Description:FIELD OF THE INVENTION
[0001] The present subject matter is related, in general to a battery pack, and more particularly, but not exclusively to an interconnector being configured with a fuse to prevent thermal runaways in a battery pack.
BACKGROUND OF THE INVENTION
[0002] The current situation presents a significant dependency on battery packs for the functioning of electrical and electronic components. Further, in the pursuit of curbing greenhouse emissions, a significant demand has been put upon the technological development of rechargeable battery packs for the purpose of utility in electric and plug-in hybrid vehicles. The application of rechargeable battery packs involving high power applications raises critical concerns regarding safe and secure operation of the battery pack. Consequently, intense research and development persists in the field of battery pack development which deals with detection and diagnosis of miscellaneous or abnormal functioning of the battery pack.
[0003] A battery pack is an electrical energy storage device configured to supply the stored electrical energy to an external load as and when demanded by the external load. The battery pack employ a plurality of battery cells which are connected either in a series configuration or in a parallel configuration. The connection between the plurality of battery cells is secured through one or more interconnectors which provide an electrical connection.
[0004] The phenomenon of thermal runaway occurring in battery packs lead to propagation of fire from the battery pack to the adjacent operational environment of the battery pack causing catastrophic accidents. Thermal runaway is an accelerated release of heat inside the battery cells due to uncontrolled exothermic reactions. In the event of uncontrolled exothermic reactions occurring in the battery pack, the battery cell is no longer capable of dissipating the heat as quickly as it is generated which leads to thermal instability of the battery cell and consequently the battery pack.
[0005] Further, to ensure safety of battery packs, the battery packs should equipped with active paralleling circuits for battery packs having parallel connection of cells and strings. The safety measure should enable isolation of faulty cells and strings in the battery pack in order to eliminate the circulating currents.
[0006] In the pursuit of detection and diagnosis of miscellaneous functioning of the battery pack, the battery pack is provided with a battery management system (hereinafter referred to as BMS). The BMS monitors the health of the battery pack through battery parameters such as voltage, charging current, temperature and state of charge of the battery cells. Typically, the miscellaneous functionality of the battery pack is manifested in the form of an abnormal rise in temperature in the battery pack. The BMS upon sensing the abnormal temperature rise, ceases the functioning of the entire battery pack in coping with the possibility of thermal runaway occurring in the battery pack.
[0007] The techniques known in the art for curbing abnormal functioning of the battery pack results in complete standstill of the functioning of the battery pack and the associated electrical or electronic appliance. While for safety concerns it is acceptable that the entire functioning of the battery pack come to a standstill, a corollary associated cost and time of operation is neglected. Thus, there is a requirement to devise a battery pack which upon detection of abnormal functioning of a cell, isolates that cell from the other cells of the battery pack allowing the other cells of the battery pack continue its operation.
[0008] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.
SUMMARY
[0009] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
[00010] According to embodiments illustrated herein, the present invention provides a battery pack comprising of a plurality of cells. The plurality of cells are connected using one or more busbars where each of the one or more busbars comprises of a plurality of interconnectors. Each interconnector of the busbar is defined by a first portion, a second portion, a third portion, and a fourth portion. The first portion has a curved profile on left and right side of the interconnector, protruding upwardly from the bus bar, wherein both the left curve and the right curve are connected by a first centre portion. The second portion extends downwardly from a substantially middle portion of the first centre portion, the third portion extends downwardly from the second portion and a fourth portion extending parallelly below the bus bar from the third portion. The third portion being extending parallelly to the first centre portion. The fourth portion of the interconnector being configured to connect a plurality of cells of the battery pack. The second portion of the interconnector acts as a fusing element to isolate a malfunctioning cell of the plurality of cells of the battery pack when a current passing through the second portion exceeds a pre-defined current value. The second portion acting as a fusing element isolates the malfunctioning cell from the circuit by confining the risk of fire hazard to the malfunctioning cell. Thus, the fire hazard is not propagated to the adjacent cells of the plurality of cells of the battery pack.
[00011] According to embodiments illustrated herein, the present invention also discloses a busbar comprising of a plurality of interconnectors where each of the plurality of interconnectors is defined by the first portion, the second portion, the third portion, and the fourth portion. The first portion has a curved profile on left and right side of the interconnector, protruding upwardly from the bus bar wherein both the left curve and the right curve are connected by a first centre portion, the second portion extends downwards from a middle portion of the first center portion and the third portion extends downwardly from the second portion, and the third portion is disposed parallelly to the first center portion. The fourth portion extends parallelly below the busbar.
