DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of Invention:
A BATTERY PACK ASSEMBLY

APPLICANT:
EXPONENT ENERGY PRIVATE LIM

An Indian entity having address as:
No.76/2, Site No.16,
Khatha, No 69, Singasandra Village,
Begur Hobli, Bengaluru Urban,
Karnataka (IN) - 560068

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

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[0001] The present application claims priority from an Indian patent application no. 202341018074, filed on March 17, 2023. The entire contents of the aforementioned application are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to the field of battery. More specifically, the present invention relates to a battery pack assembly.
BACKGROUND
[0003] This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
[0004] In the field of architecture for battery pack assembly, preferably for electric vehicles (EVs). The existing battery pack assembly architectures in the EVs face significant challenges primarily in three key areas: mechanical vibrations, electrical isolation, and thermal efficiency. These existing architectures aim to provide structural integrity, electrical safety, and optimal temperature regulation for cells of the battery pack assembly. However, they fail to address these critical/crucial aspects effectively.
[0005] Firstly, the mechanical vibrations originating from the road can pose a risk to the integrity of the battery pack assembly. Conventional battery pack assembly architectures, such as those employing sheet metal and foam pads for structural support, may not sufficiently dampen vibrations, leading to potential damage and reduced lifespan of the cells of the battery pack assembly.
[0006] Secondly, ensuring adequate electrical isolation between cells is crucial for preventing short circuits and ensuring overall safety. However, the existing battery pack assembly architecture may not offer robust isolation measures. Thus, increasing the risk of electrical faults and safety hazards. The direct placement of cells onto the battery casing in cell-to-pack architecture, for instance, may not provide sufficient insulation, especially in environments with high electrical demands and fluctuations.
[0007] Thirdly, thermal efficiency is most important in maintaining the optimal operating temperature range for cells of the battery pack assembly. However, the conventional architectures, which often relies on separate cooling systems detached from the module packaging, may result in inefficiencies and uneven temperature distribution within the battery pack assembly. This lack of integrated thermal management can lead to localized hotspots, accelerated degradation of cells, and minimized overall performance and longevity of the battery pack assembly. Conventional battery pack assemblies rely on separate cooling systems (mostly an external cooling system), which further worsens this issue by adding complexity and potential points of failure.
[0008] Currently, the battery pack assemblies for EVs employ two primary assembly architectures: cell-to-pack and module-to-pack. In cell-to-pack architecture, cells are directly placed onto a casing of the battery pack assembly, and connected both electrically and mechanically to form the battery pack assembly. Similarly, in module-to-pack architecture, cells are grouped into modules, which are then assembled to create the battery pack assembly. However, these architectures lack the above crucial functions, including maintaining electrical isolation between cells, providing structural support to withstand automotive vibrations, and managing thermal regulation to ensure optimal operating temperatures for the cells.
[0009] In addition, currently available battery pack assembly architectures in the market, such as the VDA module, utilize sheet metal welded with foam pads between cells to secure them structurally within the pack. However, these designs also face limitations in thermal management. For instance, the VDA module can only be cooled using a bottom cooling method, which necessitates a separate cooling system distinct from the module packaging. Companies often employ large bottom cooling heat sinks, either utilizing extruded cooling channels welded together or employing brazed heat sink methods.
[0010] Furthermore, traditional electric vehicle (EV) battery packs exhibit bulkiness, leading to significant challenges in managing thermal conditions and minimizing voltage drops during charging and discharging cycles. These issues stem largely from the arrangement of cells within the battery pack. Additionally, they struggle to withstand the structural loads induced by vehicle vibrations.
[0011] Thus, overcoming at least one of above-mentioned limitations is essential for advancing battery technology towards safer, more efficient, and longer-lasting electric vehicles. Therefore, there exists a need for an improved battery pack assembly.
SUMMARY
[0012] This summary is provided to introduce concepts related to the field of batteries. More specifically, the present invention relates to a battery pack assembly. This summary is not intended to identify the essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[0013] In an example aspect, a battery pack assembly is disclosed. The battery pack assembly includes a plurality of modules, a plurality of conditioning plates and one or more adhesive layers. Additionally, each module from the plurality of modules includes a plurality of cells. In addition, the plurality of conditioning plates includes a top conditioning plate and a bottom conditioning plate. Further, the plurality of modules is adhered using the one or more adhesive layers to form a battery pack. Furthermore, the top conditioning plate is adhered to the top side of the battery pack using one or more adhesive layers. Also, the bottom conditioning plate is adhered to the bottom side of the battery pack using one or more adhesive layers.
