Description:FIELD OF THE INVENTION
[001] The present invention generally relates to a battery pack and more particularly relates to an interconnector plate and a separator plate of the battery pack.

BACKGROUND OF THE INVENTION
[002] A battery pack includes a plurality of battery modules having many battery cells interconnected to each other. The battery pack achieves desired voltage by connecting several battery cells in series, such that each battery cell adds its voltage potential to derive the total terminal voltage. Similarly, the battery pack achieves desired current by connecting several battery cells in parallel. If higher voltages or currents are needed and larger battery cells are not available or do not fit the design constraint, one or more battery cells can be connected in series or parallel to achieve the desired electrical output. Generally, the battery pack employs a combination of series and parallel connections for its many battery cells. This enables for design flexibility and achieves the desired voltage and current ratings with a standard battery cell size. Conventionally, the battery cell is provided with two cells tabs, one positive and other negative to connect the battery cell to another battery cell or to an external load. The aforementioned series and/or parallel connections between the individual battery cells of the battery module are achieved by electrically connecting the cell tabs of different battery cells.
[003] A Battery Management System (BMS) plays a vital role in monitoring health of the battery pack. The BMS monitors voltage, charging current, temperature, state of charge, and the like of the battery cells of the battery pack to ensure effective working and longevity of the battery pack. Effective electrical connection between the battery cells and the BMS is crucial for efficient working of the battery pack. Generally, interconnector plates made of metal and wiring harnesses are used to electrically connect the battery cells to the BMS. The interconnector plate is welded to the respective cell tabs of the battery cells and connected to the BMS through wiring harnesses. However, if number of rows or columns of battery cells is increased in the battery modules of the battery pack, number of interconnectors required to connect the battery cells to the BMS also needs to be increased, thus resulting in increase of number of wiring harnesses required. This leads to complexity in configuration of the battery pack, wire entanglement and increased assembly time for the battery pack.
[004] Measuring voltage across the cell tabs of each battery cell of the battery pack is a difficult and complex affair. In order to ensure that all rows or columns of battery cells of each battery module of the battery pack, as the case may be, are providing equal charge for driving various load conditions, the voltage across each row is measured, as opposed to measuring voltage across the cell tabs of each battery cell. In existing battery pack designs, battery cell imbalance is a recurring problem which is to be solved. During charging and discharging cycles of the battery pack, if any battery cell reaches its maximum limit or working threshold (which is below absolute threshold) before the other battery cells have reached their working threshold, battery cell imbalance occurs. Capacity of the battery pack to retain optimum charge levels is limited by imbalance in the battery cells of the battery pack. This reduces energy usage efficiencies and shortens longevity of the battery pack. Furthermore, if lithium-ion cells, used in modern day automobile battery packs, are overheated, or overcharged, they are prone to accelerated battery cell degradation. The battery cells can catch fire or even explode as a thermal runaway condition can occur if voltage of one or more lithium-ion cells exceeds by even a few hundred millivolts as compared to its predetermined threshold voltage. To avoid this, charging and discharging cycles need to be stopped as soon as any battery cell reaches its threshold limit. Thus, battery cell balancing is a basic but essential function of the BMS and is necessary for secure and healthy operation of battery packs. Two known ways of balancing the battery cells of the battery pack are used in the industry: active balancing and passive balancing. Conventional passive balancing method prevents bleeding of excess energy from the overcharged battery cells into heat. In active balancing, there is a transfer of excess energy from the overcharged one or more battery cells into energy-depleted cells. However, both active balancing and passive balancing are relatively expensive and needs complex hardware and firmware for their application.
