DESC:“A METHOD FOR DISPENSING ONE OR MORE LAYERS INTO A BATTERY PACK”

FIELD OF THE INVENTION
The present disclosure relates to battery packs, and more particularly to a battery pack and a method for dispensingone or more layers intothe battery pack. The present application is based on, and claims priority from an Indian Provisional Application Number 202341025038 filed on 01-04-2023, the disclosure of which is hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION
In general, a battery pack includes a plurality of cells. The cell is a device that stores electrical energy to provide power to a load. The plurality of cells may be connected in a series, a parallel, or a combination of both (series, and parallel) to deliver the desired voltage, capacity, or power density.
In a conventional method, the battery pack includes at least one cell holder, the plurality of cells, an interconnector, a heat sink, etc. A thermalconductive layer is dispensed to a predetermined height of a bottom battery casing of thebattery pack. The cell holder and the plurality of cells are placed into the bottom battery casing of the battery pack so that the thermalconductive layer faces an axial surface of the plurality of cells to dissipate heat from the plurality of the cells. The entire battery pack is immersed in different types of layers. Therefore, the cost and weight of the conventional method is increased.
Nowadays automobile manufacturers make the battery packs in different orientations such as vertical orientation or horizontal orientation. The dispensing process of the thermalconductive layer into the battery pack is a tricky task due to the vertical orientation of the battery pack. The vertical orientation of the battery pack will not allow the thermalconductive layer to spread equally and settle at the bottom battery casing of the battery pack. In some specific cases, even the battery pack with the horizontal orientation also does not support the equal distribution of the thermalconductive layer. So, the conventional method is not capable to dispensethe thermalconductive layer into the battery pack to spread equally and settle at the bottom battery casing of the battery pack.
Hence, there remains a need for an improved approach to provide a better battery pack and therefore address the aforementioned issues.

SUMMARY OF THE INVENTION
Accordingly, the embodiments herein disclose a method for dispensingone or more layers into a battery pack. The one or more layers may include, but not limited to,a first layer and a second layer. The method includes the following steps: (a)positioning the battery pack at a first predetermined angleto allow the first layer to flow equally into the battery pack, (i) the first predetermined angle varies based on viscosity of the first layer, temperature of the first layer, dispensing flow rate of the first layer and curing time of the first layer;(b) dispensing, using a first set of openings, the first layer into the battery pack, (i) the first set of openings located on a Battery Management System (BMS) mounting member of the battery pack; (c) holding the battery pack at the first predetermined angle for a first predetermined time to allow the first layer to spread into the battery pack, (i) the first predetermined time varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer and the curing time of the first layer; (d) positioning the battery pack at a second predetermined angle to allow the first layer to flow equally into the battery pack, (i) the second predetermined angle varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer and the curing time of the first layer; (e) holding the battery pack at the second predetermined angle for a second predetermined time to allow the first layer to settle into the battery pack, (i) the second predetermined time varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer and the curing time of the first layer;(f) positioning the battery pack in a horizontal position for a first holding time, (i) the first holding time may vary depends on viscosity of the first layer, temperature of the first layer, curing time of the first layer, casing material compatibility, and the curing property of the material of the first layer being used and accelerated by placing in an oven for curing; (g) positioning the battery pack at a third predetermined angle to allow the second layer to flow equally into the battery pack, (i) the third predetermined angle varies based on viscosity of the second layer, temperature of the second layer, dispensing flow rate of the second layer and curing time of the second layer;(h) dispensing the second layer into the battery pack by using a second set of openings, (i) the second set of openings located on the BMS mounting member of the battery pack; (i) holding the battery pack at the third predetermined angle for a third predetermined time to allow the second layer to spread into the battery pack, (i) the third predetermined time varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer and the curing time of the second layer; (j) positioning the battery pack at a fourth predetermined angle to allow the second layer to flow equally into the battery pack, (i) the fourth predetermined angle varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer;(k) holding the battery pack at the fourth predetermined angle for a fourth predetermined time to allow the second layer to settle into the battery pack, (i) the fourth predetermined angle varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer and the curing time of the second layer; and (l) positioning the battery pack in the horizontal position for a second holding time, and (i) the second holding time varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, curing time of the second layer, quantity of the second layer, casing material compatibility, and curing property of the material of the second layer being used and accelerated by placing in an oven for curing.
In some embodiments, the first predetermined angle is less than or equal to 90°.
In some embodiments, the second predetermined angle is 270° to 360°.
In some embodiments, the third predetermined angle is less than or equal to 90°.
In some embodiments, the fourth predetermined angle is 270° to 360°.
In some embodiments, the first layer includes a thermalconductive material.The thermalconductive material includes resin, polymeric/non-polymeric material, polyurethane, epoxy, dielectric, organic/inorganic Phase Changing Material (PCM), and silicon encapsulant.
In some embodiments, the second layer includes a thermal propagation mitigation material. The thermal propagation mitigation material includes silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, poly is ocyanurate, mica-based materials with filter composites and powder type, and organic/inorganic Phase Changing Material (PCM).
In some embodiments, the first set of openings varies in number and location based on the viscosity of the first layer, the quantity of the first layer, the height of the first layer, the expansion properties of the material, and one or more dimensions of the battery pack.
In some embodiments, the second set of openings varies in number and location based on the viscosity of the second layer, the quantity of the second layer, the height of the second layer, the expansion properties of the material, and the one or more dimensions of the battery pack.
In another aspect, the battery pack includes a bottom battery casing that includes a plurality of mounting means, an extrusion, a plurality of cell holder sleeves, a first cell holder, a plurality of cells, a second cell holder, an interconnector, a top battery casing, a Battery Management System. The plurality of mounting means configured to couple the bottom battery casing to the extrusion.
The extrusion includes a plurality of fins to transfer heat generated by the battery pack. The extrusion includes a thermal conductive material configured to increase the rate of heat transfer from the battery pack. The plurality of cell holder sleeves configured to support and hold a first cell holder, and a second cell holder along with the plurality of cells. The first cell holder is positioned on top of the bottom battery casing. The first cell holder includes a plurality of cavities and is configured to hold the plurality of cells in a predetermined position. The first cell holder is configured to provide a predetermined space between the bottom battery casing and the bottom surface of the plurality of cells.
The plurality of cells is positioned on top of the first cell holder. The second cell holder is positioned on top of the plurality of cells. The second cell holder includes a plurality of cavities and is configured to hold the plurality of cells in a predetermined position.
The interconnector is positioned on top of the second cell holder. The interconnector is configured to connect different polarities of the plurality of cells using a plurality of connectors. The plurality of connectors is placed between the terminals of the plurality of cells and the interconnector. The top battery casing is configured to close the battery pack from the top. The Battery Management System (BMS) mounting member is configured to mount a BMS using a plurality of mounting points. The BMS mounting member is positioned on top of the extrusion. The BMS mounting member includes a first set of openings and a second set of openings. The first set of openings is configured to dispense a first layer into the battery back. The second set of openings is configured to dispense a second layer into the battery back. The BMS mounting memberacts as a heatsink for the BMS to absorb heat from the BMS and transfer the heat to the extrusion.
In some embodiments, the plurality of cell holder sleeves is configured to support and hold the first cell holder, and the second cell holder, along with the plurality of cells.
In some embodiments, the first set of openings,and the second set of openingsare positioned at a predetermined location of the BMS mounting member based on the height of the first layer, and the second layer.
