Description:FIELD OF THE INVENTION

The present disclosure relates to electric vehicles. More particularly, the present disclosure relates to a cell holding structure for a battery pack of an electric vehicle.

BACKGROUND

Nowadays, electric vehicles (EVs) have become more popular due to heightened environmental concerns and increased cost competitiveness with conventional gas vehicles. Typically, an electric vehicle includes a battery pack having a plurality of cells positioned in a preset configuration to each other. Currently, the battery pack includes a cell holder adapted to hold the plurality of cells and a plurality of interconnects. The plurality of interconnects is adapted to form electrical connections with the plurality of cells to extract power.

In the existing battery pack, the use of the cell holder and the plurality of interconnects are separate units, increases the number of the components of the battery pack thereby making the manufacturing of the battery pack time and effort consuming task and at the same time increases an overall installation cost of the battery pack. Further, the existing interconnects are connected to the plurality of cells by using existing welding techniques such as spot welding, laser welding or ultrasonic welding. Thus, the welding techniques require a skilled person and is a time consuming task. Herein, the material of the interconnects and the material of the cells are required to be equally susceptible to the welding joints. Therefore, this restricts the interconnects and the cells to specific materials.

Therefore, in view of the above-mentioned problems, there is a need to provide a cell holder, that can eliminate one or more above-mentioned problems associated with the existing cell holders and the interconnects.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that is further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

The present disclosure discloses a cell holding structure adapted to electrically connect a plurality of cells. The cell holding structure may include a plurality of slots adapted to receive the plurality of cells. Each of the plurality of slots may include a first connecting member and a second connecting member. The first connecting member is adapted to electrically connect with a first terminal of a cell from among the plurality of cells. The second connecting member is adapted to electrically connect with a second terminal of the cell from among the plurality of cells. The first connecting member and the second connecting member are connected with each other in a predefined configuration to electrically connect the plurality of cells in one of a series or a parallel configuration.

Further, a battery pack is disclosed herein. The battery pack may include a plurality of cells and a cell holding structure. The plurality of cells is adapted to be connected with each other in one of a series and a parallel configuration. The cell holding structure is adapted to secure and electrically connect the plurality of cells. The cell holding structure may include a top cell holder, a bottom cell holder, a first connecting member and a second connecting member. The top cell holder is adapted to support a top portion of the cell from among the plurality of cells. The bottom cell holder is adapted to support a bottom portion of the cell. The bottom cell holder may include a plurality of slots adapted to receive the plurality of cells. The first connecting member is integrated to the top cell holder and is adapted to electrically connect to a first terminal of the cell. The second connecting member is integrated to the bottom cell holder and is adapted to electrically connect to a second terminal of the cell. The first connecting member and the second connecting member are connected with each other in a predefined configuration to electrically connect the plurality of cells. The top cell holder and the bottom cell holder secure and electrically connect the first connecting member and the second connecting member with the cell.

As explained above, the cell holding structure having the first connecting member and the second connecting member as integral components. Thus, the cell holding structure may mechanically secure and electrically connect the plurality of cells. This reduces the number of components of the battery pack and also reduces the number of steps associated with the assembly of the battery pack. Therefore, the implementation of the cell holding structure reduces the time and effort associated with the installation of the battery pack which reduces the overall installation cost.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates an exploded view of a battery pack, according to an embodiment of the present disclosure;
Figure 2 illustrates an enlarged view of a portion ‘A’ as shown in the Figure 1, according to an embodiment of the present disclosure;
Figure 3 illustrates a top view of the battery pack, according to an embodiment of the present disclosure;
Figure 4(a) illustrates a top view of a second connecting member of the battery pack, according to an embodiment of the present disclosure;
Figure 4(b) illustrates the top view of the second connecting member of the battery pack, according to another embodiment of the present disclosure;
Figure 4(c) illustrates the top view of the second connecting member of the battery pack, according to another embodiment of the present disclosure;
Figure 4(d) illustrates the top view of the second connecting member of the battery pack, according to another embodiment of the present disclosure;
Figure 5 illustrates a perspective view of the battery pack depicting adhesives adapted to attach the second connecting member with the cell holding structure, according to an embodiment of the present disclosure;
Figure 6(a) illustrates a perspective view of the cell holding structure depicting the second connecting member electrically connected to a body in proximity to a top portion of the cell, according to an embodiment of the present disclosure;
Figure 6(b) illustrates a perspective view of the cell holding structure depicting the second connecting member electrically connected to the body in proximity to a bottom portion of the cell, according to another embodiment of the present disclosure;
Figure 6(c) illustrates a perspective view of the cell holding structure depicting the second connecting member electrically connected to the bottom portion, according to another embodiment of the present disclosure;
Figure 6(d) illustrates a perspective view of the cell holding structure depicting the second connecting member electrically connected to the bottom portion and the body, according to another embodiment of the present disclosure; and
Figure 6(e) illustrates a perspective view of the cell holding structure depicting the second connecting member electrically connected to the top portion and the body, according to another embodiment of the present disclosure.