[005] In order to allow the BMS to perform battery cell balancing without use of active and passive balancing methods, accurate measurement of voltage is a prerequisite. Existing interconnector designs of the battery pack show higher row to row or column to column voltage difference, as the case may be, when current flows through the interconnector. This is because resistance of the interconnector is not distributed equally between the one or more rows or columns of the battery cells of the battery pack. Existing design has single row or single column battery cells connected parallelly and adjacent rows or columns connected in series. So, the interconnector used to connect two rows or two columns of battery cells in series ends up with a smaller surface area for current flow, which leads to more losses due to higher resistance. This resistance inequality leads to voltage measurement error due to unequal voltage losses from neighbouring rows or columns of battery cells.
[006] Furthermore, existing battery pack designs have separate battery packs connected in parallel or series through wiring harnesses, leading to greater space consumption and component requirement. A separate BMS is required to be connected to each of the battery packs. Another problem faced is having half of voltage tapping points of the interconnectors being placed on one side of the battery module and the other half of voltage tapping points being connected on the other side of the battery module. All the voltage tapping points are then connected to the BMS either by wires or couplers, which is cumbersome and difficult during assembly and handling of the battery pack. This also necessitates need of external relays to utilise the tapping points provided on opposite sides of the battery pack.
[007] Also, spacers are used between adjacent battery cells to achieve a compact secured fit for the battery cells within the battery pack. The spacers ensure constant pressure on the sides of the individual battery cells to ensure a tight packing of the battery cells within a battery module. However, the use of spacers increases the total footprint and the overall space requirement for the battery module. This creates challenges in applications where space limitation exists. Spacers, however, do not provide structural support for the battery pack and is difficult to be mounted to the other support structures provided for the battery pack.
[008] Thus, there is a need in the art for a battery module which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[009] In one aspect, the present invention is directed to a battery pack. The battery pack includes a plurality of battery modules disposed beside one another, each battery module having a plurality of battery cells arranged in at least one cell stack. The battery pack also includes a BMS module disposed on the plurality of battery modules and configured to manage the plurality of battery modules. The battery pack includes an interconnector plate corresponding to each cell stack disposed on a side of the corresponding battery module. The interconnector plate is adapted to electrically connect the plurality of battery cells of the cell stack. The battery pack further includes a separator plate disposed between each of the plurality of battery modules and is adapted to electrically insulate the plurality of battery modules from each other. In an embodiment, at least one cell stack having the plurality of battery cells are arranged in at least four columns. Also, the interconnector plate overlaps with the plurality of battery cells arranged in the columns of the corresponding cell stack. Furthermore, each of the interconnector plates have a tapping arm extending orthogonally from an edge of the interconnector plate so as to be disposed between the cell stack and the BMS module.
[010] In another embodiment, the interconnector plates corresponding to a pair of cell stacks disposed at a distal end of the battery pack includes a secondary arm extending orthogonally from an edge of the interconnector plate so as to be disposed between the cell stack and the BMS module. The secondary arm is adjacent to the tapping arm. In an embodiment, the secondary arm corresponding to the pair of cell stacks are power interconnectors that are adapted to draw power from the battery pack to drive a load.
[011] In another embodiment, the battery pack includes a plurality of voltage sensing points communicatively coupled to the BMS module. The tapping arm corresponding to each interconnector plate is electrically and physically connected to the corresponding voltage sensing point. In yet another embodiment, the battery pack includes a Printed Circuit Board (PCB) disposed between the plurality of voltage sensing points and the BMS module. The PCB is adapted to electrically connect the plurality of voltage sensing points to the BMS module.
[012] In a further embodiment, each battery module includes a cell holder plate having a plurality of cells holders projecting orthogonally from the cell holder plate. The cell holder plate is adapted to receive the plurality of battery cells to be arranged in at least one cell stack. Each battery cell is received by a corresponding cell holder of the cell holder plate.
[013] In another embodiment, the battery pack includes a busbar disposed on the plurality of battery modules. The busbar is adapted to electrically connect the plurality of battery modules. The BMS module is provided with a first cut out to accommodate the busbar. In yet another embodiment, the battery pack includes a fuse disposed on the plurality of battery modules. The BMS module is provided with a second cut out to accommodate the fuse.