[0014] In an example embodiment, the plurality of cells is adhered with each other using one or more adhesive layers.
[0015] In another example embodiment, each cell from the plurality of cells includes one or more terminals. In addition, each terminal from the one or more terminals is associated with a terminal axis. Also, the terminal axis traverses through each terminal of the one or more terminals.
[0016] In yet another example embodiment, the plurality of cells is arranged according to a coordinate system in a three-dimensional space. The coordinate system includes X-orientation, Y-orientation and Z-orientation. Further, the X-orientation corresponds to a horizontal axis, the Z-orientation corresponds to a vertical axis, and the Y-orientation corresponds to an axis perpendicular to the X-orientation and the Z-orientation. Furthermore, each cell from the plurality of cells is placed in a way such that the terminal axis of each cell is parallel to one of, the X-orientation, the Y-orientation, and a combination thereof.
[0017] In yet another example embodiment, the plurality of conditioning plates is adhered to the plurality of cells in a direction perpendicular to the Z-orientation of the plurality of cells, using the one or more adhesive layer.
[0018] In yet another example embodiment, the assembly includes a side cover designed to encapsulate the battery pack. In addition, the side cover is adhered to the battery pack using one or more adhesive layers. The side cover is positioned between the top conditioning plate and the bottom conditioning plate.
[0019] In yet another example embodiment, the assembly includes a plurality of spacers configured for maintaining equal spacing between the plurality of cells and each conditioning plate from the one or more conditioning plates. Further, the plurality of spacers is applied between the top conditioning plate and the battery pack. Furthermore, the plurality of spacers is applied between the bottom conditioning plate and the battery pack.
[0020] In yet another example embodiment, the battery pack assembly includes a plurality of supporting plates. In addition, each module from the plurality of modules includes the plurality of cells adhered with each other on a supporting plate from the plurality of supporting plates using the one or more adhesive layers. Additionally, the plurality of modules is adhered to each other through the plurality of supporting plates, using the one or more adhesive layer.
[0021] In yet another example embodiment, each terminal from the one or more terminals of the plurality of cells are connected using a plurality of bus bars. Additionally, the plurality of bus bars, for a module from the plurality of modules, are positioned opposite to the supporting plate of the module.
[0022] In yet another example embodiment, the adhesive of one or more adhesive layers is at least one of a fast curing, thermally conductive, structural member, or an electrically insulative adhesive, and combination thereof. In a related embodiment, the adhesive of one or more adhesive layers may correspond to Polyurethane acrylate adhesive.
[0023] In yet another example embodiment, each conditioning plate from the plurality of conditioning plates includes an inlet port, an outlet port, and a plurality of conditioning channels to facilitate flow of conditioning fluid. In addition, the inlet port is configured to insert the conditioning fluid into the conditioning plate and the outlet port is configured to exit the conditioning fluid from the conditioning plate. Additionally, the plurality of conditioning channels forms a serpentine passage inside the conditioning plate.
[0024] In yet another example embodiment, the inlet port and the outlet port, of each conditioning plate from the plurality of conditioning plates, are connected to a conditioning station via a connector during charging or conditioning, for flowing the conditioning fluid to the battery pack assembly. Additionally, the conditioning fluid is a cold fluid, or a hot fluid based on thermal requirements of the battery pack assembly.
[0025] In another example aspect, a method for assembling a battery pack assembly is disclosed. The method includes the step of arranging one or more terminals of each cell from a plurality of cells in the same orientation with respect to each other. The method further includes the step of adhering the plurality of cells using one or more adhesive layers to form a module. The method further includes the step of adhering a plurality of modules using the one or more adhesive layers to form a battery pack. The method further includes the step of adhering a top conditioning plate on top side of the battery pack using the one or more adhesive layers. The method further includes the step of adhering a bottom conditioning plate on the bottom side of the battery pack using one or more adhesive layers.
