DESC:FORM 2
The Patent Act 1970
(39 of 1970)
and
The Patent Rules, 2005

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF THE INVENTION

“ADVANCED CONDUCTIVE ASSEMBLY SHEET FOR A BATTERY PACK”

Endurance Technologies Limited
E-92, M.I.D.C. Industrial Area, Waluj,
Chh. Sambhajinagar – 431136 (formerly Aurangabad),
Maharashtra, India

The following specification describes the nature of the invention and ascertains the manner in which it is to be performed.

Field of Invention

[001] The present invention relates to battery pack of vehicles and energy storage systems. More particularly it relates to an advanced conductive assembly sheet comprising a printed circuit board (PCB) and a plurality of busbars intelligently configured thereon to improve electrical conduction, thermal management, and structural integration of battery packs, especially for vehicular applications.

Background of the Invention

[002] The rapid development and deployment of clean energy solutions, particularly in the fields of electric vehicles and residential energy storage systems, has necessitated significant improvements in battery technology. A battery pack typically consists of multiple battery cells connected in series or parallel, with conductive busbars forming the primary interface for electrical conduction between the cells and the power circuitry.

[003] The busbars are metallic strips that distribute electrical current and also provide pathways for fusing individual cells to enhance safety. These busbars are commonly mounted on printed circuit boards (PCBs) which house temperature sensors, a requirement in many regulatory standards such as those from the Automotive Research Association of India (ARAI).

[004] Effective temperature monitoring of each cell is crucial for generating an accurate thermal map of the battery pack, enabling precise thermal management strategies. Moreover, the heat dissipation characteristics of the PCB and busbar assembly directly affect the overall efficiency, safety, and lifecycle of the battery pack.
[005] Hence, in order to overcome the prevalent problems in the prior art and/or conventional solutions, there is prolonged unmet need to provide a solution which ensures not only the electrical management but an effective thermal management as well in a battery pack. Therefore, there exists a need to provide an optimized conductive assembly sheet design that integrates structural strength, thermal performance, accurate sensing, and manufacturing cost-efficiency.

Objectives of the Present Invention

[006] The main objective of the present invention is to provide an advanced conductive assembly sheet for a battery pack of a vehicle, which offers an integrated solution for electrical conduction, temperature sensing, and thermal management.

[007] Another objective of the present invention is to provide a conductive assembly sheet configured to have a plurality of uniquely profiled busbars intelligently mounted over a PCB in a manner that ensures uniform current distribution and effective thermal dissipation across the battery pack.

[008] Another objective of the present invention is to provide a conductive assembly sheet wherein the busbars are configured with fusible neck portions to act as individual cell-level fuses, thereby enhancing safety and preventing propagation of thermal runaway events.

[009] Yet, the objective of the present invention is to provide a conductive assembly sheet having busbar configuration with gas venting slots on the lobes of the busbar to allow safe release of pressure from the battery cells during over-temperature or failure conditions.

[0010] Still the objective of the present invention is to provide a conductive assembly sheet wherein a temperature sensor is embedded within a cavity on the stem of the busbar, enabling precise and localized thermal monitoring of individual cells.

[0011] Further, the objective of the present invention is to provide a busbar and PCB assembly that eliminates the need for wiring harnesses, thereby improving structural rigidity, simplifying the assembly making it compact, and reducing manufacturing cost.

Brief Description of Drawings

[0012] This invention is illustrated in the accompanying drawings, throughout which like reference letters and numerals indicate corresponding parts in the various figures. The embodiments herein and advantages thereof will be better understood from the following description when read with reference to the following drawings, wherein

[0013] Figure 1 discloses the front view of the conductive sheet assembly in accordance with the first embodiment of the present invention.

[0014] Figure 2 shows the bottom view of the conductive sheet assembly in accordance with the first embodiment of the present invention.

[0015] Figures 3a to 4b presents the different busbars of the conductive sheet assembly as per the first embodiment of the present invention.
[0016] Figure 5 illustrates the front view of the conductive sheet assembly as per the second embodiment of the present invention.

[0017] Figures 6a to 6b presents the different busbars of the conductive sheet assembly as per the second embodiment of the present invention.

[0018] Figure 7 discloses the isometric view of the battery module with assembly of battery cells and the conductive sheet assemblies of the first and second embodiments of the present invention.