BRIEF DESCRIPTION OF THE DRAWINGS
[00012] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein
[00013] Figure 1 illustrates a block diagram of the battery pack, in accordance with some embodiments of the present disclosure.
[00014] Figure 2 (a) illustrates a top perspective view of the bus bar of the battery pack, in accordance with some embodiments of the present disclosure.
[00015] Figure 2 (b) illustrates a rear perspective view of the bus bar of the battery pack, in accordance with some embodiments of the present disclosure.
[00016] Figure 3 illustrates a perspective view of the interconnector of the battery pack, in accordance with some embodiments of the present disclosure.
[00017] Figure 4 illustrates a perspective view of the interconnector of the battery pack , in accordance with some embodiments of the present disclosure.
DETAILED DESCRIPTION
[00018] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[00019] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[00020] The present invention now will be described more fully hereinafter with different embodiments. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather those embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the invention to those skilled in the art.
[00021] The present invention is illustrated with a battery pack. However, a person skilled in the art would appreciate that the present invention is not limited to a battery pack and certain features, aspects and advantages of embodiments of the present invention can be used with other types and forms of energy storage devices or energy storage packs used in conjunction with various types of vehicles such as electric vehicle and plug-in hybrid vehicles as well as other electrical equipment and external electrical loads using a rechargeable energy storage pack. In an embodiment, the electric vehicles, hybrid vehicle, electrical equipment, external electrical load draw electric current from the energy storage pack.
[00022] It is an object of the present subject matter to provide a battery pack comprising of a plurality of cells configured to isolate a malfunctioning cell from the entire battery pack.
[00023] To this end, the present subject matter discloses a plurality of interconnectors having a second portion configured to act like a fusing element when the current passing through the cell exceeds a pre-defined current value. In the event of an electrical mishap or malfunctioning of a cell of the battery pack, the current circulating through the plurality of cells is dumped on the malfunctioning cell, the second portion of the interconnector connected to the malfunctioning cell would sense the higher current value passing through the malfunctioning cell. In the event the higher current value passing through the malfunctioning cell exceeds a pre-defined current, the second portion of the interconnector connected to the malfunctioning cell acts as a fusing element and will blow-off to isolate the malfunctioning cell from the circuit.
[00024] In accordance with the configuration of the plurality of interconnectors having a second portion acting as a fusing element, the blow-off of the second portion of the interconnector isolates the malfunctioning cell from the plurality of cells of the circuit and protects the functioning of the adjacent cells. The fusing configuration of the second portion of the interconnector reduces the risk of thermal runaway propagating to the adjacent cells of the battery pack and keeps the working environment of the battery pack safe and secure from potential fire hazards.
[00025] Further, in parallel configuration of the plurality of cells of the battery pack the current circulating through the parallel cells is distributed in the entire battery pack. In the event of a cell malfunctioning, the current circulating through the circuit is dumped on the malfunctioning cell which would lead the entire battery pack to go into thermal runaway.
[00026] In accordance with the configuration of the battery pack disclosed in the present subject matter, the second portion of the interconnector connected to the malfunctioning cell senses the rise in temperature of the malfunctioning cell owing to the higher current value passing through the cell. The second portion of the interconnector is configured to blow-off when the current value of the malfunctioning cell exceeds the pre-defined current value, thus isolating the malfunctioning cell from the plurality of cells of the battery pack in parallel configuration.
[00027] It is known in the art, to provide a battery management system (hereinafter referred to as BMS) for assessing and monitoring the state of health and state of charge of the plurality of cells of the battery pack. Any malfunction of a cell of the battery pack would lead to dumping of current on the malfunctioning cell which would lead to rise in temperature of the battery pack. The BMS configured to monitor the state of health and state of charge of the battery pack detects the abnormal rise in temperature and cuts-off or ceases the entire functionality of the battery pack in pursuit of avoidance of thermal runaway in the battery pack. The evident drawback of the BMS as illustrated above results in complete halt of the functionality of the battery pack and the entire electrical equipment or vehicle coming to a standstill.