In some embodiments, the BMS mounting member is coupled to the extrusion, using a plurality of fasteners.
These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the invention thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWING
This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
FIG. 1 illustrates an exploded perspective view of a secondary battery pack according to an embodiment as disclosed herein;
FIG. 2 illustrates an exploded perspective view of a primary battery pack, according to an embodiment as disclosed herein;
FIG. 3 illustrates an exploded view of a Battery Management System (BMS) mounting member, according to an embodiment as disclosed herein; and
FIG. 4A and 4B illustrate flow diagram of a method for dispensingone or more layers into the battery pack, according to the embodiment as disclosed herein.

DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
The ensuing description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.
The word “exemplary” and/or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and/or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive—in a manner similar to the term “comprising” as an open transition word—without precluding any additional or other elements.
Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this 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.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
Accordingly, the embodiments herein disclose a method for dispensing one or more layers into a battery pack. The one or more layers may include, but not limited to, a first layer, and a second layer. The method includes the following steps: (a) positioning the battery pack at a first predetermined angle to allow the first layer to flow equally into the battery pack, (i) the first predetermined angle varies based on viscosity of the first layer, temperature of the first layer, dispensing flow rate of the first layer and curing time of the first layer; (b) dispensing, using a first set of openings, the first layer into the battery pack, (i) the first set of openings located on a Battery Management System (BMS) mounting member of the battery pack; (c) holding the battery pack at the first predetermined angle for a first predetermined time to allow the first layer to spread into the battery pack, (i) the first predetermined time varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer and the curing time of the first layer; (d) positioning the battery pack at a second predetermined angle to allow the first layer to flow equally into the battery pack, (i) the second predetermined angle varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer and the curing time of the first layer; (e) holding the battery pack at the second predetermined angle for a second predetermined time to allow the first layer to settle into the battery pack, (i) the second predetermined time varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer and the curing time of the first layer; (f) positioning the battery pack in a horizontal position for a first holding time, (i) the first holding time may vary depends on viscosity of the first layer, temperature of the first layer, curing time of the first layer, casing material compatibility, and the curing property of the material of the first layer being used and accelerated by placing in an oven for curing; (g) positioning the battery pack at a third predetermined angle to allow the second layer to flow equally into the battery pack, (i) the third predetermined angle varies based on viscosity of the second layer, temperature of the second layer, dispensing flow rate of the second layer and curing time of the second layer; (h) dispensing the second layer into the battery pack by using a second set of openings, (i) the second set of openings located on the BMS mounting member of the battery pack; (i) holding the battery pack at the third predetermined angle for a third predetermined time to allow the second layer to spread into the battery pack, (i) the third predetermined time varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer and the curing time of the second layer; (j) positioning the battery pack at a fourth predetermined angle to allow the second layer to flow equally into the battery pack, (i) the fourth predetermined angle varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer; (k) holding the battery pack at the fourth predetermined angle for a fourth predetermined time to allow the second layer to settle into the battery pack, (i) the fourth predetermined angle varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer and the curing time of the second layer; and (l) positioning the battery pack in the horizontal position for a second holding time, (i) the second holding time varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, curing time of the second layer, quantity of the second layer, casing material compatibility, and curing property of the material of the second layer being used and accelerated by placing in an oven for curing.
Referring now to the drawings and more particularly to FIGS. 1 to 4, where similar reference characters denote corresponding features consistently throughout the figure, these are shown as preferred embodiments.
FIG. 1 illustrates an exploded perspective view of a secondary battery pack 100 according to an embodiment herein. An architecture/stack up of the secondary battery pack 100 may be applicable for a primary battery back (as shown in figure 2). The secondary battery pack 100 and the primary battery pack include one or more layers. In one embodiment, the one or more layersmay include, but not limited to, a first layer and a second layer. In another embodiment, the one or more layers may include a third layer. In yet another embodiment, material of the one or more layers may include any type of properties, thermal conduction, fire mitigation, and increase the cell life through heat isolation in a circumferential direction.The secondary battery pack 100 includes a bottom battery casing 102, an extrusion 104, a plurality of cell holder sleeves 106, a first cell holder 108, a plurality of cells 110, a battery management system (BMS) 112, a second cell holder 114, an interconnector 116, a top battery casing 118, a heatsink 120, and a plurality of connectors (not shown in the figure). In one embodiment, the secondary battery pack 100 may/may not include the second cell holder 114.
In one embodiment, the secondary battery pack 100 further includes one or more vents for air circulation andoptimizing pressure of the secondary battery pack 100 to maintain thermal issues or performance degradation. In an embodiment, the one or more vents may be positioned on the extrusion 104.In another embodiment, the one or more vents may be positioned on the top battery casing 118. In yet another embodiment, the one or more vents may be positioned on the bottom battery casing102. The bottom battery casing 102 includes a plurality of mounting means. In one embodiment, the plurality of mounting means includes, but not limited to, a plurality of fasteners to couple the bottom battery casing 102 to the extrusion 104. In one embodiment, the plurality of fasteners may include, but not limited to, screws, nails, bolts, nuts, washers, anchors, rivets, grommets,snap fits,and studs.The plurality of mounting means configured to couple the bottom battery casing 102 with the extrusion 104. The extrusion 104 is made up of a thermalconductive material to increase the rate of heat transfer from the secondary battery pack 100 to the environment.
In one embodiment, the extrusion 104 includes a plurality of fins to transfer heat generated by the secondary battery pack 100. The extrusion 104 includes a thermalconductive material. In one embodiment, the thermalconductive material may include, but not limited to, aluminum, resin, polymeric/non-polymeric material, polyurethane, epoxy, dielectric, organic/inorganicPhase Changing Material (PCM), and silicon encapsulant. In another embodiment, the thermalconductive material may be a metal or non-metal-like composite.The extrusion 104 is made up of the thermalconductive material to increase the rate of heat transfer from the secondary battery pack 100 to the environment. The extrusion 104 acts as an outer wall of the secondary battery pack 100. In an embodiment, the one or more vents may be positioned on the extrusion 104. In another embodiment, the one or more vents may be positioned on the top battery casing 118. In yet another embodiment, the one or more vents may be positioned on the bottom battery casing 102.
In one embodiment, the plurality of cell holder sleeves 106 configured to support and hold the first cell holder 108, and the second cell holder 114 along with the plurality of cells 110. In one embodiment, the plurality of cell holder sleeves 106 configured to support and hold the first cell holder 108, the second cell holder 114, and the interconnector 116 along with the plurality of cells 110.
In yet another embodiment, the plurality of cell holder sleeves 106 configured to support and hold the first cell holder 108, the second cell holder 114, and the interconnector 116 along with the plurality of cells 110 using the plurality of fasteners. In one embodiment, the plurality of cell holder sleeves 106 may include, but not limited to, metal or non-metal. The plurality of cell holder sleeves 106 may include an insulation layer around to avoid short-circuiting.The interconnector 116 is positioned on a top portion of the second cell holder 114. The first cell holder 108 is positioned on a top portion of the bottom battery casing 102. The first cell holder 108 includes a plurality of cavities and is configured to hold the plurality of cells 110 in a predetermined position.