[014] In another embodiment, the battery pack includes a casing. The casing includes a shell with a hollow space adapted to receive the plurality of battery modules, a bottom cover attached to the shell to cover the hollow space from a bottom of the shell and a top cover attached to the shell to cover the hollow space from a top of the shell.
[015] In a further embodiment, the separator plate includes at least one through hole adapted to receive a fastener to detachably attach each of the corresponding battery modules to the separator plate. In another embodiment, the separator plate includes a plurality of mounting brackets integrally formed with the separator plate and projecting orthogonally from edges of the separator plate. The plurality of mounting brackets is adapted to detachably attach the separator plate to the casing.
[016] In yet another embodiment, the casing includes a fastening means corresponding to each mounting bracket, the fastening means being adapted to receive a fastener to detachably attach the separator plate to the casing.

BRIEF DESCRIPTION OF THE DRAWINGS
[017] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a perspective view of an exemplary battery pack, in accordance with an embodiment of the present invention.
Figure 2 illustrates another perspective view of the battery pack, in accordance with an embodiment of the present invention.
Figure 3 illustrates a perspective view of an exemplary cell holder plate of the battery module with a plurality of battery cells, in accordance with an embodiment of the present invention.
Figure 4 illustrates a top view of the battery pack, in accordance with an embodiment of the present invention.
Figure 5 illustrates a side elevation view of the battery pack, in accordance with an embodiment of the present invention.
Figure 6 illustrates an elevation view of the battery pack, in accordance with an embodiment of the present invention.
Figure 7 illustrates a perspective view of the battery pack, in accordance with an embodiment of the present invention.
Figure 8 illustrates a top view of the battery pack, in accordance with an embodiment of the present invention.
Figure 9 illustrates a perspective view of an exemplary interconnector plate of the battery pack, in accordance with an embodiment of the present invention.
Figure 10 illustrates a perspective view of an exemplary interconnector plate corresponding to a pair of cell stacks disposed at a distal end of the battery pack, in accordance with an embodiment of the present invention.
Figure 11 illustrates a perspective view of an exemplary casing of the battery pack, in accordance with an embodiment of the present invention.
Figure 12 illustrates a perspective view of an exemplary separator plate of the battery pack, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[018] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder. The present invention generally relates to a battery pack and more particularly relates to an interconnector plate and separator plate of the battery pack.
[019] Figure 1 illustrates a perspective view of an exemplary battery pack 10, in accordance with an embodiment of the present subject matter. Figure 2 illustrates another perspective view of the battery pack 10, in accordance with an embodiment of the present subject matter. Referring to Figures 1 and 2, the battery pack 10 includes a plurality of battery modules 102, 104 disposed beside one another. Each battery module 102, 104 includes a plurality of battery cells 112 arranged in at least one cell stack 110a, 110b, 110c, 110d (shown in Figure 3). In the illustrated embodiment, the battery pack 10 has two battery modules 102, 104 disposed beside one another. Each battery module 102, 104 has the plurality of cells 112 arranged in four cell stacks 110a, 110b, 110c, 110d, which are arranged one beside the other. The battery pack 10 also includes an interconnector plate 120a, 120b, 120c, 120d corresponding to each cell stack 110a, 110b, 110c, 110d disposed on a side of the corresponding battery module 102, 104. The interconnector plates 120a, 120b, 120c, 120d are adapted to electrically connect the plurality of battery cells 112 within the respective cell stack 110a, 110b, 110c, 110d. The interconnector plates 120a, 120b, 120c, 120d are used to connect the battery cells 112 in series and parallel, as the case may be. The battery pack 10 further includes a separator plate 30 disposed between each of the plurality of battery modules 102, 104. The separator plate 30 is adapted to electrically insulate the plurality of battery modules 102, 104 from each other. In the illustrated embodiment, the separator plate 30 is disposed in between the two battery modules 102, 104.