Detailed Description of the Present Invention

[0019] The invention will now be described in detail with reference to the accompanying drawings which must not be viewed as restricting the scope and ambit of the invention. Referring to Figs. 1 to 2, the present invention discloses an advanced conductive assembly sheet (500, 1000) for a battery module (2000) of a battery pack used in electric vehicles and energy storage systems. The assembly sheet (500) comprises a printed circuit board (PCB) (50) and a plurality of busbars (100, 150, 200) and said busbars (100, 150, 200) are conductively and structurally integrated to form a thermally optimized, modular electrical interface for a battery pack.

[0020] The PCB (50) is a polygonal sheet, preferably a rectangular sheet for battery pack of a vehicle, having a front face (50F) and a rear face (50R) wherein the front face (50F) is configured to have a L-shaped cut (L) at its top left end and a rectangular tab (50T) projecting out at its top right end. The PCB is configured to have a plurality of circular holes (55) adapted to receive battery cells (57) and a plurality of non-plated through (NPT) holes (60) positioned over the rear face (50R) of the PCB (50). These NPT holes (60) are strategically optimized to align with the stem portions of the busbars and facilitates bonding of the busbars (100, 150, 200) with the PCB (50) with the help of a thermally conductive adhesive, preferably selected from Boron Nitride paste. The PCB (50) is fabricated from thermally conductive material selected from ceramic, CE (composite epoxy), or epoxy materials and like for its excellent dielectric strength and thermal conductivity.

[0021] The PCB (50) is configured to have a plurality of built-in conductive traces (not shown) connecting the output terminals of the battery cells to the output terminal (35) of the conductive assembly sheet (500, 1000). The conductive traces are routed from each of the battery cells to the output terminal of the busbars in a manner such that the each of the conductive traces imparts same effective resistance (impedance). This is optimized by varying the resistive length of a conductive loop wherein the resistive length of the conductive traces is directly proportionated to the resistance offered by it. These conductive traces provide accurate and synchronized voltage measurement by to a Battery Management System (BMS) and enhanced calibration accuracy of the battery pack, leading to more precise state-of-charge (SOC) and state-of-health (SOH) readings.

[0022] Each of the busbars (100) is configured with a central stem (110) extending longitudinally along its body. The said busbar (100) has a pair of circular lobes (120) extending laterally from the stem (110) in opposite direction to each other and the said pair is symmetrically distributed across the length of the stem (110). The circular lobes (120) are formed in a set of multiple of four so as to have a busbar (100) with a minimum of four lobes (120) and a maximum of eight lobes (120) and are configured to facilitate the electrical connection of battery terminals with the busbars. Each lobe (120) is designed to correspond to one cell terminal in a standard cell array.

[0023] Each of the busbars (100) is configured to have a plurality of uniquely profiled slits (130) positioned between the stem (110) and each of the circular lobes (120). The profiled slits (130) are formed in the shape of a half-moon thus forming a fusible neck (130N) having portions (130A) and (130B) at the interface of the circular lobes (120) and the stem portion (110) of the busbar (100). These neck portions (130A, 130B) acts as a fuse element allowing disconnection of the corresponding cell under overcurrent conditions. This unique profile of the neck portion (130A, 130B) creates a low resistance path in the busbar because of its curved profile which leads to lower down the energy (heat) losses by achieving the desired application.

[0024] Further, each of the busbars (100) is configured to have a plurality of crescent-shaped venting slots (140) formed at the extreme edge of each of the circular lobes (120). These venting slots (140) facilitates the venting of gases released by the battery cells during thermal incidents or failure, thereby enhancing safety of the battery pack. These unique venting slots (140) helps avoid obstructing the gas flow path, thus ensuring unimpeded venting. A set of two rectangular profiled connecting tabs (45) is positioned in between two consecutive pairs of lobes (120) extending laterally outward from the stem (110) of the busbar (100) and a through cavity (65) is positioned at the geometric center of the stem (110) of the busbar (100). The connecting tabs (45) are used as soldering points to affix the busbar (100) mechanically and electrically onto the PCB (50) and the through cavity (65) is configured to house a temperature sensor (not shown), preferably selected from a surface-mount NTC thermistor and equivalent sensing element.
[0025] The busbar (200) is similar to the busbar (100) except for the fact that the busbar (200) is configured to have asymmetric distribution of the pair of circular lobes (220) around its central stem (210). The said busbar (200) has three pair of symmetric circular lobes (220) extending laterally from the stem (210) in opposite direction from each other and distributed uniformly across the length of the stem (210) and two single circular lobes (220) extending laterally in either of the directions (i.e. left or right side) from the stem (210) of the busbar (200) in light with the packaging requirement of the battery pack. The profiled slits (230) are formed in the shape of a half-moon thus forming a fusible neck (230N) having portions (230A) and (230B) at the interface of the circular lobes (220) and the stem portion (210) of the busbar (200). These neck portions (230A, 230B) acts as a fuse element allowing disconnection of the corresponding cell under overcurrent conditions. This unique profile of the neck portion (230A, 230B) creates a low resistance path in the busbar because of its curved profile which leads to lower down the energy (heat) losses by achieving the desired application.