The first cell holder 108 may be an electrically insulative and structurally rigid material. In another embodiment, the plastic composite may be a non-metallic plastic composite or polymer-based single-part or two-part material. In yet another embodiment, the electrically insulative material may have the characteristics to withstand high temperatures, without losing natural properties. In yet another embodiment, the electrically insulative material may be a plastic composite.The plurality of cells 110 is positioned on a top portion of the first cell holder 108. In one embodiment the plurality of cells 110 is positioned on the plurality of cavities of the first cell holder 108. In another embodiment, the plurality of cells 110 may include, but not limited to, nickel cadmium, alkaline, nickel metal hydride (NIMH), lithium-ion, nickel hydrogen, nickel-zinc, lithium iron phosphate (LiFePO) or LFP (lithium ferrophosphate), sodium ion, electro-chemical cells, and the like.The first cell holder 108 is configured to provide a predetermined space between the bottom battery casing 102 and the bottom surface of the plurality of cells 110. The plurality of cells 110 is positioned on a top portion of the first cell holder 108.
The BMS 112 is configured to protect the secondary battery pack 100 from being overcharged/over-discharged.The BMS 112 is configured to monitor the temperature level of the plurality of cells 110. The BMS 112 is configured to monitor the voltage level of each of the plurality of cells 110. In further, the secondary battery pack 100 includes a BMS mounting member (as shown in figure 3) to hold the BMS 112. In one embodiment, the BMS mounting member acts as a heatsink for the BMS 112 to absorb heat from the BMS 112 and transfer the heat to the extrusion 104. TheBMS mounting member is configured to mount the BMS 112 using a plurality of mounting points. The BMS mounting member is positioned on a top portion of the extrusion 104. The BMS 112 is mounted on a top portion of the BMS mounting member. The BMS mounting member is fastened with the casing of the secondary battery pack 100.
In one embodiment, the BMS mounting member may include, but not limited to, metal, nonmetal, structurally rigid, and thermalconductive material.The BMS mounting member includes a plurality of openings. In one embodiment, the plurality of openings may include, but not limited to, a first set of openings and a second set of openings. In another embodiment, the plurality of openings may include a third set of openings. The first set of openings is configured to dispensea first layer into the secondary battery pack 100. In one embodiment, the first layer may in clude, a thermal conductive material, or a thermalpropagation mitigation material. In another embodiment, the height of the first layer may vary based on the type of battery packs or form factors or material. In one embodiment, the thermalconductive material may include, but not limited to, thermalstability, vibration damping, structural stability,and rigidity.In one embodiment, the first set of openings varies in number and location based on viscosity of the first layer, quantity of the first layer, height of the first layer, and the one or more dimensions of the secondary battery pack 100. The second set of openings is configured to dispense a second layer into the secondary battery pack 100. In one embodiment, the second layer may include, a thermalconductive material, or a thermalpropagation mitigation material. In one embodiment, the second set of openings varies in number and location based on the viscosity of the second layer, quantity of the second layer, height of the second layer, and the one or more dimensions of the secondary battery pack 100.In one embodiment, the third set of openings is configured to dispense a third layer into the secondary battery pack 100. In another embodiment, the third set of openings varies in number and location based on the viscosity of the third layer, quantity of the third layer, height of the third layer, and the one or more dimensions of the secondary battery pack 100.
In one embodiment, the first set of openings, and the second set of openingsare positioned at a predetermined location of the BMS mounting member based on the height of the first layer, and the second layer. In another embodiment, the third set of openings is positioned at a predetermined location of the BMS mounting member based on the height of the third layer. The BMS mounting member further includes a plurality of mounting points to couple the BMS mounting member to the BMS 112. The BMS mounting member acts as the heatsink for the BMS 112 to absorb the heat from the BMS 112 and transfer the heat to the extrusion 104. The BMS mounting member provides structural strength to the BMS 112, the second cell holder 114, and the second set of openings. In an embodiment, the BMS mounting member is coupled to the extrusion 104 using the plurality of fasteners. In another embodiment, the BMS mounting member is coupled to the top battery casing118 using a plurality of fasteners. In yet another embodiment, the BMS mounting member is coupled to the bottom battery casing102 using the plurality of fasteners.
The second cell holder 114 is positioned on a top portion of the plurality of cells 110. The second cell holder 114 includes a plurality of cavities and is configured to hold the plurality of cells 110 in a predetermined position. The second cell holder 114 may be an electrically insulative and structurally rigid material. In one embodiment, the electrically insulative material may be a plastic composite. In another embodiment, the plastic composite may be a non-metallic plastic composite or polymer-based single-part or two-part material.
The interconnector 116 is positioned on a top portion of the second cell holder 114. The interconnector 116 is configured to connect different polarities of the plurality of cells 110 using the plurality of connectors. In one embodiment, the electrical connection may include, but not limited to, a series connection, a parallel connection, and a combination of a series and a parallel connection. In an embodiment, the interconnector 116 may include, but not limited to, a Printed Circuit Board (PCB).
The plurality of connectors is placed between the terminals of the plurality of cells 110 and the interconnector 116. The thermal interface material (not shown in the figure) may be dispensed above the interconnector 116.In one embodiment, the thermal interface material may include, but not limited to, a thermal pad, a thermal paste, a silicon pad, a gap pad, a thermal grease, a thermal gap filler, a phase change material, and the like. In another embodiment, the thermal interface material may include good thermal conductivity.The thermal interface material is configured to receive the heat generated from the secondary battery pack 100 through the conduction process.
In one embodiment, the thermal interface material is configured to receive the heat generated from the terminals of the plurality of cells 110 through the conduction process. The thermal interface material is configured to transfer the heat to a casing. The casing is configured to transfer the heat to the top battery casing 118 and the bottom battery casing. In one embodiment, the casing may include, but not limited to, a metal or any good thermally conductive material. The top battery casing 118 is configured to close the secondary battery pack 100 from top. The thermal interface material is compressed by the heatsink 120 to transfer the heat, which is generated from the plurality of cells 110, and the interconnector 116. The heatsink 120 is placed on a top portion of the thermal interface material. The heatsink 120 is configured to increase the heat flow away from the secondary battery pack 100. In one embodiment, the heatsink 120 acts as a guide for the insertion of the battery stack up into the extrusion 104.
In addition to that, the extrusion 104 includes one or more mating fins and the thermal interface material is dispensed to achieve effective thermal conduction from the secondary battery pack 100 to the extrusion 104. In one embodiment, the heatsink 120 may include, but not limited to, metal, nonmetal, structurally rigid, and thermalconductive material. The extrusion 104 includes one or more mating fins and a third thermal interface material is dispensed to achieve effective thermal conduction from the secondary battery pack 100 to the extrusion 104. The top battery casing 118 is configured to close the secondary battery pack 100 from the top. The top battery casing 118 includes a handle.
The top battery casing 118 further includes the plurality of mounting means to couple with the extrusion 104. In one embodiment, the plurality of mounting means may include, but not limited to, the plurality of fasteners.The BMS mounting member is connected to the extrusion 104. Position the secondary battery pack 100 at a first predetermined angle to allow the first layer to flow equally into the secondary battery pack 100. In one embodiment, the first layer may include, but not limited to, a thermalconductive material and a propagation mitigation material.In another embodiment, the height of the first layer may vary based on the type of battery packs or form factors or material. In yet another embodiment, the first layer may include, but not limited to, stable, vibration damping, structural stability, rigidity, and durability. In one embodiment, the conductive material includes resin, polymeric/non-polymeric material, polyurethane, epoxy, dielectric, organic/inorganicPhase Changing Material (PCM), and silicon encapsulant. In another embodiment, the first predetermined angle may vary based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer. In another embodiment, the first predetermined angle may be less than or equal to 90°. In yet another embodiment, the first predetermined angle may be measured with respect to a surface and one or more walls of the battery pack 100.