[0026] In an example embodiment, the step of arranging the one or more terminals of each cell from the plurality of cells in the same orientation with respect to each other includes the step of arranging the plurality of cells according to a coordinate system in a three-dimensional space. Additionally, each terminal from the one or more terminals is associated with a terminal axis. The terminal axis traverses through each terminal from the one or more terminals of each cell from the plurality of cells. The coordinate system includes X-orientation, Y-orientation and Z-orientation. In addition, the X-orientation corresponds to a horizontal axis, the Z-orientation corresponds to a vertical axis, and the Y-orientation corresponds to an axis perpendicular to the X-orientation and the Z-orientation. Further, each cell from the plurality of cells is placed in a way such that the terminal axis of each cell from the plurality of cells is parallel to one of, the X-orientation, the Y-orientation, and a combination thereof.
[0027] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the following detailed description.
BRIEF DESCRIPTION OF DRAWINGS
[0028] Having thus described the invention in general terms, references will now be made to the accompanying figures, wherein:
[0029] Figure 1 illustrates an assembly diagram of a battery pack assembly (100), in accordance with various embodiments of the present subject matter; and
[0030] Figure 2 illustrates a method (200) for assembling a battery pack assembly, in accordance with various embodiments of the present subject matter.
[0031] It should be noted that the accompanying figures are intended to present illustrations of exemplary embodiments of the present disclosure. These figures are not intended to limit the scope of the present disclosure. It should also be noted that accompanying figures are not necessarily drawn to scale.
DETAILED DESCRIPTION
[0032] Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0033] The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. For example, the term “an article” may include a plurality of articles unless the context clearly dictates otherwise. Although any methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary methods are described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0034] Various modifications to the embodiment may be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art may readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein. The detailed description of the invention will be described hereinafter referring to accompanied drawings.
[0035] In the various embodiments disclosed herein, a ‘battery pack assembly’ may be interchangeably read and/or interpreted as ‘energy storage assembly’ or ‘battery module assembly’ or ‘battery cell assembly’, and the like. Further, an ‘adhesive’ may be interchangeably read and/or interpreted as ‘glue’ or ‘sealant’ or ‘adhesive layer,’ and the like. Additionally, a ‘cell’ may be interchangeably read and/or interpreted as ‘battery cell’ or ‘energy storage cell’ or ‘energy storage device’, and the like. Also, a ‘conditioning station’ may also be interchangeably read and/or interpreted as a ‘charging station’ or ‘charging point’ or ‘electric vehicle supply equipment (EVSE),’ and the like.
[0036] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention.
[0037] Those with ordinary skill in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated, relative to other elements, in order to improve the understanding of the present invention. There may be additional components described in the foregoing application that are not depicted on one of the described drawings. In the event such a component is described, but not depicted in a drawing, the absence of such a drawing should not be considered as an omission of such design from the specification.
[0038] In the accompanying drawings components have been represented, showing only specific details that are pertinent for an understanding of the present invention so as not to obscure the disclosure with details that will be readily apparent to those with ordinary skill in the art having the benefit of the description herein.
[0039] In accordance with an embodiment of the present subject matter, referring to Figure 1, a battery pack assembly (100) is described herein.
[0040] In a non-limiting embodiment, a battery pack assembly (100) is disclosed. The battery pack assembly (100) includes a plurality of modules (112), a plurality of conditioning plates (104, 106) and one or more adhesive layers (108). Additionally, each module from the plurality of modules (112) includes a plurality of cells (102). In addition, the plurality of conditioning plates (104, 106) includes a top conditioning plate (104) and a bottom conditioning plate (106). Further, the plurality of modules (112) is adhered using the one or more adhesive layers (108) to form a battery pack. Furthermore, the top conditioning plate (104) is adhered to the top side of the battery pack using one or more adhesive layers (108). Also, the bottom conditioning plate (106) is adhered to the bottom side of the battery pack using one or more adhesive layers (108).
[0041] In one example embodiment, the plurality of cells (102) is adhered with each other using one or more adhesive layers (108). In another example embodiment, each cell from the plurality of cells (102) includes one or more terminals. In addition, each terminal from the one or more terminals is associated with a terminal axis. Also, the terminal axis traverses through each terminal of the one or more terminals.
[0042] In yet another example embodiment, the plurality of cells is arranged according to a coordinate system in a three-dimensional space. The coordinate system includes X-orientation, Y-orientation and Z-orientation. Further, the X-orientation corresponds to a horizontal axis, the Z-orientation corresponds to a vertical axis, and the Y-orientation corresponds to an axis perpendicular to the X-orientation and the Z-orientation. Furthermore, each cell from the plurality of cells (102) is placed in a way such that the terminal axis of each cell is parallel to one of, the X-orientation, the Y-orientation, and a combination thereof.