[0026] Similarly, the busbar (300) is configured to have two pairs of symmetric circular lobes (320) extending laterally from the stem (310) in opposite direction from each other and distributed uniformly across the length of the stem (310) and four single circular lobes (320) extending laterally in either of the directions (i.e. left or right side) from the stem (310) of the busbar (300) depending on the packaging requirement of the battery pack. The profiled slits (330) are formed in the shape of a half-moon thus forming a fusible neck (330N) having portions (330A) and (330B) at the interface of the circular lobes (320) and the stem portion (310) of the busbar (300). These neck portions (330A, 330B) acts as a fuse element allowing disconnection of the corresponding cell under overcurrent conditions.
[0027] Each of the busbars (100, 200, 300) is configured to have a plurality of crescent-shaped venting slots (140, 240, 340) formed at the extreme edge of each of the circular lobes (120, 220, 320). These venting slots (140, 240, 340) facilitate the venting of gases released by the battery cells during thermal incidents or failure, thereby enhancing safety of the battery pack. These unique venting slots (140, 240, 340) helps to avoid obstructing the gas flow path, thus ensuring unimpeded venting.

[0028] The positioning of the circular lobes (120, 220, 320) around the central stem (110, 210, 310) of the busbar (100, 200, 300) is variable in nature and is selected in a manner to have a minimum eight number of circular lobes (120, 220, 320) so as to form a uniform array of connected battery cells (57) to match the shape of the PCB (50). The selection of lobe distribution is further based on cell spacing and current carrying requirements of the specific battery module.

[0029] Each of the busbar (100, 200, 300) is configured to house a temperature sensor (not shown) mounted in the through cavity (65) of the busbar (100, 200, 300) in a manner such that it is configured to rest in thermal contact with the PCB (50), and is fixed there by using soldering technique. The integration of the temperature sensor directly within the busbar (100, 200, 300) enables accurate, localized temperature monitoring of individual battery cells (57).

[0030] The busbars (100, 200, 300) are arranged over the PCB (50) in an arrayed configuration to interface with a large number of battery cells (57) simultaneously. This unique arrangement of busbars (100, 200, 300) results in a high-performance, scalable conductive assembly sheet (500) that provides efficient electrical distribution, individual cell-level fusing, localized temperature sensing, and improved thermal dissipation across the battery pack. This modular construction also allows flexibility in adapting the assembly sheet (500) for varied pack sizes and a variety of cell chemistry.

[0031] During assembly of the conductive assembly sheet (500), the busbars (100, 200, 300) are mounted over the PCB (50) in a manner such that each pair of circular lobes (120, 220, 320) aligns with the circular holes (55) of the PCB (50). The busbars (100, 200, 300) are fixed in place by applying Boron Nitride paste through the NPT holes (60), ensuring thermal bonding of the stem (110, 210, 310) to the PCB (50). Additionally, the connecting tabs (45) are soldered to the front face (50F) of the PCB (50), reinforcing both the mechanical attachment and the electrical connection to form the conductive assembly sheet (500).

[0032] The conductive assembly sheet (1000) comprises a printed circuit board (PCB) (50) and a plurality of busbars (100, 600, 700), which are conductively and structurally integrated to form a thermally optimized, modular electrical interface for a battery pack. The said busbar (600) is configured to have an L-shaped stem (610A) and a connecting bracket stem (610B) projecting orthogonally from the edge of the L-shaped stem (610A). The connecting bracket stem (610B) of the busbar (600) is configured to have a plurality of mounting holes (600H), preferably at least two holes for facilitating the mounting of the busbar to fixture structures of a cell holder / power connecting elements (not shown). The said busbar (600) has a plurality of circular lobes (620), preferably four circular lobes (620) extending in a lateral direction from the stem (610A) and said circular lobes (620) are symmetrically distributed across the length of the L-shaped stem (610A). The profiled slits (630) are formed in the shape of a half-moon thus forming a fusible neck (630N) having portions (630A) and (630B) at the interface of the circular lobes (620) and the stem portion (610) of the busbar (600). These neck portions (630A, 630B) acts as a fuse element allowing disconnection of the corresponding cell under overcurrent conditions.