Then the first layer is dispensed into the secondary battery pack 100 by using the first set of openings. The first set of openings is located on the BMS mounting member. Then hold the secondary battery pack 100 at the first predetermined angle for a first predetermined time to allow the first layer to spread into the secondary battery pack 100. In one embodiment, the first predetermined time may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer.
In yet another embodiment, at the time of dispensing, the first layer will be in a predetermined pressure.The predetermined pressure depends on the viscosity and the flow rate of the material which is used in the first layer.The quantity of dispensed material in the given volume of the battery pack will determine the height of the layer.
Position the secondary battery pack 100 at a second predetermined angle to allow the first layer to flow equally into the secondary battery pack 100. In one embodiment, the second predetermined angle may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer. In another embodiment, the second predetermined angle may be (270° to 360°). In yet another embodiment, the second predetermined angle may be measured with respect to the surface and the one or more walls of the battery pack 100.
Hold the secondary battery pack 100 at the second predetermined angle for a second predetermined time to allow the first layer to settle into the secondary battery pack 100. In one embodiment, the second predetermined time may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer. Then position the secondary battery pack 100 in a horizontal position for a first holding time. In one embodiment, the first holding time may vary based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, the quantity of the first layer, the curing time of the first layer, the casing material compatibility, and the curing property of the material of the first layer being used and accelerated by placing in an oven for curing.
Then position the secondary battery pack 100 at a third predetermined angle to allow the second layer to flow equally into the secondary battery pack 100. In one embodiment, the second layer may include, but not limited to, a thermalconductive material or a thermal propagation mitigation material. In another embodiment, the height of the second layer may vary based on the type of battery packs or form factors or material. In another embodiment, the thermal propagation mitigation material includes silicon foam, foam, polyurethane, polystyrene, silicon, polyisocyanurate, and organic/inorganicPhase Changing Material (PCM). In one embodiment, the third predetermined angle may vary based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer.In another embodiment, the third predetermined angle may be less than 90°. In yet another embodiment, the third predetermined angle may be measured with respect to the surface and the one or more walls of the battery pack 100.
Then the second layer is dispensed into the secondary battery pack 100 by using the second set of openings. The second set of openings is located on the BMS mounting member. In one embodiment, the second set of openings may be positioned on the bottom battery casing 102 and the top battery casing 118. In another embodiment, the second set of openings may be positioned on the extrusion 104.
Then hold the secondary battery pack 100 at the third predetermined angle for a third predetermined time to allow the second layer to spread into the secondary battery pack 100. In one embodiment, the third predetermined time may be varied based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. In another embodiment, at the time of dispensing, the second layer will be in a predetermined pressure. The predetermined pressure depends on the viscosity and the flow rate of the material which is used in the second layer. The quantity of dispensed material in the given volume of the battery pack will determine the height of the layer.
Position the secondary battery pack 100 at a fourth predetermined angle to allow the second layer to flow equally into the secondary battery pack 100. In one embodiment, the fourth predetermined angle may be varied based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. In another embodiment, the fourth predetermined angle may be (270° to 360°). In yet another embodiment, the fourth predetermined angle may be measured with respect to the surface and one or more walls of the secondary battery pack 100.
Hold the secondary battery pack 100 at the fourth predetermined angle for a fourth predetermined time to allow the second layer to settle into the secondary battery pack 100. In one embodiment, the fourth predetermined time may be varied based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. Then position the secondary battery pack 100 in the horizontal position for a second holding time.In an embodiment, the second holding time may vary based onthe viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, quantity of the second layer, the curing time of the second layer, casing material compatibility, and curing property of the material of the second layer being used and accelerated by placing in an oven for curing.
After a certain duration, the first layer and the second layer will be in a gel state on the first cell holder 108, so the time taken by the first layer and the second layer to convert from a liquid state to a gel state is called gelling time. In one embodiment, the certain duration may vary based on the material, manufacturer, composition, temperature, UV or special curing agents or catalysts, and inhibitors in contact with the material of the first layer and the second layer. After a certain duration, the first layer and the second layer will be in a solid state on the first cell holder 108, so the time taken by the first layer and the second layer to convert from a liquid state to a solid state is called curing time. In another embodiment, the certain duration may vary based on the viscosity of the first layer. In one aspect, after dispensing the first layer and the second layer, a plurality of layers may be dispensed into the secondary battery pack 100.
The above dispensing methodology and the stack-up will apply to both the secondary battery pack 100, and the primary battery pack 200.
FIG. 2 illustrates an exploded perspective view of a primary battery pack 200 according to an embodiment disclosed herein. The primary battery pack 200 includes a bottom battery casing 202, an extrusion 204, a plurality of cell holder sleeves 206, a first cell holder 208, a plurality of cells 210, a Battery Management System (BMS) 212, a second cell holder 214, an interconnector 216, a top battery casing 218, a heat sink 220, and a plurality of connectors (not shown in the figure). In one embodiment, the primary battery pack 200 may/may not include the second cell holder214.
The primary battery pack 200 further includes one or more vents for air circulation and optimizing pressure of the primary battery pack 200 to maintain thermal issues or performance degradation. In one embodiment, the one or more vents may be positioned on the extrusion204. In another embodiment, the one or more vents may be positioned on the bottom battery casing 202. In yet another embodiment, the one or more vents may be positioned on the top battery casing 218. The bottom battery casing 202 includes a plurality of mounting means. In one embodiment, the plurality of mounting means may include a plurality of fasteners to couple the bottom battery casing 202 to the extrusion 204. In one embodiment, the plurality of fasteners may include, but not limited to, screws, nails, bolts, nuts, washers, anchors, rivets, grommets, snap-fits, and studs. The plurality of mounting means configured to couple the bottom battery casing 202 with the extrusion 204. In one embodiment, the plurality of mounting means may include a plurality of fasteners to couple the bottom battery casing 202 to the extrusion 204. The extrusion 204 is made up of a thermalconductive material to increase the rate of heat transfer from the primary battery pack 200 to the environment.
In one embodiment, the extrusion 204 includes a plurality of fins to transfer heat generated by the primary battery pack 200. The extrusion 204 includes a thermalconductive material. In one embodiment, the thermalconductive material may include, but not limited to, aluminum, resin, polymeric/non-polymeric material, polyurethane, epoxy, dielectric, organic/inorganic Changing Material (PCM), and silicon encapsulant. In another embodiment, the thermalconductive material may be a metal or non-metal-like composite.The extrusion 204 acts as anouter wall of the primary battery pack 200. In oneembodiment, the extrusion 204 includes one or more vents for air circulation. In another embodiment, the bottom battery casing 202 includes one or more vents for air circulation. In yet another embodiment, the top battery casing 218 includes one or more vents for air circulation.
The plurality of cell holder sleeves 206 configured to support and hold the first cell holder 208, and the second cell holder 214 along with the plurality of cells 210. In one embodiment, the plurality of cell holder sleeves 206 is configured to support and hold the first cell holder 208, the second cell holder 214, and the interconnector 216 along with the plurality of cells 210.