[00028] The disclosed subject matter addresses this exact drawback of the known art by isolating the malfunctioning cell from the adjacent cells of the battery pack, allowing the battery pack to resume its normal functioning. The halt in the operation of the battery pack yields a wastage of concomitant time, money and energy which the present subject matter appositely solves.
[00029] It is an object of the present subject matter to provide a battery pack configured to isolate a malfunctioning cell without increasing the overall weight and number of components of the battery pack.
[00030] In accordance with the configuration of the plurality of interconnectors, the second portion of the plurality of interconnectors being configured as a neck, which are formed as a fusing element. The second portion of the interconnector are integrated with the interconnector and mounted on the busbars. The present subject matter negates the requirement of equipping the battery pack with additional fusing devices for isolation of malfunctioning cells. Consequently, the overall weight of the battery pack and the number of components of the battery pack is reduced. Further, the overall cost associated with the battery pack as per the present subject matter is significantly reduced. The associated manufacturing and assembly time of the battery pack is also reduced in accordance with the present disclosure.
[00031] In accordance with the configuration of the present subject mattery, the usage of interconnectors integrated with a second portion acting as fusing element reduces the number of components of the battery pack and eases and enhances the accessibility, serviceability and maintenance of the components of the disclosed battery pack.
[00032] It is known in the art to provide additional electrical fuses connected to printed circuit boards (hereinafter referred to as PCBs) in connection with the battery pack to isolate the malfunctioning battery pack. However, the disclosed configuration known in the art results in an excessive increase in the number of components associated with the battery pack and the corresponding weight of the battery pack. Further, addition of extra components such as electrical fuses connected to PCBs increases the manufacturing and assembly time of the battery pack as well as the cost associated with the battery pack. The configuration of the known art further apprehensively impacts the serviceability, maintainability, and accessibility of the components of the battery pack as already known in the prior art.
[00033] Further, the disclosed subject matter relating to an interconnector with the second portion being configured as neck of the interconnector acts as a fusing element, which can be easily implemented in traditional battery pack and energy storage pack configuration and layout without significant manufacturing deviations. The disclosed subject matter enables modified versions of existing battery packs with minimal changes in the battery pack design, electrical connections in the battery pack and even the manufacturing set-up without major revamping of the core manufacturing process.
[00034] In accordance with the configuration of the disclosed subject matter, an additional advantage of the disclosed battery pack is the flexibility to manufacture variants in forms of size of the battery pack, range of power supply and capacity of the battery pack.
[00035] The embodiments of the present invention will now be described in detail with reference to a battery pack along with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[00036] Figure 1 illustrates a block diagram of the battery pack, in accordance with some embodiments of the present disclosure.
[00037] With reference to Figure 1, 100 denotes a battery pack for supplying stored electrical energy to an external electrical load, 102 denotes a plurality of cells, 104 denotes one or more bus bars and 106 denotes a plurality of interconnectors. With reference to the plurality of interconnectors, 108a denotes a first portion of the interconnector, 108b denotes a second portion of the interconnector,108c denotes a third portion of the interconnector, and 108d denotes a fourth portion of the interconnector.
[00038] In an embodiment, the battery pack 100 comprises of a plurality of cells 102. The plurality of cells 102 are connected used one or more bus bars 104. Each bus bar 104 further comprises a plurality of interconnectors 106.
[00039] In an embodiment, the battery pack 100 disclosed in relation to the present subject matter includes any electrical equipment configured to store electrical energy and may include an energy storage pack, a plurality of battery cells 102, a plurality of battery modules and other forms of electrical energy storage equipment. The battery pack 100 is rechargeable and is configured to have a charged and discharged state. In a charged state of the battery pack, the battery pack 100 supplies the stored electrical energy to an external electrical load, an electrical or electronic equipment, electric or hybrid vehicle as and when required.
[00040] In an aspect of the present invention, the battery pack 100 comprises of a plurality of cells 102. The plurality of cells 102 of the battery pack 100 are connected in either in series configuration or parallel configuration based on the intended use of the battery pack 100.