[020] Figure 3 illustrates a perspective view of an exemplary cell holder plate 160 of the battery module 102, 104 with a plurality of battery cells 112, in accordance with an embodiment of the present subject matter. Each battery module 102, 104 includes a cell holder plate 160. In an embodiment, each cell holder plate 160 has a plurality of cell holders 162 projecting orthogonally from the cell holder plate 160. The plurality of cell holders 162 are used to hold the battery cells 112 firmly and isolate them from each other to prevent external short circuit. In the illustrated embodiment, the plurality of cell holders 162 are adapted to receive the plurality of battery cells 112 to be arranged in the four cell stacks 110a, 110b, 110c, 110d. In another embodiment, at least one cell stack 110a, 110b, 110c, 110d has the plurality of battery cells 112 arranged in at least four columns of battery cells 112. In the illustrated embodiment, three cell stacks 110a, 110b, 110c have the battery cells 112 arranged in four columns of battery cells 112 in the corresponding plurality of cell holders 162. The fourth cell stack 110d, however has only two columns of the plurality of cell holders 162 and the battery cells 112 are arranged in four columns of battery cells 112 in the corresponding plurality of cell holders 162. In the illustrated embodiment, first two columns of battery cells 112 of the cell stacks 110a, 110b, 110c, 110d are connected with each other in parallel. Similarly, third and fourth columns of battery cells 112 of the cell stacks 110a, 110b, 110c are also connected with each other in parallel. The set of battery cells 112 in first column and second column of the cell stacks 110a, 110b, 110c are connected in series with the set of battery cells 112 in third column and fourth column of battery cells 112 of the cell stacks 110a, 110b, 110c by means of the interconnector plates 120a, 120b, 120c, 120d.
[021] Figure 4 illustrates a top view of the battery pack 10, in accordance with an embodiment of the present subject matter. In an embodiment, the battery pack 10 includes a busbar 170 disposed on the plurality of battery modules 102, 104. The busbar 170 is adapted to electrically connect the plurality of battery modules 102, 104 with each other. In the illustrated embodiment, the busbar 170 is used to join the two battery modules 102, 104 in series. In another embodiment, the busbar 170 also acts as an interconnector by connecting the two battery modules 102, 104 with each other. In a further embodiment, a fuse 174 is disposed on the plurality of battery modules 102, 104. The fuse 174 is provided to protect the battery pack 10 in instances of electricity surges. In yet another embodiment, a plurality of voltage sensing points 130 are provided on the plurality of battery modules 102, 104. The plurality of voltage sensing points 130 are adapted to measure voltage across the plurality of battery cells 112 of each of the corresponding cell stacks 110a, 110b, 110c, 110d.
[022] Figure 6 illustrates an elevation view of the battery pack 10, in accordance with an embodiment of the present subject matter. Each interconnector plate 120a, 120b, 120c, 120d overlaps with the plurality of battery cells 112 arranged in the columns of battery cells 112 of the corresponding cell stack 110a, 110b, 110c, 110d. Each interconnector plate 120a, 120b, 120c, 120d extends over the width of the columns of battery cells 112 of the corresponding cell stack 110a, 110b, 110c, 110d. In the illustrated embodiment, each interconnector plate 120a, 120b, 120c, 120d overlaps with all the battery cells 112 arranged in the corresponding cell stack 110a, 110b, 110c, 110d. In the illustrated embodiment, the interconnector plates 120a, 120b, 120c, 120d which are covering the four adjacent columns of battery cells 112 provide more surface area for electricity to flow. This increased surface area of the interconnector plates 120a, 120b, 120c, 120d reduces resistance to flow of electricity in the interconnector plates 120a, 120b, 120c, 120d. Wider interconnectors 120a, 120b, 120c, 120d provide more surface area for electricity flow leading to increased conductance and reduced resistance, thus preventing unequal voltage measurement loss from adjacent parallel columns of battery cells 112 of the corresponding cell stack 110a, 110b, 110c, 110d.