[0033] Similarly, the busbar (700) is configured to have a first L-shaped stem (710A), a connecting bracket stem (710B) projecting orthogonally from the edge of the stem (710A) and a rectangular bracket (710C) positioned at an offset from the L-shaped stem (710A). The connecting bracket stem (710B) is configured to have a mounting hole (700H) for facilitating the mounting of the busbar to fixture structures of a cell holder / power connecting elements (not shown). The said busbar (700) has a pair of circular lobes (720) extending laterally from the stem (710A) opposite to each other in a manner such that one of the said circular lobes (720) is positioned in between the stem (710A) and the rectangular bracket (710C). Further, a plurality of circular lobes (720), preferably two circular lobes (720) are positioned longitudinally in between the stem (710A) of the busbar (700) and the rectangular bracket (710C) of the said busbar (700). The profiled slits (730) are formed in the shape of a half-moon thus forming a fusible neck (730N) having portions (730A) and (730B) at the interface of the circular lobes (720) and the stem portion (710) of the busbar (700). This unique and optimized construction of the busbar (700) not only enhances the space utilization but the electrical symmetry as well in compact battery layouts.

[0034] Further, the busbars (600 and 700) has fuse portions (630, 730), connecting tabs (45) and temperature sensors (not shown) positioned in the through cavity (65) which bears the same characteristics and arrangement as that of the busbars (100, 200, 300). These novel features of the busbars (600, 700) ensure continuity of performance, protection over current, and monitoring functions across both types of conductive assembly sheets thereby consequently enhancing the performance of the battery pack. Each of the busbars (600, 700) is configured to have a plurality of crescent-shaped venting slots (640, 740) formed at the extreme edge of each of the circular lobes (620, 720). These venting slots (640, 740) facilitate the venting of gases released by the battery cells during thermal incidents or failure, thereby enhancing safety of the battery pack. These unique venting slots (640, 740) effectively facilitate to avoid obstructing the gas flow path, thus ensuring unimpeded venting.

[0035] During assembly of the conductive assembly sheet (1000), the busbars (100, 600 and 700) are mounted over the PCB (50) in a manner such that each pair of circular lobes (120, 620, 720) aligns with the circular holes (55) of the PCB (50). The busbars (100, 600, 700) are fixed in place by applying Boron Nitride paste through the NPT holes (60), ensuring thermal bonding of the stem (110, 610, 710) to the PCB (50). Additionally, the connecting tabs (45) are soldered to the front face (50F) of the PCB (50), reinforcing both the mechanical attachment and the electrical connection to form the conductive assembly sheet (1000). This ensures consistency in electrical performance, thermal conduction, and structural stability of the battery pack.

[0036] The conductive assembly sheets (500 and 1000) are configured to facilitate the electrical and thermal connection in between the terminals of the battery cells and the power circuitry of the battery pack. The battery cells are positioned in between the conductive assembly sheet (500) and the conductive assembly sheet (1000) in a manner such that either of the terminals of the battery cells are conductively connected to the circular lobes (120, 220, 320, 620, 720) of the busbars (100, 200, 300, 600, 700) to form the battery module (2000).

[0037] The present invention therefore addresses key challenges in thermal and electrical management of battery packs while offering a compact and manufacturable solution that meets safety and performance standards set by regulatory bodies such as ARAI (Automotive Research Association of India).

[0038] The advanced conductive assembly sheet in accordance with the present invention and its unique / novel features as described above provides the following technical advantages that contributes to the advancement of technology establishing the inventive step:
- It facilitates the direct integration of temperature sensors with ease into the busbar structure which improves temperature detection and thermal mapping accuracy.
- It helps in an establishing an effective overcurrent protection mechanism by the virtue of the individual cell level fuse formed at the fusible portion of the busbar.
- It imparts dual fixation using soldering and thermal paste which increases the mechanical integrity and simplifies assembly.
- It helps in better heat dissipation, reducing the chances of thermal runaway and enhancing the overall safety and longevity of the battery pack.
- It provides a precise voltage sensing and enhanced thermal management making it highly effective for improving battery pack performance, safety, and reliability.
- It helps in an effective venting of the gases from the battery pack by the virtue of uniquely profiled circular lobes and thus, reduces the risk of pressure buildup during thermal incidents.