[0043] In one example embodiment, the plurality of conditioning plates (104, 106) is adhered to the plurality of cells (102) in a direction perpendicular to Z-orientation of the plurality of cells (102), using the one or more adhesive layers (108). In another example embodiment, the battery pack assembly (100) includes a side cover designed to encapsulate the battery pack. In addition, the side cover is adhered to the battery pack using the one or more adhesive layers (108). The side cover is positioned between the top conditioning plate (104) and the bottom conditioning plate (106).
[0044] In yet another example embodiment, the battery pack assembly (100) includes a plurality of spacers configured for maintaining equal spacing between the plurality of cells (102) and each conditioning plate from the one or more conditioning plates (104, 106). Further, the plurality of spacers is applied between the top conditioning plate (104) and the battery pack. Furthermore, the plurality of spacers is applied between the bottom conditioning plate (106) and the battery pack.
[0045] In one example embodiment, the battery pack assembly includes a plurality of supporting plates. In addition, each module from the plurality of modules (112) includes the plurality of cells (102) adhered with each other on a supporting plate from the plurality of supporting plates using the one or more adhesive layers (108). Additionally, the plurality of modules (112) is adhered to each other through the plurality of supporting plates, using the one or more adhesive layers (108).
[0046] In another example embodiment, each terminal from the one or more terminals of the plurality of cells (102) are connected using a plurality of bus bars (110). Additionally, the plurality of bus bars (110), for a module from the plurality of modules (112), are positioned opposite to the supporting plate from the plurality of supporting plates. In yet another example embodiment, the adhesive of one or more adhesive layers (108) is at least one of a fast curing, thermally conductive, structural member, or an electrically insulative adhesive, and combination thereof. In a related embodiment, the adhesive of one or more adhesive layers (108) may correspond to Polyurethane acrylate adhesive.
[0047] In one example embodiment, each conditioning plate from the plurality of conditioning plates (104, 106) includes an inlet port, an outlet port, and a plurality of conditioning channels to facilitate flow of conditioning fluid. In addition, the inlet port is configured to insert the conditioning fluid into the conditioning plate and the outlet port is configured to exit the conditioning fluid from the conditioning plate. Additionally, the plurality of conditioning channels forms a serpentine passage inside the conditioning plate.
[0048] In another example embodiment, the inlet port and the outlet port, of each conditioning plate from the plurality of conditioning plates (104, 106), are connected to a conditioning station via a connector during charging or conditioning, for flowing the conditioning fluid to the battery pack assembly (100). Additionally, the conditioning fluid is a cold fluid, or a hot fluid based on thermal requirements of the battery pack assembly (100).
[0049] In accordance with an embodiment of the present subject matter, referring to Figure 2, a method (200) for assembling a battery pack assembly is described herein.
[0050] In another non-limiting embodiment, the method (200) for assembling a battery pack assembly is disclosed. The method (200) includes the step of arranging (202) one or more terminals of each cell from a plurality of cells (102) in the same orientation with respect to each other. The method (200) further includes the step of adhering (204) the plurality of cells (102) using one or more adhesive layers (108) to form a module. The method (200) further includes the step of adhering (206) a plurality of modules (112) using the one or more adhesive layers (108) to form a battery pack. The method (200) further includes the step of adhering (208) a top conditioning plate (104) on top side of the battery pack using the one or more adhesive layers (108). The method (200) further includes the step of adhering (210) a bottom conditioning plate (106) on a bottom side of the battery pack using the one or more adhesive layers (108).
[0051] In one example embodiment, the step of arranging (202) the one or more terminals of each cell from the plurality of cells (102) in same orientation with respect to each other includes the step of arranging the plurality of cells (102) according to a coordinate system in a three-dimensional space. Additionally, each terminal from the one or more terminals is associated with a terminal axis. The terminal axis traverses through each terminal from the one or more terminals of each cell from the plurality of cells (102).
[0052] In an example, the coordinate system includes X-orientation, Y-orientation and Z-orientation. In addition, the X-orientation corresponds to a horizontal axis, the Z-orientation corresponds to a vertical axis, and the Y-orientation corresponds to an axis perpendicular to the X-orientation and the Z-orientation. Further, each cell from the plurality of cells (102) is placed in a way such that the terminal axis of each cell from the plurality of cells (102) is parallel to one of, the X-orientation, the Y-orientation, and a combination thereof.