In yet another embodiment, the plurality of cell holder sleeves 206 configured to support and hold the first cell holder 208, the second cell holder 214, and the interconnector 216 along with the plurality of cells 210 using a plurality of fasteners. In one embodiment, the plurality of cell holder sleeves 206 may include, but not limited to, metal or non-metal. The plurality of cell holder sleeves 206 may include an insulation layer around to avoid short-circuiting.The interconnector 216 is positioned on a top portion of the second cell holder 214. The first cell holder 208 is positioned on a top portion of the bottom battery casing 202. The first cell holder 208 includes a plurality of cavities and is configured to hold the plurality of cells 210 in a predetermined position.
The interconnector 216 is positioned on a top portion of the second cell holder 214. In one embodiment, the plurality of cell holder sleeves 206 may include, but not limited to, metal or non-metal.The plurality of cell holder sleeves 206 may include an insulation layer around to avoid short-circuiting. The first cell holder 208 is positioned on a top portion of the bottom battery casing 202. The first cell holder 208 includes a plurality of cavities and is configured to hold the plurality of cells 210 in a predetermined position.
In another embodiment, the first cell holder 208 may be an electrically insulative and structurally rigid material. In another embodiment, the plastic composite may be a non-metallic plastic composite or polymer-based single-part or two-part material. In yet another embodiment, the electrically insulative material may have the characteristics to with stand high temperatures, without losing natural properties. In yet another embodiment, the electrically insulative material may be a plastic composite. The plurality of cells 210 positioned on a top portion of the first cell holder 208. In one embodiment the plurality of cells 210 is positioned on the plurality of cavities of the first cell holder208. In another embodiment, the plurality of cells 210 may include, but not limited to, nickel cadmium, alkaline, nickel metal hydride (NIMH), lithium-ion, nickel hydrogen, nickel-zinc, lithium iron phosphate battery (LiFePO) or LFP (lithium ferrophosphate), electro-chemical cells, and the like. The first cell holder 208 is configured to provide a predetermined space between the bottom battery casing 202 and the bottom surface of the plurality of cells 210.The plurality of cells 210 is positioned on a top portion of the first cell holder 208.
The BMS 212 is configured to protect the primary battery pack 200 from being overcharged/over-discharged. The BMS 212 is configured to monitor the temperature level of the plurality of battery cells 210. The BMS 212 is configured to monitor the voltage level of each of the plurality of cells 210. In further, the primary battery pack 200 includes a BMS mounting member (as shown in figure. 3) to hold the BMS 212. In one embodiment, the BMS mounting member acts as a heatsink for the BMS 212 to absorb heat from the BMS 212 and transfer the heat to the extrusion 204. The BMS mounting member provides better structural strength to the BMS 212, the second cell holder 214, and the second set of openings. The BMS mounting member is configured to mount the BMS 212 using a plurality of mounting points. The BMS mounting member is positioned on a top portion of the extrusion 204. The BMS 212 is mounted on a top portion of the BMS mounting member. The BMS mounting member is fastened with the casing of the primary battery pack200.
In one embodiment, the BMS mounting member may include, but not limited to, metal, nonmetal, structurally rigid, and thermalconductive material. The BMS mounting member includes a plurality of openings. In one embodiment, the plurality of openings may include, but not limited to afirst set of openings and a second set of openings. In another embodiment, the plurality of openings may include a third set of openings. The first set of openings is configured to dispensea first layer into the primary battery pack 200. In one embodiment, the first layer may include, a thermalconductive material, or a thermalpropagation mitigation material. In another embodiment, the height of the first layer may vary based on the type of battery packs or form factors or material. In yet another embodiment, the first layer may include, but not limited to, stable, vibration damping, structural stability, rigidity, and durability. In one embodiment, the conductive material includesresin, polymeric/non-polymeric material, polyurethane, epoxy, dielectric, organic/inorganic Phase Changing Material (PCM), and silicon encapsulant. In one embodiment, the first set of openings varies in number and location based on viscosity of the first layer, quantity of the first layer, and height of the first layer. The second set of openings is configured to dispense a second layer into the primary battery pack 200. In one embodiment, the second layer may include, a thermalconductive material, or a thermalpropagation mitigation material. In another embodiment, the height of the second layer may vary based on the type of battery packs or form factors or material. In yet another embodiment, the second layer may include, but not limited to, stable, vibration damping, structural stability, rigidity, and durability. In another embodiment, the thermal propagation mitigation material includes silicon foam, foam, polyurethane, polystyrene, silicon, polyisocyanurate, and organic/inorganic Phase Changing Material (PCM). In one embodiment, the second set of openings varies in number and location based on the viscosity of the second layer, quantity of the second layer, and height of the second layer.The third set of openings is configured to dispense a third layer into the primary battery pack 200. In another embodiment, the height of the third layer may vary based on the type of battery packs or form factors or material. In yet another embodiment, the third set of openings varies in number and location based on the viscosity of the third layer, quantity of the third layer, and height of the third layer.
In one embodiment, the first set of openings, and the second set of openingsare positioned at a predetermined location of the BMS mounting member based on the height of the first layer, and the second layer. Inanother embodiment, the third set of openings is positioned at a predetermined location of the BMS mounting member based on the height of the third layer. The BMS mounting member further includes a plurality of mounting points to couple the BMS mounting member to the BMS 212. The BMS mounting member is coupled to the extrusion 204 and using the plurality of fasteners.
The second cell holder 214 is positioned on a top portion of the plurality of cells 210. The second cell holder 214 includes a plurality of cavities and is configured to hold the plurality of cells 210 in a predetermined position. The second cell holder 214 may be an electrically insulative structurally rigid material. In another embodiment, the electrically insulative material may be a plastic composite. In another embodiment,the plastic composite may be a non-metallic plastic composite or polymer-based single-part or two-part material.
The interconnector 216 is positioned on a top portion of the second cell holder 214. The interconnector 216 is configured to connect different polarities of the plurality of cells 210 using the plurality of connectors. In one embodiment, the electrical connection may include, but not limited to, a series connection, a parallel connection, and a combination of a series and a parallel connection. In an embodiment, the interconnector 216 may include, but not limited to, Printed Circuit Board (PCB).
The plurality of connectors is placed between the terminals of the plurality of cells 210 and the interconnector 216. The thermal interface material (not shown in the figure) may be dispensed above the interconnectors 216.In one embodiment, the thermal interface material may include, but not limited to, a thermal pad, a thermal paste, a silicon pad, a gap pad, a thermal grease, a thermal gap filler, and the like. In another embodiment, the thermal interface material may include good thermal conductivity. The thermal interface material is configured to receive the heat generated from the primary battery pack 200 through the conduction process.
In one embodiment, the thermal interface material is configured to receive the heat generated from the terminals of the plurality of cells 210 through the conduction process. The thermal interface material is configured to transfer the heat to the top battery casing 218. The top battery casing 218 is configured to close the primary battery pack 200 from top. The thermal inter face material is compressed by the heat sink 220 to transfer the heat, which is generated from the plurality of cells 210, and the interconnector 216. The heatsink 220 is placed on a top portion of the thermal interface material.The heatsink 220 is configured to increase the heat flow away from the primary battery pack 200. In one embodiment, the heatsink 220 acts as a guide for the insertion of the battery stack up into the extrusion 204.