[00041] In an aspect of the present invention, the connection of the plurality of cells 102 in series or parallel is based on the sector in which the battery pack 100 is utilised, and the energy demands of the external electrical load, electrical or electronic equipment or the electric vehicle. The difference in series configuration and parallel configuration of the plurality of the cells 102 is the impact the same holds on the output voltage of the battery pack 100 and the capacity of the battery pack 100. The plurality of cells 102 of the battery pack 100 are connected in a parallel configuration when the current flowing through the battery pack 100 is to be distributed in the entire battery pack 100. In the event of an electrical shock because of a cell malfunctioning, the parallel configuration of the plurality of cells 102 would lead to the occurrence of thermal runaway in the entire battery pack 100 leading to a fire hazard in the entire battery pack 100. During malfunctioning of the cell, the current circulating through the pack is dumped on that cell leading to thermal runaway in the battery pack.
[00042] In an embodiment, the plurality of cells 102 is connected using one or more busbars 104. The plurality of cells 102 may be connected in series or in parallel. The one or more busbars 104 connecting the plurality of cells 102 ensure electrical connectivity between the plurality of cells 102 and carry current in the circuit of the battery pack 100.
[00043] In an aspect of the present invention, the one or more busbars 104 are composed of a material. The material used for composition of the one or more busbars 104 is selected from at least one of or a combination of nickel and copper. The material used for one or more busbars 104 should allow electrical connectivity between the plurality of cells 102 in the battery pack 100.
[00044] In an aspect of the present invention, the battery pack 100 comprises a plurality of battery modules and each battery modules comprises of a plurality of battery cells 102. The one or more busbars 104 connect the plurality of cells 102 as well as the plurality of battery modules either in series configuration or parallel configuration.
[00045] In an embodiment, the one or more busbars 104 comprises a plurality of interconnectors 106. The plurality of cells 102 are connected to each other using interconnectors 106. The plurality of interconnectors 106 are spot welded on each cell terminal of the plurality of cells 102. The plurality of interconnectors 106 help in carrying electric current from each cell of the plurality of cells 102 in the battery pack 100.
[00046] In an embodiment, each interconnector of the plurality of interconnectors 106 is defined by a first portion 108a, a second portion 108b, a third portion 108c, and a fourth portion 108d.
[00047] Figure 2(a) illustrates a top perspective view of the busbar of the battery pack, in accordance with some embodiments of the present disclosure. Figure 2(b) rear perspective view of the bus bar of the battery pack, in accordance with some embodiments of the present disclosure. For the sake of brevity, Fig.2a and 2b will be discussed together.
[00048] With reference to figure 2(a) and 2(b), 104 denotes a bus bar, 106 denotes the plurality of interconnectors 106 with 108b denoting a second portion of the interconnector and 108c denoting a third portion of the interconnector, and 108c denoting the third portion of the interconnector.
[00049] With reference, to figure 2(a) and 2(b), the bus bar 104 comprises a plurality of interconnectors 106. The plurality of interconnectors 106 is connect to the plurality of cells through a negative terminal (not shown) or a positive terminal (not shown). The plurality of cells is disposed beneath the plurality of interconnectors 106. The bus bar 104 also includes plurality of openings 104a. The plurality of openings 104a are configured to dissipate heat from the plurality of cells.
[00050] In an aspect of the present invention, the plurality of interconnectors 106 are disposed along plurality of columns on the bus bar 104. As per yet another embodiment of the present invention, the columns of the plurality of interconnectors 106 being disposed either along a left side of the bus bar 104, or along the right side of the bus bar 104, or along the all the side of the bus bar 104.
[00051] In an aspect of the present invention, the present subject matter additionally discloses a busbar 104. The busbar 104 comprises of a plurality of interconnectors 106 with each interconnector 106 being defined by a first portion 108a (shown in Figure 3), a second portion 108b, a third portion 108c, and a fourth portion 108d.
[00052] In an aspect of the present invention, the first portion 108a extends upwardly from the busbar 104 through protruding left curve 108aa, and a right curve 108ab; the second portion 108b extends downwardly from a middle portion of the first centre portion 108a and the third portion 108c which extends downwardly from the second portion 108b. The fourth portion 108d extends parallelly below the busbar 104.
Figure 3 illustrates a top perspective view of an interconnector 106 of the battery pack 100, in accordance with some embodiments of the present disclosure. Figure 4 illustrates a top perspective view of an interconnector of the battery pack, in accordance with another embodiments of the present disclosure. For the sake of brevity, Fig.3 and 4 will be discussed together for sake of brevity.
[00053] In an aspect of the present invention, the first portion 108a comprises a left curve 108aa and right curve 108ab on the left and right side of the interconnector respectively. The left curve 108aa and right curve 108ab protrude upwardly from a portion of the bus bar 104 of the battery pack 100. The left curve 108aa and the right curve 108ab are connected to each other by a first centre portion 108ac of the first portion 108a.