[023] Figure 7 illustrates a perspective view of the battery pack 10 with a BMS module 150, in accordance with an embodiment of the present subject matter. A BMS module 150 is disposed on the plurality of battery modules 102, 104. The BMS module 150 is adapted to manage the plurality of battery modules 102, 104. In the illustrated embodiment the two battery modules 102, 104 are connected to a single BMS module 150. Each cell stack 110a, 110b, 110c, 110d provides data related to SOC, SOH, battery cell temperature, and the like of the battery cells 112 of the cell stack 110a, 110b, 110c, 110d to the BMS module 150 for monitoring and controlling function and operation of the battery pack 10. The BMS module 150 collects all relevant data from the battery pack 10 via the plurality of voltage sensing points 130, which are communicatively coupled to the BMS module 150. In the illustrated embodiment, the BMS module 150 is directly placed on the plurality of voltage sensing points 130 to measure the voltage of columns of the battery cells 112 of each cell stack 110a, 110b, 110c, 110d and communicate the same to the BMS module 150. The BMS module 150 safeguards the battery pack 10 by maintaining the battery pack 10 within the recommended safety operating limits of the battery pack 10 including current, voltage, temperature. In an embodiment, the battery pack 10 includes a PCB board disposed between the plurality of voltage sensing points 130 and the BMS module 150, such that the PCB board is adapted to electrically connect the plurality of voltage sensing points 130 to the BMS module 150. Hence, the PCB can be used to electrically connect the BMS module 150 and the plurality of battery modules 102, 104. If the battery pack 10 by design and construction fits well on the plurality of battery modules 102, 104 so as to establish a reliable connection for electrical communication between them, the BMS module 150 is directly mounted on the plurality of voltage sensing points 130 and are electrically and mechanically connected. However, if the BMS module 150 used is of a different design, then a PCB suited to the design of the battery pack 10 can be made to form a connection between the plurality of battery modules 102, 104 and the BMS module 150.
[024] Figure 8 illustrates a top view of the battery pack 10, in accordance with an embodiment of the present subject matter. In an embodiment, the BMS module 150 has a first cut out 152 to accommodate the bus bar 170. In another embodiment, the BMS module 150 has a second cut out 154 to accommodate the fuse 174.
[025] Figure 9 illustrates a perspective view of an exemplary interconnector plate 120a, 120b, 120c of the battery pack 10, in accordance with an embodiment of the present subject matter. Figure 10 illustrates a perspective view of an exemplary interconnector plate 120d corresponding to a pair of cell stacks 110d disposed at a distal end of the battery pack 10, in accordance with an embodiment of the present subject matter. Referring to Figures 2, 7, 9 and 10, each of the interconnector plates 120a, 120b, 120c, 120d has a tapping arm 122 extending orthogonally from an edge of the interconnector plate 120a, 120b, 120c, 120d. The tapping arm 122 is provided so as to be disposed between the corresponding cell stack 110a, 110b, 110c, 110d and the BMS module 150. The tapping arm 122 corresponding to each interconnector plate 120a, 120b, 120c, 120d is electrically and physically connected to the corresponding voltage sensing point 130 of the corresponding cell stack 110a, 110b, 110c, 110d. In an embodiment, the interconnector plates 120a, 120b, 120c, 120d can be welded or fastened to the corresponding voltage sensing point 130. In an embodiment, the tapping arm 122 is provided to the centre of each of the interconnector plates 120a, 120b, 120c, 120d. The centred location of the tapping arm 122 on the interconnector plates 120a, 120b, 120c, 120d prevents unequal losses of voltage measurement of adjacent columns of battery cells 112 of the cell stacks 110a, 110b, 110c, 110d. This ensured that the most accurate voltage measurement is achieved for monitoring purposes of the battery pack 10 by the BMS module 150. Further, since the tapping arms 122 of each of the interconnector plates 120a, 120b, 120c, 120d can be placed on one single side of each of the plurality of battery modules 102, 104, the mounting points of the BMS module 150 on the corresponding voltage sensing points 130 which are connected to the corresponding the tapping arms 122 can be provided on the same side of the battery pack 10. This would help to mount the BMS module 150 directly on the plurality of battery modules 102, 104 which would prevent the need for external relays and current sensors required in case of mounting the BMS module 150 with cables on opposite sides of the battery pack 10. This also reduces the part count as now only a single BMS module 150 is used. In another embodiment, to reduce resistance of current flow path, a cross-sectional area of the interconnector plates 120a, 120b, 120c, 120d or the busbar 170 or wires used for electrical connection in the battery pack 10 may be increased.
