) as claimed in claim 1, wherein said lower section (102) further comprises a thermally conductive layer disposed beneath each receptacle (104), said thermally conductive layer being configured to dissipate heat generated by the first portion of the battery cell during operation, thereby maintaining an optimal temperature range for each battery cell housed in said modular battery pack (100).
9. The modular battery pack (100) as claimed in claim 1, wherein said resilient engagement unit (112) comprises a multi-point contact structure configured to ensure uniform pressure distribution across the second portion of the battery cell, such configuration minimizing the risk of mechanical stress and ensuring stable electrical connectivity during operation.
10. The modular battery pack (100) as recited in claim 1, wherein each receptacle (104) and each recess (110) comprise an adjustable mechanism configured to expand or contract to accommodate battery cells of varying diameters, wherein the adjustable mechanism comprises:
a threaded collar disposed around an inner wall of the receptacle (104) and the recess (110), wherein rotation of the threaded collar adjusts the diameter of the receptacle (104) and the recess (110); and
a locking assembly coupled to the threaded collar to secure the receptacle (104) and the recess (110) at a desired diameter.