[00054] In an aspect of the present invention, the second portion 108b of the interconnector extends downwardly from a middle portion of the first centre portion 108ac of the interconnector 106.
[00055] In an aspect of the present invention, the third portion 108c of the interconnector extends downwardly from the second portion 108b of the interconnector 106, wherein the third portion 108c being extending parallelly from the first centre portion 108ac.
[00056] Further, as per an aspect of the present invention the fourth portion 108d of the interconnector extends parallelly below the busbar, wherein the fourth portion 108d being configured to connect to a terminal of the plurality of cells disposed beneath the fourth portion 108d.
[00057] In an aspect of the present invention, the width of the second portion 108b of the interconnector 106 is lesser than the width of the first centre portion 108ac and the width of the third portion 108c of the interconnector 106.
[00058] In an aspect of the present invention, the cross-sectional area of the second portion 108b of the interconnector 106 has an associated diameter of 0.2mm.
[00059] In operation, the second portion 108b of the interconnector 106 is configured to possess a high resistance in comparison to the resistance of the first centre portion 108ac and the third portion 108c of the interconnector 106. The width of the second portion 108b of the interconnector 106 being less than the width of the first centre portion 108ac and the third portion 108c results in decreased resistance of the second portion 108b.
[00060] In an embodiment, the second portion 108b of the interconnector 106 is composed of a material different from the material used for composing the first portion 108a, the third portion 108c, and the fourth portion 108d. The material selected for composing the second portion 108b possesses a higher resistivity in comparison to the material selected for composing the first centre portion 108a and the third portion 108c of the interconnector 106.
[00061] In an embodiment, the material used for composing the second portion 108b of the interconnector 106 is same as the material used for composing the first portion 108a and the third portion 108c of the interconnector. The width of the second portion 108b being lesser than the first portion 108a and the third portion 108c results in increased resistivity of the second portion 108b despite the same material being used in the composition of the first portion 108a, second portion 108b and the third portion 108c.
[00062] In an aspect of the present invention, the material used for composing at least one of the first portion 108a, second portion 108b, the third portion 108c, and the fourth portion 108d of the interconnector 106 comprises of two or more distinct metals or alloys having different properties. The two or more distinct metals or alloys used in composing the material must possess electrical conductivity to allow passage of electric current through the plurality of cells 102 connected by the interconnector 106.
[00063] In an aspect of the present invention, the two or more distinct metals or alloys used for composing the material are metallurgically bonded together to achieve the functional benefits which are otherwise deemed unachievable by a single metal.
[00064] In an aspect of the present invention, the material used for composing at least one of the first portion 108a, the second portion 108b, the third portion 108c and the fourth portion 108d of the interconnector 106 is selected from a combination of at least one of aluminium, nickel and copper.
[00065] In an embodiment, the plurality of interconnectors 106 is modified as the second portion 108b being configured as a neck of the interconnector which acts as a fuse when the current flowing through the respective connected cell exceeds a pre-defined current value.
[00066] For example, the pre-defined current value in the second portion 108b of the interconnector 106 for fusing purposes is 10 A and there are 5 cells of the plurality of cells 102 connected in parallel and configured to carry a maximum of 8A of current. In the unfortunate event of an electrical mishap where one cell behaves abnormally or is deemed to malfunction, the electric current flowing through the plurality of cells 102 is dumped on the malfunctioning cell. The second portion 108b of the interconnector having necks formed carries the current flowing through the plurality of cells 102. The current passing through the interconnector 106 is sensed by the second portion 108b and when the current passing through the interconnector 108b exceeds 10A, the heat generated due to the high current is transmitted to the second portion 108b. In the event of the current passing through the second portion 108b of the interconnector exceeding 10A, the second portion would blow out due to the transmitted heat, disconnecting or isolating the malfunctioning cell from the plurality of cells 102.
[00067] The above-mentioned example is only provided in pursuit of clarity, illustration and elucidation purposes of the present subject matter and shall not be construed to limit the scope of the present subject matter to abovementioned aspects of the invention.