In addition to that, the extrusion 204 includes one or more mating fins and the thermal interface material is dispensed to achieve effective thermal conduction from the primary battery pack 200 to the extrusion 204. In one embodiment, the heatsink 220 may include, but not limited to, metal, nonmetal, structurally rigid, and thermalconductive material. The extrusion 204 includes one or more mating fins and a third thermal interface material is dispensed to achieve effective thermal conduction from the primary battery pack 200 to the extrusion 204. The top battery casing 218 is configured to close the primary battery pack 200 from the top.
The top battery casing 218 includes a plurality of mounting means to couple with the extrusion 204. In one embodiment, the plurality of mounting means may include, but not limited to, the plurality of fasteners. In one embodiment, the plurality of fasteners may include, but not limited to, screws, nails, bolts, nuts, washers, anchors, rivets, grommets, snap-fits, and studs.The BMS mounting member is connected to the extrusion 204 using the plurality of fasteners. Position the primary battery pack 200 at a first predetermined angle to allow the first layer to flow equally into the primary battery pack 200. In one embodiment, the first layer may includea thermalconductive material. In another embodiment, the first layer may include a propagation mitigation material.
In another embodiment, the first predetermined angle may vary based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer. In another embodiment, the first predetermined angle may be less than or equal to 90°.
Then the first layer is dispensed into the primary battery pack 200 by using the first set of openings. The first set of openings is located on the BMS mounting member.
Then hold the primary battery pack 200 at the first predetermined angle for a first predetermined time to allow the first layer to spread into the primary battery pack 200. In one embodiment, the first predetermined time may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer. In another embodiment, the first predetermined time depends on the quantity of the first layer, casing material compatibility, and the curing property of the material of the first layer being used and accelerated by placing in an oven for curing. In yet another embodiment, at the time of dispensing, the first layer will be in a predetermined pressure.The predetermined pressure depends on the viscosity and the dispensing flow rate of the material which is used in the first layer. The quantity of dispensed material in the given volume of the battery pack will determine the height of the layer.
Position the primary battery pack 200 at a second predetermined angle to allow the first layer to flow equally into the primary battery pack 100. In one embodiment, the second predetermined angle may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer.In another embodiment, the second predetermined angle may be (270° to 360°).
Hold the primary battery pack 200 at the second predetermined angle for a second predetermined time to allow the first layer to settle into the primary battery pack 200. In one embodiment, the second predetermined time may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer. Then hold the primary battery pack 200 in a horizontal position for a first holding time. In one embodiment, the first holding time depends onthe viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, the curing time of the first layer, the casing material compatibility,and the curing property of the material of the first layer and accelerated by placing in an oven for curing.
Then position the primary battery pack 200 at a third predetermined angle to allow the second layer to flow equally into the primary battery pack 200. In one embodiment, the second layer may include, but not limited to, a thermal propagation mitigation material. In another embodiment, the thermal propagation mitigation material includes silicon foam, foam, polyurethane, polystyrene, silicon, polyisocyanurate, and organic/inorganic Phase Changing Material (PCM).In one embodiment, the third predetermined angle may vary based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. In another embodiment, the third predetermined angle may be less than or equal to 90°.
Then the second layer is dispensed into the primary battery pack 200 by using the second set of openings. The second set of openings is located on the BMS mounting member. In one embodiment, the second set of openings may be positioned on the bottom battery casing 202 and the top battery casing 218. In one embodiment, the top battery casing 218 includes one or more layers.
Then hold the primary battery pack 200 at the third predetermined angle for a third predetermined time to allow the second layer to settle into the primary battery pack 200. In one embodiment, the third predetermined time may vary based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. In another embodiment, the third predetermined time depends on the quantity of the second layer, the casing material compatibility, and the curing property of the material of the second layer and accelerated by placing in an oven for curing. In yet another embodiment, at the time of dispensing, the second layer will be in a predetermined pressure.The predetermined pressure depends on the viscosity and the dispensing flow rate of the material which is used in the second layer. The quantity of dispensed material in the given volume of the battery pack will determine the height of the layer.
Position the primary battery pack 200 at a fourth predetermined angle to allow the second layer to flow equally into the primary battery pack 200. In one embodiment, the fourth predetermined angle may vary based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. In another embodiment, the second predetermined angle may be (270° to 360°).
Hold the primary battery pack 200 at the fourth predetermined angle for a fourth predetermined time to allow the second layer to settle into the primary battery pack 200. In one embodiment, the fourth predetermined time may vary based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. Then position the primary battery pack 200 in the horizontal position for a second holding time. In another embodiment, the second holding time depends on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, the curing time of the second layer,the casing material compatibility, the quantity of the second layer, and the curing property of the material of the second layer and accelerated by placing in an oven for curing.
After a certain duration, the first layer and the second layer will be in a gel state on the first cell holder 208, so the time taken by the first layer and the second layer to convert from a liquid state to a gel state is called gelling time.In one embodiment, the certain duration may vary based on the material, manufacturer, composition, temperature, UV or special curing agents or catalysts, and inhibitors in contact with the materialof the first layer and the second layer. After a certain duration, the first layer and the second layer will be in a solid state on the first cell holder208, so the time taken by the first layer and the second layer to convert from a liquid state to a solid state is called curing time. In another embodiment, the certain duration may vary based on the viscosity of the first layer. In one aspect, after dispensing the first layer and the second layer, a plurality of layers may be dispensed into the primary battery pack 200.
The above dispensing methodology and the stack-up will apply to both the secondary battery pack 100 and the primary battery pack 200.
FIG. 3 illustrates an exploded view of the Battery ManagementSystem (BMS) mounting member 300 according to an embodiment as disclosed herein. The secondary battery pack 100 includes the BMS mounting member 300 to hold the BMS 112. The BMS 112 is mounted on a top portion of the BMS mounting member 300. The BMS mounting member 300 is positioned on a top portion of the extrusion 104. The BMS mounting member 300 includes a plurality of openings. In one embodiment, the plurality of openings may include, but not limited to, a first set of openings 302, and a second set of openings 304. In another embodiment, the plurality of openings may include a third set of openings. The first set of openings 302 configured to dispense a first layer into the secondary battery back 100. The second set of openings 304 configured to dispense a second layer into the secondary battery back 100. In one embodiment, the third set of openings is configured to dispense a third layer into the secondary battery back 100. In one embodiment, the first set of openings 302, and the second set of openings 304may be positioned on the BMS mounting member 300. In another embodiment, the third set of openings may be positioned on the BMS mounting member 300. In one embodiment, the first set of openings 302, and the second set of openings 304 may be positioned on the one or more walls of the secondary battery pack 100.In another embodiment, the third set of openings may be positioned on the one or more walls of the secondary battery pack 100. In yet another embodiment, the BMS mounting member 300 may be a heat sink, a base plate, or a separator.
In one embodiment, the first set of openings 302, and the second set of openings 304are positioned at a predetermined location of the BMS mounting member 300 based on the height of the first layer, and the second layer. In another embodiment, the third set of openings is positioned at the predetermined location of the BMS mounting member 300 based on the height of the third layer. The BMS mounting member 300 further includes a plurality of mounting points 306 to couple the BMS mounting member to the BMS 112. The BMS mounting member 300 is coupled to the extrusion 104 using a plurality of fasteners. The top battery casing 118 is coupled to the extrusion 104using the plurality of fasteners. In one embodiment, the plurality of fasteners may include, but not limited to, screws, nails, bolts, nuts, washers, anchors, rivets, grommets, snap-fits,and studs. The BMS mounting member 300 is configured to hold and provide a space for the BMS 112. In one embodiment, the top battery casing 118 includes one or more layers.