[0039] The foregoing description of the specific embodiment of the invention will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiment/s without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiment. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiment herein has been described in terms of preferred embodiment, those skilled in the art will recognize that the embodiment herein can be practiced with modification within the spirit and scope of the embodiment as described herein. ,CLAIMS:We Claim

1. An advanced conductive assembly sheet (500, 1000) for a battery pack, comprising a printed circuit board (PCB) (50) and a plurality of busbars (100, 150, 200, 300, 600, 700); wherein
- the PCB (50) is a polygonal sheet having a front face (50F) and a rear face (50R) and said sheet (50) is configured to have a L shaped cut (L) at its top left end and a rectangular tab (50T) projecting at its top right end;
- said PCB (50) has a plurality of conductive traces connecting battery cell output terminals to an output terminal (35), and each of said traces being configured to maintain equal effective resistance and optimized resistive length to provide accurate voltage readings to a Battery Management System (BMS);
- each of said busbars (100, 200, 300, 600, 700) is configured to have a stem portion (110, 210, 310, 610, 710), a plurality of circular lobes (120, 220, 320, 620, 720), connecting tabs (45), at least one temperature sensor through cavity (65), fusible neck portions (130, 230, 330, 630, 730) and venting slots (140, 240, 340, 640, 740); and
- said busbars (100, 200, 300, 600, 700) are structurally and conductively integrated with said PCB (50) by means of thermally conductive adhesive and soldered at the connecting tabs (45).

2. The advanced conductive assembly sheet (500, 1000) for a battery pack as claimed in claim 1, wherein
- said PCB (50) is configured to have a plurality of circular holes (55) to receive battery cells (57), and a plurality of non-plated through holes (60) positioned on the rear face (50R) for bonding the busbars (100, 200, 300, 600, 700);
- the polygonal profile of said PCB (50) is selected from a rectangular profile for a battery pack; and
- the thermally conductive adhesive is selected from Boron Nitride paste.

3. The advanced conductive assembly sheet (500) as claimed in claim 2, wherein
- each of the said busbars (100, 200, 300) is configured to have a central linear stem portion (110, 210, 310), circular lobes (120, 220, 320), a plurality of half-moon profiled slits (130, 230, 330) and at least a through cavity (65);
- a pair of circular lobes (120, 220, 320) are extending laterally from said stem portion (110, 210, 310) in opposite direction with each other and are uniformly spaced and positioned to match the circular holes (55) of the PCB (50);
- said half moon profiled slits (130, 230, 330) are optimizedly carved between said lobes (120, 220, 320) and said stem portion (110, 210, 310) thereby forming fusible neck portions (130A & 130B, 230A & 230B and 330A & 330B) which is configured to disconnect a faulty cell under overcurrent conditions;
- the rectangular connecting tabs (45) extending from each of the stem portions (110, 210, 310) are configured to facilitate the soldering of the busbar (100, 200, 300) with the front face (50F) of the PCB (50); and
- said thorough cavity (65) is positioned at the geometric center of the stem portion (110, 210, 310) and is configured to house a temperature sensor therein.

4. The advanced conductive assembly sheet (500) as claimed in claim 3, wherein the busbar (200, 300) has at least two pairs of symmetric circular lobes (220, 320) extending laterally from the stem (210, 310) in opposite direction from each other and two single circular lobes (220, 320) extending laterally in either of the directions (left side or right side) from the stem (210, 310) of the busbar (200, 300) in light with the packaging requirement of the battery pack; and said lobes (220, 320) are distributed uniformly across the length of the stem (210, 310).

5. The advanced conductive assembly sheet (1000) for a battery pack as claimed in claim 2, wherein
- the busbar (600) is configured to have a L shaped stem (610A), a connecting bracket (610B), a plurality of lobes (620) and a venting slot (640);
- said connecting bracket (610B) is configured to project orthogonally from the edge of the L-shaped stem (610A) and has a pair of mounting holes (600H);
- a plurality of circular lobes (620) extend in a lateral direction from the stem (610A) and said circular lobes (620) are symmetrically distributed across the length of the L-shaped stem (610A);
- the half-moon profiled slits (630) are configured to form a fusible neck (630N) having portions (630A) and (630B) at the interface of the circular lobes (620) and the stem portion (610) of the busbar (600);
- the thorough cavity (65) is positioned at the geometric center of the stem portion (610) and is configured to house a temperature sensor therein; and
- said busbar (600) is structurally and conductively integrated with said PCB (50) by means of thermally conductive adhesive and soldered at the connecting tabs (45).