[00068] The disclosed configuration of the present subject matter isolates the malfunctioning cell from the circuit without any hinderance in operation being caused to the adjacent cell and reducing the risk of fire hazard in the battery pack 100. Owing to the disclosed configuration of the battery pack 100, thermal runaway in the battery pack 100 is not only restricted or confined but also protection is accorded to the operational environment of the battery pack 100.
[00069] In an embodiment, the fourth portion 108d of the interconnector 106 is configured to have a plurality of openings 108da. The plurality of openings 108da of the fourth portion 108d enable spot welding of the fourth portion 108d of the interconnector 106 to at least one of a positive terminal or a negative terminal of a respective cell of the cell of the plurality of cells 102 of the battery pack 100.
[00070] In an aspect of the present invention, the interconnector has necks formed in the second portion 108b of the interconnector 106 which act as fuse when the current passing through the interconnector 106 and the plurality of cells 102 surpasses a pre-defined current.
[00071] In an aspect of the present invention, the neck formed in the second portion 108b of the interconnector 106 is offset to a centre line of a welding zone of each of the interconnector 106. The disclosed configuration of the second portion 108b permits numerous possibilities in developing different layouts for the interconnector 106 as well as the battery pack 100.
[00072] In an aspect of the present invention, the neck formed in the second portion 108b of the interconnector 106 is formed on a portion of the second portion 108b such as the extreme ends or at a dead centre of the interconnector 106.
[00073] As an illustration shown in figure 5, the second portion 108b is provided at an offset from the centre portion of the interconnector 106. A pre-defined current in the second portion 108b of the interconnector 106 for fusing purpose is configured to be 10A. Figuratively, 4 cells of the battery pack are connected in parallel configuration with each cell configured to carry a maximum current of 8A. In the event of an electrical mishap where one of the 4 cells behave abnormally, the electric current flowing through the 4 cells is dumped on the abnormally functioning cell leading to heat generation in the malfunctioning cell. Upon the current being dumped on the malfunctioning cell, the current sensed at the interconnector of the malfunctioning cell exceeds the pre-defined current of 10A. The second portion 108b of the interconnector having necks senses the exceeded current and blows-out due to the transmitted heat and isolates the malfunctioning cell from the circuit of the battery pack 100.
[00074] In an embodiment, the plurality of interconnectors 106 are communicatively connected to an electronic component where the electronic component is configured to alert authorities in the event of a detected blow-off of the fusing element of the second portion 108b of the interconnector 106.
[00075] In an aspect of the present invention, the plurality of interconnectors 106 are electrically connected to the electronic component. In another aspect of the present subject matter, the plurality of interconnectors is wirelessly connected to the electronic component.
[00076] In an aspect, the authorities alerted in the event of a blow-off include a user of the electrical equipment or the vehicle as well as maintenance authorities to ensure a quick response to replace the blow-off second portion 108b.
[00077] The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the invention(s)” unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but not limited to”, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.
[00078] The disclosed claimed limitations and the disclosure provided herein provides a battery pack 100 with an interconnector 106 configuration. The claimed invention in an aspect provides enhanced safety and security in the operating environment of the battery pack 100. In an embodiment, the interconnector 106 comprises of a second portion 108b acting as a fusing element which is configured to blow-off once the current passing through the interconnector exceeds a pre-defined current resulting in isolation of the malfunctioning cell from the plurality of cells and allowing the other cells of the battery pack to resume their normal operation.
[00079] In an aspect, the blow-off of the second portion of the interconnector prevents the occurrence of thermal runaway in the battery pack and maintains a safe operational environment of the battery pack.
[00080] In an aspect, the blow-off of the second portion of the interconnector ensures the normal functioning of the other cells of the battery pack without halting of the overall functioning of the battery pack. The disclosed configuration in turn saves money, time and energy by allowing normal functioning of the battery pack after isolating the malfunctioning cell.
[00081] In an aspect, the disclosed configuration of the battery pack does not require the involvement of additional semiconductor components to isolate the malfunctioning cell by forming necks in the interconnector itself. Consequently, the disclosed configuration does not affect the overall weight, number of components and cost of the battery pack.
[00082] Further, in accordance with the present disclosure, the disclosed configuration enhances accessibility, serviceability and maintenance of the battery pack. Additionally, the disclosed configuration allows adaptability of the interconnector configuration in conventional battery pack without any significant deviations or revamping of the core manufacturing process.