The BMS mounting member 300 is connected to the extrusion 104. In one embodiment, the BMS mounting member 300 acts as a heatsink for the BMS 112 to absorb heat from the BMS 112 and transfer the heat to the extrusion 104. The BMS mounting member 300 provides better structural strength to the BMS 212, the second cell holder 214, and the second set of openings 304. In one embodiment, the BMS mounting member 300 will apply to the primary battery pack 200. In one embodiment, both the secondary battery pack 100, and the primary battery pack 200 include the BMS mounting member 300 to hold the BMS 112.
FIG. 4A&4Billustrate a flow diagram of a method 400 of dispensing one or more layersinto the battery pack 100, 200, according to an embodiment as disclosed herein. In one embodiment, the one or more layers may include, but not limited to a first layer, and a second layer. In another embodiment, the one or more layers may includea third layer. The battery pack 100, 200 may includea primary battery pack 200 and secondary battery pack 100.
At step 402, positioning the battery pack 100, 200 at a first predetermined angle to allow the first layer to flow equally into the battery pack 100, 200. In one embodiment, the first predetermined angle may vary based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer.In another embodiment, the first predetermined angle of the battery pack 100, 200 is less than or equal to 90°.
In one embodiment, the first layer may include a conductive material, or a propagation mitigation material. In another embodiment, height of the first layer may vary based on type of battery packs or form factors or material.In one embodiment, the conductive material may include, but not limited to, stable, vibration damping, structural stability, rigidity, and durability.
At step 404, dispensing the first layer into the battery pack 100, 200 by using a first set of openings 302. The first set of openings 302 is located on the BMS mounting member300 of the battery pack 100, 200.
In one embodiment, the first set of openings 302 varies in number and location based on the viscosity of the first layer, the quantity of the first layer, the height of the first layer, and one or more dimensions of the secondary battery pack 100.
At step 406, holding the battery pack 100, 200 at the first predetermined angle for a first predetermined time to allow the first layer to spread into the battery pack 100, 200. In one embodiment, the first predetermined time may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, the curing time of the first layer, and casing material compatibility. In another embodiment, at the time of dispensing, the first layer will be in a predetermined pressure. The predetermined pressure depends on the viscosity and the dispensing flow rate of the material which is used in the first layer. The quantity of dispensed material in the given volume of the battery pack 100, 200 will determine the height of the layer.
At step 408, positioning the battery pack 100, 200 at a second predetermined angle to allow the first layer to flow equally into the battery pack 100, 200. In one embodiment, the second predetermined angle may be varied based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer. In another embodiment, the second predetermined angle may be (270° to 360°).
At step 410, holding the battery pack 100, 200 at the second predetermined angle for a second predetermined time to allow the first layer to settle into the battery pack 100, 200. In one embodiment, the second predetermined time may be varied based on the viscosity of the first layer.
At step 412, holding the battery pack 100, 200 in a horizontal positionfor a first holding time. In one embodiment, the first holding time depends on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, the curing time of the first layer, the quantity of the first layer, the casing material compatibility, andthe curing property of the material of the first layer and accelerated by placing in an oven for curing.
At step 414, positioning the battery pack 100, 200 at a third predetermined angle to allow the second layer to flow equally into the battery pack 100, 200. In one embodiment, the third predetermined angle may vary based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer.In another embodiment, the third predetermined angle of the battery pack 100, 200 is less than or equal to 90°).
In one embodiment, the second layer may include a conductive material, or a propagation mitigation material. In another embodiment, the height of the second layer may vary based on the type of battery packs or form factors or material. In another embodiment, the thermal propagation mitigation material includes silicon foam, foam, polyurethane, polystyrene, silicon, polyisocyanurate, and organic/inorganic Phase Changing Material (PCM).
At step 416, dispensing the second layer into the battery pack 100, 200 by using a second set of openings 304. The second set of openings 304 is located on the BMS mounting member300 of the battery pack 100, 200.
In one embodiment, the second set of openings 304 varies in number and location based on the viscosity of the second layer,the quantity of the second layer, the height of the second layer, and the one or more dimensions of the secondary battery pack 100. In another embodiment, the first set of openings 302 and the second set of openings 304 are positioned at a predetermined location of the BMS mounting member based on the height of the first layer, and the second layer.
At step 418, holding the battery pack 100, 200 at the third predetermined angle for a third predetermined time to allow the second layer to spread into the battery pack 100, 200. In one embodiment, the third predetermined time may be varied based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. In another embodiment, at the time of dispensing, the second layer will be in a predetermined pressure. The predetermined pressure depends on the viscosity and the dispensing flow rate of the material which is used in the second layer. The quantity of dispensed material in the given volume of the battery pack 100, 200 will determine the height of the layer.
At step 420, positioning the battery pack 100, 200 at a fourth predetermined angle to allow the second layer to flow equally into the battery pack 100, 200. In one embodiment, the fourth predetermined angle may be varied based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer. In another embodiment, the fourth predetermined angle may be (270° to 360°).
At step 422, holding the battery pack 100, 200 at the fourth predetermined angle for a fourth predetermined time to allow the second layer to settle into the battery pack 100, 200. In one embodiment, the fourth predetermined time may be varied based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer.
At step 424, positioning the battery pack 100, 200 in the horizontal position for a second holding time. In one embodiment, the second holding time depends on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, the curing time of the second layer, the quantity of the second layer, the casing material compatibility, andthe curing property of the material of the second layer and accelerated by placing in an oven for curing.
In one embodiment, dispensing the third layer into the battery pack 100, 200 by using a third set of openings. The third set of openings is located on the BMS mounting member 300 of the battery pack 100, 200. In one embodiment, the third set of openings is positioned at a predetermined location of the BMS mounting member based on the height of the third layer.In another embodiment, the third set of openings varies in number and location based on the viscosity of the third layer, the quantity of the third layer, the height of the third layer, and the one or more dimensions of the secondary battery pack 100.
After a certain duration, the first layer and the second layer will be in a gel state on the first cell holder 108, so the time taken by the first layer and the second layer to convert from a liquid state to a gel state is called gelling time.In an embodiment, the certain duration may vary based on the viscosity, the temperature, the dispensing flow rate, and the curing time of the first layer and the second layer. After a certain duration, the first layer will be in a solid state on the first cell holder, so the time taken by the first layer and the second layer to convert from a liquid state to the solid state is called curing time. In one embodiment, the certain duration may vary based on the viscosity, the temperature, the dispensing flow rate, and the curing time of the first layer and the second layer. In one aspect, after dispensing the first layer and the second layer, the one or more layers may be dispensed into the battery pack 100, 200. In one embodiment, the above method 400 will apply to both the primary battery pack 200, and the secondary battery pack 100. In the proposed method 400, the one or more layers are not fully immersed in the entire battery pack 100, 200. Therefore, the cost and weight of the proposed method 400 are saved.