[0053] In another example embodiment, the method (200) also includes the steps of placing a spacer from the plurality of spacers between the plurality of cells.
[0054] In one example embodiment, the method (200) also includes the steps of placing and adhering the plurality of supporting plates between the modules from the plurality of modules (112). In another example embodiment, the method (200) also includes the steps of placing a spacer from the plurality of spacers between the plurality of modules (112). In yet another example embodiment, the method (200) also includes the steps of adhering the battery pack into a side cover using the on or more adhesive layers (108).
[0055] In one example embodiment, the method (200) also includes the steps of placing a spacer from the plurality of spacers between the battery pack and the top conditioning plate (104). In another example embodiment, the method (200) also includes the steps of placing a spacer from the plurality of spacers between the battery pack and the bottom conditioning plate (106). In yet another example embodiment, the method (200) also includes the steps of adhering a battery management system (BMS) on the top side of the top conditioning plate (104) or on the bottom side of the bottom conditioning plate (106).
[0056] The present disclosure lowers the voltage drop in the battery pack during charging and discharging by reducing the bulkiness of the battery pack assembly. In the present disclosure, the width of the battery pack is reduced, and the length of the battery pack is increased. The battery pack assembly (100) incorporates longer battery modules to reduce the width of the battery. The battery pack assembly (100) lowers the voltage drop in the battery pack assembly (100), during charging and discharging conditions. In addition, the architecture of the battery pack assembly (100), as disclosed above, makes the battery pack structurally strong. The battery pack assembly (100) can sustain loads exerted on it from any direction. The present disclosure provides structural integrity, electrical safety, and optimal temperature regulation for the plurality of cells (102) of the battery pack assembly (100).
[0057] The battery pack assembly (100) of the present disclosure exhibits the following advantages:
• Increased structural integrity/rigidity and stiffness.
• Lower Voltage drop during charging and discharging conditions.
• Structural isolation of battery assembly components.
• Reduced susceptibility to short-circuit with terminals facing away from each other.
• Enhanced serviceability of battery modules.
• Unibody architecture for the battery assembly.
• Consistent spacing between battery cells maintained by spacers.
• Uniform thickness of adhesive throughout the assembly.
• Battery assembly acts as a cage for equal load distribution across cells.
• Prolonged shelf-life of battery cells and assembly.
[0058] The foregoing description shall be interpreted as illustrative and not in any limiting sense. a person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure.
[0059] The embodiments, examples, and alternatives of the preceding paragraphs or the description, including any of their various aspects or respective individual feature(s), may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.
,CLAIMS:WE CLAIM:
1. A battery pack assembly (100), comprising:
a plurality of modules (112), wherein each module from the plurality of modules (112) comprises a plurality of cells (102);
a plurality of conditioning plates (104, 106), wherein the plurality of conditioning plates (104, 106) comprises a top conditioning plate (104) and a bottom conditioning plate (106); and
one or more adhesive layers (108),
wherein the plurality of modules (112) is adhered using the one or more adhesive layers (108) to form a battery pack,
wherein the top conditioning plate (104) is adhered to a top side of the battery pack using one or more adhesive layers (108), wherein the bottom conditioning plate (106) is adhered to a bottom side of the battery pack using one or more adhesive layers (108).
2. The battery pack assembly (100) as claimed in claim 1, wherein the plurality of cells (102) is adhered with each other using one or more adhesive layers (108).
3. The battery pack assembly (100) as claimed in claim 1, wherein each cell from the plurality of cells (102) comprises one or more terminals, wherein each terminal from the one or more terminals is associated with a terminal axis, wherein the terminal axis traverses through each terminal of the one or more terminals.
4. The battery pack assembly (100) as claimed in claim 3, wherein the plurality of cells is arranged according to a coordinate system in a three-dimensional space,
wherein the coordinate system comprises X-orientation, Y-orientation and Z-orientation, wherein the X-orientation corresponds to a horizontal axis, the Z-orientation corresponds to a vertical axis, and the Y-orientation corresponds to an axis perpendicular to the X-orientation and the Z-orientation,
wherein each cell from the plurality of cells (102) is placed in a way such that the terminal axis of each cell is parallel to one of, the X-orientation, the Y-orientation, and a combination thereof.