[00083] In an aspect, the disclosed battery pack adheres to the Rechargeable Electrical Energy Storage System (REESS) against events of thermal runaway in cells connected in parallel. Keeping in mind the safety features, active paralleling circuits for parallel connection of cells and strings shall be provided with semiconductor devices to eliminate circulating currents. The power semiconductor devices used for interconnecting the strings and cells are to act as safety switched in the event of detection of any faulty strings or cells and consequently the power semiconductor devices should be configured to isolate the faulty cells and strings. The power semiconductor devices shall allow bidirectional flow of currents for charging and discharging of the battery pack. It is necessary to have an active paralleling in battery packs. Alternatively, fuses or bond wires can be used to prevent circulation of currents flowing through the cells connected in parallel in a battery pack in the event of an electrical mishap. The fuses or bond wires used isolate the faulty cells connected in parallel.
[00084] The disclosed subject matter provides necks formed in the interconnector which act as fusing element for isolating faulty or malfunctioning cell in the battery pack in the event the current circulating through the cells exceeds a predefined current.
[00085] In light of the above-mentioned advantages and the technical advancements provided by the disclosed method and system, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the device itself as the claimed steps provide a technical solution to a technical problem.
[00086] A description of an embodiment with several components in communication with another does not imply that all such components are required, On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention,
[00087] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[00088] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[00089] The present disclosure may be realized in hardware, or a combination of hardware and software. The present disclosure may be realized in a centralized fashion, in at least one computer system, or in a distributed fashion, where different elements may be spread across several interconnected computer systems, a computer system or other apparatus adapted for carrying out the methods described herein may be suited. A combination of hardware and software may be a general-purpose computer system with a computer program that, when loaded and executed, may control the computer system such that it carries out the methods described herein. The present disclosure may be realized in hardware that comprises a portion of an integrated circuit that also performs other functions.
[00090] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[00091] Those skilled in the art will appreciate that any of the aforementioned steps and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and system modules, and are not limited to any particular computer hardware, software, middleware, firmware, microcode, and the like. The claims can encompass embodiments for hardware and software, or a combination thereof.
[00092] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure is not limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
, C , Claims:I/We claim:
1. A battery pack (100) comprising:
a plurality of cells (102),
wherein each of the plurality of cells (102) being connected using one or more busbars (104),
wherein each of the one or more busbars (104) comprises of a plurality of interconnectors (106), each of the plurality of the interconnectors (106) being configured to connect to respective cells of the plurality of cells (102),
wherein each of the plurality of interconnectors (106) comprises:
a first portion (108a), the first portion (108a) comprise a left curve (108aa) and a right curve on left and right side of the interconnector respectively, the left and right curve (108aa, 108ab) being protruding upwardly from a portion of the one or more bus bars (104),
wherein each of the left curve (108aa) and the right curve (108ab) being connected by a first centre portion (108ac) of the first portion (108a),
a second portion (108b) extending downwardly from a portion of the first center portion (108ac),
a third portion (108c), extending downwardly from the second portion (108b) and being parallel to the first centre portion (108ac), and
a fourth portion (108d) extending from the third portion (108c) parallelly below the one or more busbars (104).
2. The battery pack (100) as claimed in claim 1, wherein the second portion (108b) being extending from a middle portion of the first center portion (108ac).
3. The battery pack (100) as claimed in claim 1, wherein the second portion (108b) being configured to act as a fusing element when an amount of current passing through the any of the respective plurality of cells (102) exceeds a predetermined value.
4. The battery pack (100) as claimed in claim 1, wherein the second portion (108b) being disposed offset to a centre line of a welding zone on each of the plurality of interconnectors (106).
5. The battery pack (100) as claimed in claim 1, wherein the second portion (108b) being disposed on either on extreme ends or at a centre portion of the each of the plurality of interconnectors (106).
6. The battery pack (100) as claimed in claim 1, wherein the width of the second portion (108b) being less than the first center portion (108ac) and the third portion (108c), whereby the first center portion (108ac), the second portion (108b), and the third portion being configured to form an “I” shaped profile.
7. The battery pack (100) as claimed in claim 1, wherein the cross-sectional area of the second portion (108b) being 0.2mm.
8. The battery pack (100) as claimed in claim 5, wherein resistance of the second portion (108b) being higher as compared to resistance of the first center portion (108ac) and resistance of the third portion (108c).