6. The advanced conductive assembly sheet (1000) for a battery pack as claimed in claim 2, wherein
- the busbar (700) is configured to have a first L-shaped stem (710A), a connecting bracket stem (710B), plurality of circular lobes (720) and a rectangular bracket (710C);
- said connecting bracket stem (710B) is configured to project out orthogonally from the edge of the stem (710A) and a rectangular bracket (710C) is positioned at an offset from the L-shaped stem (710A);
- the connecting bracket stem (710B) is configured to have a mounting hole (700H) for facilitating the mounting of the busbar to fixture structures of a cell holder / power connecting elements;
- said busbar (700) has a pair of circular lobes (720) extending laterally from the stem (710A) opposite to each other in a manner such that one of the said circular lobes (720) is positioned in between the stem (710A) and the rectangular bracket (710C);
- at least two circular lobes (720) are positioned longitudinally in between the stem (710A) of the busbar (700) and the rectangular bracket (710C) of the said busbar (700);
- the profiled slits (730) are formed in the shape of a half-moon thus forming a fusible neck (730N) having portions (730A) and (730B) at the interface of the circular lobes (720) and the stem portion (710) of the busbar (700);
- the thorough cavity (65) is positioned at the geometric center of the stem portion (710) and is configured to house a temperature sensor therein; and
- said busbar (700) is structurally and conductively integrated with said PCB (50) by means of thermally conductive adhesive and soldered at the connecting tabs (45).

7. The advanced conductive assembly sheet (500, 1000) as claimed in any of the claims 3 and 6, wherein
- said lobes (120, 220, 320, 620, 720) are configured to align with the circular holes (55) of the PCB (50) for direct connection with positive or negative terminals of battery cells (57); and
- the plurality of non plated through holes (60) in the PCB (50) are configured to enable the application of thermally conductive adhesive for affixing the rear surfaces of said busbars (100, 200, 300, 600, 700) to the PCB (50).
8. The advanced conductive assembly sheet (500, 1000) as claimed in claim 7, wherein each of the busbars (100, 200, 300, 600, 700) is configured to have a crescent shaped venting slots (140, 240, 340, 640, 740) formed at the extreme edge of the circular lobes (120, 220, 320, 620, 720) to facilitate gas venting in the event of cell venting or thermal runaway.

9. The advanced conductive assembly sheet (500, 1000) as claimed in claim 8, wherein the positioning of the circular lobes (120) around the central stem (110) of the busbar (100) is variable in nature and is selected in a manner to have a minimum eight number of circular lobes (120) so as to form a uniform array of connected battery cells (57) to match the shape of the PCB (50).

10. The advanced conductive assembly sheet (500, 1000) as claimed in claim 9, wherein
- the PCB (50) is made from thermally conductive material selected from ceramic, CE (composite epoxy) and epoxy material;
- the integrated conductive traces on said PCB (50) are configured to provide uniform resistance across all paths from cell terminals to the output terminal (35) thereby ensuring synchronized and accurate voltage readings for the BMS; and
- the temperature sensor housed in through cavity (65) of each of the busbars (100, 200, 300, 600, 700) is soldered to the PCB and is configured to monitor temperature of the battery cells for thermal protection.

11. The advanced conductive assembly sheet (500, 1000) as claimed in claim 10, wherein any of the conductive assembly sheet (500 or 1000) is configured to mount as a top or bottom interface in a battery module (2000) such that busbar lobes (120, 220, 320, 620, 720) connect directly to battery terminals and said sheets (500, 1000) are configured for thermal management, voltage sensing, and overcurrent protection.

12. The advanced conductive assembly sheet (1000) as claimed in claim 11, wherein said busbars (600, 700) are adapted to connect with the cell-holder structures and power interconnects via their bracket stems (610B, 710B) and corresponding mounting holes (600H, 700H).

Dated this 23rd day of July 2025

Sahastrarashmi Pund
Head - IPR
Endurance Technologies Ltd.

To
The Controller of Patents,
The Patent Office, at Mumbai