[026] In an embodiment, the interconnector plate 120d corresponding to a pair of cell stacks 110d disposed at a distal end of the battery pack 10 comprise a secondary arm 124 extending orthogonally from an edge of the interconnector plate 120d. The secondary arm 124 is disposed between the cell stack 110d and the BMS module 150. The secondary arm 124 is also adjacent to the tapping arm 122 of the corresponding interconnector plate 120d. In an embodiment, the secondary arm 124 of the interconnector plate 120d corresponding to a pair of cell stacks 110d disposed at a distal end of the battery pack 10 are power interconnectors configured to draw power from the battery pack 10 to drive an external load. In the illustrated embodiment, two secondary arms 124 corresponding to the two battery modules 102, 104 are provided as power interconnectors. The power interconnectors have a positive polarity and a negative polarity respectively and is disposed at both the ends of the battery module 102, 104to take power connection out of the battery pack 10. In an embodiment, electric power is drawn from the power interconnectors of the battery pack 10 to operate a vehicle and related loads on the vehicle.
[027] Figure 11 illustrates a perspective view of an exemplary casing 20 of the battery pack 10, in accordance with an embodiment of the present subject matter. The casing 20 includes a shell 22 with a hollow space adapted to receive the plurality of battery modules 102, 104, a bottom cover 24 attached to the shell 22 to cover the hollow space from a bottom of the shell 22, and a top cover 26 attached to the shell 22 to cover the hollow space from a top of the shell 22.
[028] Figure 12 illustrates a perspective view of an exemplary separator plate 30 of the battery pack 10, in accordance with an embodiment of the present subject matter. The separator plate 30 includes at least one through hole 32 adapted to receive a fastener to detachably attach each of the corresponding battery modules 102, 104 to the separator plate 30. In the illustrated embodiment, the separator plate 30 electrically isolates the two battery modules 102, 104 from each other and aids in the overall assembly of the battery modules 102, 104 with the casing 20. The separator plate 30 acts as a mechanical barrier between the plurality of battery modules 102, 104. In an embodiment, the separator plate 30 is a fibre part. In another embodiment, the separator plate 30 is metal. A metallic separator plate 30 is preferred when it is used to fasten the plurality of battery modules 102, 104 to the casing 20. The metallic separator plate 30 will also help in radiating heat generated in the plurality of battery cells 112 of the battery pack 10 out from the respective battery modules 102, 104. In yet another embodiment, a gap filler or a thermal pad is disposed between each of the plurality of battery modules 102, 104 modules and the corresponding separator plate 30 to make the battery cells 112 of each of the plurality of battery modules 102, 104 electrically isolated from the battery cells 112 of the other modules 102, 104.