9. The battery pack (100) as claimed in claim 1, wherein a material of the second portion (108b) being different from that of the first center portion (108ac) and the third portion (108c), wherein resistivity of the second portion (108b) being higher than resistivity of the first center portion (108ac) and the third portion (108c).
10. The battery pack (100) as claimed in claim 1, wherein material of the second portion (108b) being same as that of the first center portion (108ac) and the third portion (108c), wherein resistivity of the second portion (108b) being higher than the resistivity of the first center portion (108ac) and the third portion (108c) as the width of the second portion (108b) being less than the first portion (108a) and third portion (108c).
11. The battery pack (100) as claimed in claim 9, wherein the material of the second portion (108b) being made of two or more distinct metals or alloys having varied properties, wherein the two or more distinct metals or alloys being metallurgically bonded together to achieve functional benefits.
12. The battery pack (100) as claimed in claim 11, wherein the material being made from a combination of aluminium, nickel and copper.
13. The battery pack (100) as claimed in claim 1, wherein the one or more busbars (104) being made from either of nickel or copper.
14. The battery pack (100) as claimed in claim 1, wherein the fourth portion (108d) comprises a plurality of openings (108da), wherein the plurality of openings (108da) enables spot welding of the fourth portion (108d) to at least one of a positive terminal or a negative terminal of the plurality of cells (102) of the battery pack (100).
15. A busbar (104), the busbar (104) comprising of a plurality of interconnectors (106):
wherein each of the plurality of interconnectors (106) comprises:
a first portion (108a), the first portion (108a) comprise a left curve (108aa) and a right curve (108ab) on left and right side of the interconnector respectively, the left and right curve (108aa, 108ab) being protruding upwardly from a portion of the one or more bus bar (104),
wherein each of the left curve (108aa) and the right curve (108ab) being connected by a first centre portion (108ac) of the first portion (108a),
a second portion (108b) extending downwardly from a portion of the first center portion (108ac),
a third portion (108c), extending downwardly from the second portion (108b) and being parallel to the first centre portion (108ac), and
a fourth portion (108d) extending from the third portion (108c) parallelly below the one or more busbar (104).
16. The bus bar (104) as claimed in claim 15, wherein the second portion (108b) being configured to act as a fusing element when a current passing through the second portion (108b) exceeds a pre-determined value.
17. The bus bar (104) as claimed in claim 15, wherein the second portion (108b) being disposed offset to a centre line of a welding zone on each of the plurality of interconnectors (106).
18. The bus bar (104) as claimed in claim 15, wherein the second portion (108b) being disposed on either on extreme ends or at a centre portion of each of the plurality of interconnectors (106).
19. The bus bar (104) as claimed in claim 15, wherein the width of the second portion (108b) being less than the first centre portion (108ac) and the third portion (108c).
20. The bus bar (104) as claimed in claim 15, wherein the cross-sectional area of the second portion (108b) being 0.2 millimeters.
21. The bus bar (104) as claimed in claim 15, wherein resistance of the second portion (108b) being higher as compared to the first center portion (108ac) and the third portion (108c) as width of the second portion (108b) being less than the first center portion (108ac) and the third portion (108c).
22. The bus bar (104) as claimed in claim 15, wherein material of the second portion (108b) being different from that of the first center portion (108ac) and the third portion (108c).
23. The bus bar (104) as claimed in claim 22, wherein the material of the second portion (108b) being made of two or more distinct metals or alloys having varied properties, wherein the two or more distinct metals or alloys being metallurgically bonded together to achieve functional benefits unachievable with a single metal.
24. The bus bar (104) as claimed in claim 23, wherein the material being made from a combination of at least aluminium, nickel and copper.
25. The bus bar (104) as claimed in claim 24, wherein the one or more busbars (104) being made from either of nickel or copper.
26. The bus bar (104) as claimed in claim 15, wherein the fourth portion (108d) has a plurality of openings (108da), wherein the plurality of openings (108da) enables spot welding of the third portion (108c) to at least one of a positive terminal or a negative terminal of a plurality of cells (102).
27. The bus bar (104) as claimed in claim 15, wherein the plurality of interconnectors (106) being disposed along plurality of columns on the bus bar (104).
28. The bus bar (104) as claimed in claim 27, the columns of the plurality of interconnectors (106) being disposed either along a left side of the bus bar (104), or along the right side of the bus bar (104), or along the all the side of the bus bar (104).