5. The battery pack assembly (100) as claimed in claim 1, wherein the plurality of conditioning plates (104, 106) is adhered to the plurality of cells (102) in a direction perpendicular to Z-orientation of the plurality of cells (102), using the one or more adhesive layers (108).
6. The battery pack assembly (100) as claimed in claim 1, wherein the assembly (100) comprises a side cover designed to encapsulate the battery pack, wherein the side cover is adhered to the battery pack using the one or more adhesive layers (108), wherein the side cover is positioned between the top conditioning plate (104) and the bottom conditioning plate (106).
7. The battery pack assembly (100) as claimed in claim 1, wherein the assembly (100) comprises a plurality of spacers configured for maintaining equal spacing between the plurality of cells (102) and each conditioning plate from the one or more conditioning plates (104, 106), wherein the plurality of spacers are applied between the top conditioning plate (104) and the battery pack, wherein the plurality of spacers are applied between the bottom conditioning plate (106) and the battery pack.
8. The battery pack assembly (100) as claimed in claim 1, wherein the battery pack assembly comprises a plurality of supporting plates, wherein each module from the plurality of modules (112) comprises the plurality of cells (102) adhered with each other on a supporting plate from the plurality of supporting plates using the one or more adhesive layers (108), wherein the plurality of modules (112) are adhered to each other through joining the plurality of supporting plates, using the one or more adhesive layers (108).
9. The battery pack assembly (100) as claimed in claim 8, wherein each terminal from the one or more terminals of the plurality of cells (102) are connected using a plurality of bus bars (110), wherein the plurality of bus bars (110), for a module from the plurality of modules (112), are positioned opposite to the supporting plate of the module.
10. The battery pack assembly (100) as claimed in claim 1, wherein the adhesive of one or more adhesive layers (108) is at least one of a fast curing, thermally conductive, structural member, or an electrically insulative adhesive, and combination thereof, wherein the adhesive of one or more adhesive layers (108) corresponds to Polyurethane acrylate adhesive.
11. The battery pack assembly (100) as claimed in claim 1, wherein each conditioning plate from the plurality of conditioning plates (104, 106) comprises an inlet port, an outlet port, and a plurality of conditioning channels to facilitate flow of conditioning fluid, wherein the inlet port is configured to insert the conditioning fluid into the conditioning plate and the outlet port is configured to exit the conditioning fluid from the conditioning plate, wherein the plurality of conditioning channels form a serpentine passage inside the conditioning plate.
12. The battery pack assembly (100) as claimed in claim 1 and 11, wherein the inlet port and the outlet port, of each conditioning plate from the plurality of conditioning plates (104, 106), are connected to a conditioning station via a connector during charging or conditioning, for flowing the conditioning fluid to the battery pack assembly (100), wherein the conditioning fluid is a cold fluid or a hot fluid based on thermal requirements of the battery pack assembly (100).
13. A method (200) for assembling a battery pack assembly, wherein the method (200) comprises the steps of:
arranging (202) one or more terminals of each cell from a plurality of cells (102) in same orientation with respect to each other;
adhering (204) the plurality of cells (102) using one or more adhesive layers (108) to form a module;
adhering (206) a plurality of modules (112) using the one or more adhesive layers (108) to form a battery pack;
adhering (208) a top conditioning plate (104) on top side of the battery pack using one or more adhesive layers (108); and
adhering (210) a bottom conditioning plate (106) on bottom side of the battery pack using one or more adhesive layers (108).
14. The method (200) as claimed in claim 13, wherein the step of arranging (202) the one or more terminals of each cell from the plurality of cells (102) in same orientation with respect to each other comprises the step of arranging the plurality of cells (102) according to a coordinate system in a three-dimensional space,
wherein each terminal from the one or more terminals is associated with a terminal axis, wherein the terminal axis traverses through each terminal from the one or more terminals of each cell from the plurality of cells (102),
wherein the coordinate system comprises X-orientation, Y-orientation and Z-orientation, wherein the X-orientation corresponds to a horizontal axis, the Z-orientation corresponds to a vertical axis, and the Y-orientation corresponds to an axis perpendicular to the X-orientation and the Z-orientation,
wherein each cell from the plurality of cells (102) is placed in a way such that the terminal axis of each cell from the plurality of cells (102) is parallel to one of, the X-orientation, the Y-orientation, and a combination thereof.
Dated this 17th Day of March 2023