[029] Referring to Figures 5, 11 and 12, the separator plate 30 includes a plurality of mounting brackets 35 integrally formed with the separator plate 30 and projecting orthogonally from edges of the separator plate 30. The plurality of mounting brackets 35 are adapted to detachably attach the separator plate 30 to the casing 20. In another embodiment, the casing 20 includes a fastening means 25 corresponding to each mounting bracket 35. The fastening means 25 is adapted to receive a fastener to detachably attach the separator plate 30 to the casing 20, thus providing mechanically stable assembly of the plurality of battery modules 102, 104 in the battery pack 10. In the illustrated embodiment, the separator plate 30 and plurality of mounting brackets 35 allow the plurality of battery modules 102, 104 to be fitted securely in the casing 20. One single fastener each, is used to mount each of the plurality of battery modules 102, 104 on the separator plate 30. The single fastener passes through an opening 32 provided in the separator plate 30. In the illustrated embodiment, there are two such openings 32, which are placed diagonally from each other on the separator plate 30 through which each fastener passes to mount the plurality of battery modules 102, 104 to the the separator plate 30.
[030] Advantageously, the present claimed invention provides a battery pack and an improved design of an interconnector plate to reduce electrical resistance and thus increase current density, leading to reduction in energy and data loss and reduction in production of heat in the battery pack. The present invention achieves an increase in the surface area of the interconnector plates to increase current flow path so that resistance loss is reduced. Further, voltage measurement error due to disposition of the tapping arm is eliminated. The use of a single common BMS module simplifies BMS installation and reduces part count, and cost. Electrical and mechanical isolation is provided between the plurality of battery modules by a separator plate, making the battery pack safer. The separator plate also provides mechanical support to the battery pack and facilitates easy assembly of the plurality of battery modules of the battery pack. Further, design improvements leading to reduction in transmission losses and heat generation enhances the overall performance of the battery pack. The present invention provides better aesthetics with a single casing of the battery pack, instead of having multiple battery packs with different battery modules being placed in different casings. Since wiring harnesses have been eliminated in connecting the plurality of battery modules to each other and to the BMS, ease in assembly is achieved. Part count reduction is achieved by eliminating use of wiring harnesses, decreasing the number of interconnectors used, employing a single common BMS to connect the plurality of battery modules. This also aids in weight reduction of the battery pack.
[031] The claimed configurations of the battery pack as discussed above are not routine, conventional, or well understood in the art, as the claimed configurations of the battery pack enable the following solutions to the existing problems in conventional technologies. Specifically, the present invention achieves an increase in the surface area of the interconnector plates to increase current flow path so that resistance loss is reduced. Further, voltage measurement error due to disposition of the tapping arm is eliminated. The use of a single common BMS module simplifies BMS installation and reduces cost. Electrical and mechanical isolation is provided between the plurality of battery modules by a separator plate, making the battery pack safer. The separator plate also provides mechanical support to the battery pack and facilitates easy assembly of the plurality of battery modules of the battery pack. Further, design improvements leading to reduction in transmission losses and heat generation enhances the overall performance of the battery pack. The present invention provides better aesthetics with a single casing of the battery pack, instead of having multiple battery packs with different battery modules being placed in different casings. Since wiring harnesses have been eliminated in connecting the plurality of battery modules to each other and to the BMS, ease in assembly is achieved. Part count reduction is achieved by eliminating use of wiring harnesses, decreasing the number of interconnectors used, employing a single common BMS to connect the plurality of battery modules. This also aids in weight reduction of the battery pack. Hence, the present claimed invention achieves a battery pack with an improved design of an interconnector plate to reduce electrical resistance and thus increase current density, leading to reduction in energy and data loss and reduction in production of heat in the battery pack. It further achieves a sturdier and stabler assembly of constituent components of the battery pack.