Improvements and modifications may be incorporated herein without deviating from the scope of the invention.The foregoing description of the specific embodiments 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 embodiments 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 embodiments. 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 embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

LIST OF REFERENCE NUMERALS

100: Secondary battery pack
200: Primary battery pack
102, 202: Bottom battery casing
104, 204: Extrusion
106, 206:Plurality of cell holder sleeves
108, 208: First cell holder
110, 210: Plurality of cells
112, 212: BMS
114, 214: Second cell holder
116, 216: Interconnector
118, 218: Top battery casing
120, 220: Heatsink
300: BMS mounting member
302: First set of openings
304: Second set of openings
306: Plurality of mounting points ,CLAIMS:I Claim:
1. A method (400) of dispensing one or more layers into a battery pack (100, 200), wherein the one or more layers comprise a first layer and a second layer, comprising: positioning the battery pack (100, 200) at a first predetermined angle to allow the first layer to flow equally into the battery pack (100, 200), wherein the first predetermined angle varies based on viscosity of the first layer, temperature of the first layer, dispensing flow rate of the first layer, and curing time of the first layer; dispensing, using a first set of openings (302), the first layer into the battery pack (100, 200), wherein the first set of openings (302) located on a BMS mounting member (300) of the battery pack (100, 200); holding the battery pack (100, 200) at the first predetermined angle for a first predetermined time to allow the first layer to spread into the battery pack (100, 200), wherein the first predetermined time varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer; positioning the battery pack (100, 200) at a second predetermined angle to allow the first layer to flow equally into the battery pack (100, 200), wherein the second predetermined angle varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer; holding the battery pack (100, 200) at the second predetermined angle for a second predetermined time to allow the first layer to settle into the battery pack (100, 200), wherein the second predetermined time varies based on the viscosity of the first layer, the temperature of the first layer, the dispensing flow rate of the first layer, and the curing time of the first layer; positioning the battery pack (100, 200) in a horizontal position for a first holding time, wherein the first holding time varies based on the viscosity of the first layer, the temperature of the first layer, the curing time of the first layer, the quantity of the first layer, the casing material compatibility, and the curing property of the material of the first layer and accelerated by placing in an oven for curing; positioning the battery pack (100, 200) at a third predetermined angle to allow the second layer to flow equally into the battery pack (100, 200), wherein the third predetermined angle varies based on viscosity of the second layer, temperature of the second layer, dispensing flow rate of the second layer, and the curing time of the second layer; dispensing, using a second set of openings (304), the second layer into the battery pack (100, 200), wherein the second set of openings (304) located on the BMS mounting member (300) of the battery pack (100, 200); holding the battery pack (100, 200) at the third predetermined angle for a third predetermined time to allow the second layer to spread into the battery pack (100, 200), wherein the third predetermined time varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer; positioning the battery pack (100, 200) at a fourth predetermined angle to allow the second layer to flow equally into the battery pack (100, 200), wherein the fourth predetermined angle varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, and the curing time of the second layer; holding the battery pack (100, 200) at the fourth predetermined angle for a fourth predetermined time to allow the second layer to settle into the battery pack (100, 200), wherein the fourth predetermined angle may varies based on viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer and the curing time of the second layer; and positioning the battery pack (100, 200) in the horizontal position for a second holding time, wherein the second holding time varies based on the viscosity of the second layer, the temperature of the second layer, the dispensing flow rate of the second layer, the curing time of the second layer, the quantity of the second layer, the casing material compatibility, and the curing property of the material of the second layer being used and accelerated by placing in an oven for curing.


2. The method (400) as claimed in claim 1, wherein the first predetermined angle is less than or equal to 90°.

3. The method (400) as claimed in claim 1, wherein the second predetermined angle is 270° to 360°.

4. The method (400) as claimed in claim 1, wherein the third predetermined angle is less than or equal to 90°.

5. The method (400) as claimed in claim 1, wherein the fourth predetermined angle is 270° to 360°.

6. The method (400) as claimed in claim 1, wherein the first layer comprises a thermal conductive material, wherein the thermal conductive material comprises resin, polymeric/non-polymeric material, polyurethane, epoxy, dielectric, organic/inorganic Phase Changing Material (PCM), and silicon encapsulant.

7. The method (400) as claimed in claim 1, wherein the second layer comprises a thermal propagation mitigation material, wherein the thermal propagation mitigation material comprises silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, polyisocyanurate, and organic/inorganic Phase Changing Material (PCM).


8. The method (400) as claimed in claim 1, wherein the first set of openings (302) varies in number and location based on the viscosity of the first layer, the quantity of the first layer, the height of the first layer, and one or more dimensions of the battery pack (100, 200).

9. The method (400) as claimed in claim 1, wherein the second set of openings (304) varies in number and location based on the viscosity of the second layer, the quantity of the second layer, the height of the second layer, and one or more dimensions of the battery pack (100, 200).

10. A battery pack (100, 200), comprising: a bottom battery casing (102) comprises a plurality of mounting means, wherein the plurality of mounting means configured to couple the bottom battery casing (102) to an extrusion (104); the extrusion (104) comprises a plurality of fins to transfer heat generated by the battery pack (100, 200), wherein the extrusion (104) comprises a thermal conductive material configured to increase rate of heat transfer from the battery pack (100, 200); a plurality of cell holder sleeves (106) configured to support and hold a first cell holder (108), and a second cell holder (114) along with the plurality of cells (110); the first cell holder (108) is positioned on top of the bottom battery casing (102), wherein the first cell holder (108) comprises a plurality of cavities and is configured to hold the plurality of cells (110) in a predetermined position, wherein the first cell holder (108) is configured to provide a predetermined space between the bottom battery casing (102) and the bottom surface of the plurality of cells (110); the plurality of cells (110) positioned on top of the first cell holder (108); the second cell holder (114) is positioned on top of the plurality of cells (110), wherein the second cell holder (114) comprises a plurality of cavities and is configured to hold the plurality of cells (110) in a predetermined position; an interconnector (116) is positioned on top of the second cell holder (114), wherein the interconnector (116) is configured to connect different polarities of the plurality of cells (110) using a plurality of connectors (122), wherein the plurality of connectors (122) is placed between the terminals of the plurality of cells (110) and the interconnector (116); a top battery casing (118) is configured to close the battery pack (100, 200) from top; and a Battery Management System (BMS) mounting member (300) is configured to mount a BMS (112) using a plurality of mounting points (306), wherein the BMS mounting member (300) is positioned on top of the extrusion (104), wherein the BMS mounting member (300) includes a first set of openings (302),and a second set of openings (304), wherein the first set of openings (302) configured to dispense a first layer into the battery back (100, 200), wherein the second set of openings (304) configured to dispense a second layer into the battery back (100, 200), wherein the BMS mounting member (300) acts as a heatsink for the BMS (112) to absorb heat from the BMS (112) and transfer the heat to the extrusion (104).
11. The battery pack (100, 200) as claimed in claim 10, wherein the plurality of cell holder sleeves (106) configured to support and hold the first cell holder (108), and the second cell holder (114), along with the plurality of cells (110).
12. The battery pack (100, 200) as claimed in claim 10, wherein the first set of openings (302),and the second set of openings (304)are positioned at a predetermined location of the BMS mounting member (300) based on height of the first layer, and the second layer.
13. The battery pack (100, 200) as claimed in claim 10, wherein the BMS mounting member (300) is coupled to the extrusion (104), using a plurality of fasteners.