[032] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims. , Claims:WE CLAIM:
1. A battery pack (10) comprising:
a plurality of battery modules (102, 104) disposed beside one another, each battery module (102, 104) having a plurality of battery cells (112) arranged in at least one cell stack (110a, 110b, 110c, 110d);
a BMS module (150) disposed on the plurality of battery modules (102, 104) and configured to manage the plurality of battery modules (102, 104);
an interconnector plate (120a, 120b, 120c, 120d) corresponding to each cell stack (110a, 110b, 110c, 110d) disposed on a side of the corresponding battery module (102, 104) and configured to electrically connect the plurality of battery cells (112) of the cell stack (110a, 110b, 110c, 110d); and
a separator plate (30) disposed between each of the plurality of battery modules (102, 104) and configured to electrically insulate the plurality of battery modules (102, 104) from each other;
wherein at least one cell stack (110a, 110b, 110c, 110d) having the plurality of battery cells (112) arranged in at least four columns;
the interconnector plate (120a, 120b, 120c, 120d) overlaps with the plurality of battery cells (112) arranged in the columns of the corresponding cell stack (110a, 110b, 110c, 110d); and
the interconnector plate (120a, 120b, 120c, 120d) having a tapping arm (122) extending orthogonally from an edge of the interconnector plate (120a, 120b, 120c, 120d) so as to be disposed between the cell stack (110a, 110b, 110c, 110d) and the BMS module (150).

2. The battery pack (10) as claimed in claim 1, wherein the interconnector plate (120d) corresponding to a pair of cell stacks (110d) disposed at a distal end of the battery pack (10) comprise a secondary arm (124) extending orthogonally from an edge of the interconnector plate (120d) so as to be disposed between the cell stack (110d) and the BMS module (150), the secondary arm (124) being adjacent to the tapping arm (122).

3. The battery pack (10) as claimed in claim 2, wherein the secondary arm (124) corresponding to the pair of cell stacks (110d) are power interconnectors configured to draw power from the battery pack (10) to drive a load.

4. The battery pack (10) as claimed in claim 1 comprising a plurality of voltage sensing points (130) communicatively coupled to the BMS module (150), wherein the tapping arm (122) corresponding to each interconnector plate (120a, 120b, 120c, 120d) is electrically and physically connected to the corresponding voltage sensing point (130).

5. The battery pack (10) as claimed in claim 4 comprising a Printed Circuit Board (PCB) disposed between the plurality of voltage sensing points (130) and the BMS module (150), the PCB configured to electrically connect the plurality of voltage sensing points (130) to the BMS module (150).

6. The battery pack (10) as claimed in claim 1, wherein each battery module (102, 104) comprises a cell holder plate (160) having a plurality of cells holders (162) projecting orthogonally from the cell holder plate (160) and configured to receive the plurality of battery cells (112) to be arranged in at least one cell stack (110a, 110b, 110c, 110d).

7. The battery pack (10) as claimed in claim 1 comprising a busbar (170) disposed on the plurality of battery modules (102, 104) and configured to electrically connect the plurality of battery modules (102, 104), the BMS module (150) having a first cut out (152) to accommodate the busbar (170).

8. The battery pack (10) as claimed in claim 1 comprising a fuse (174) disposed on the plurality of battery modules (102, 104), the BMS module (150) having a second cut out (154) to accommodate the fuse (174).

9. The battery pack (10) as claimed in claim 1 comprising a casing (20) having: a shell (22) with a hollow space configured to receive the plurality of battery modules (102, 104); a bottom cover (24) attached to the shell (22) to cover the hollow space from a bottom of the shell (22); and a top cover (26) attached to the shell (22) to cover the hollow space from a top of the shell (22).

10. The battery pack (10) as claimed in claim 9, wherein the separator plate (30) comprises: at least one through hole (32) configured to receive a fastener to detachably attach each of the corresponding battery modules (102, 104) to the separator plate (30); a plurality of mounting brackets (35) integrally formed with the separator plate (30) and projecting orthogonally from edges of the separator plate (30), the plurality of mounting brackets (35) configured to detachably attach the separator plate (30) to the casing (20).

11. The battery pack (10) as claimed in claim 10, wherein the casing (20) comprises a fastening means (25) corresponding to each mounting bracket (35), the fastening means (25) configured to receive a fastener to detachably attach the separator plate (30) to the casing (20).

Dated this 08th day of June 2022
TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471