Further, skilled artisans will appreciate those elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

While the embodiments in the invention are subject to various modifications and alternative forms, the specific embodiment thereof has been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention.

It is to be noted that a person skilled in the art would be motivated from the present invention to modify a cell holding structure for a battery pack as disclosed herein. However, such modifications should be construed to be within the scope of the invention. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present invention, so as not to obscure the invention with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

Accordingly, the cell holding structure for the battery pack is described with reference to the figures and specific embodiments; this description is not meant to be constructed in a limiting sense.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

Figure 1 illustrates an exploded view of a battery pack 100 while Figure 2 illustrates an enlarged view of a portion ‘A’ as shown in Figure 1. Further, Figure 3 illustrates a top view of the battery pack 100. Referring to Figures 1, 2, and 3, the battery pack 100 is adapted to be installed as a power source in an Electric Vehicle (EV). The battery pack 100 may supply power to an electric motor of the EV to drive the EV. In one embodiment, the battery pack 100 may be installed in hybrid vehicles. In another embodiment, the battery pack 100 may be used in various applications to supply power. In one embodiment, the battery pack 100 may be embodied as a module within a pack.

The battery pack 100 may include a plurality of cells 102 and a cell holding structure 104 adapted to secure and electrically connect the plurality of cells 102. The plurality of cells 102 is adapted to be connected with each other in one of a series and a parallel configuration. The plurality of cells 102 may be closely spaced with respect to each other. Each of the plurality of cells 102 may include a top portion, a bottom portion, and a body extending between the top portion and the bottom portion. In an embodiment, each of the plurality of cells 102 may have a cylindrical shape, or any other shape without departing from the scope of the present disclosure. In another embodiment, each of the plurality of cells 102 may have a cuboidal shape or a hexagonal shape, without departing from the scope of the present disclosure.

Each of the plurality of cells 102 defines a first terminal 122 and a second terminal 124. In one example, the first terminal 122 may be a positive terminal and the second terminal 124 may be a negative terminal, without departing from the scope of the present disclosure. In an embodiment, the first terminal 122 is in proximity to the top portion and the second terminal 124 is in proximity to one of the bottom portion and the body. In another embodiment, the second terminal 124 is in the proximity of the top portion, and the first terminal 122 is in the proximity of one of the bottom portion and the body.

The plurality of cells 102 may include a first group of cells 102-1 and a second group of cells 102-2 that may be termed as a first bank 102-1 and a second bank 102-2 respectively. The first bank 102-1 may include, but is not limited to, four cells 102 connected with each other in a parallel configuration. The second bank 102-2 may include, but is not limited to, four cells 102 connected with each other in a parallel configuration. The first bank 102-1 may be connected to the second bank 102-2 in a series configuration.

According to this disclosure, the cell holding structure 104 may secure and electrically connect the plurality of cells 102. The cell holding structure 104 may include a top cell holder 106, a bottom cell holder 108, a first connecting member 110 and a second connecting member 112. The top cell holder 106 is adapted to support one of the top portion and the body of a cell 102 from among the plurality of cells 102. The bottom cell holder 108 is adapted to support one of the body and the bottom portion of the cell. The first connecting member 110 and the second connecting member 112 may be electrically connected with the cell 102 from among the plurality of cells 102 to extract the power. The extracted power may be further supplied to the electric motor.

The bottom cell holder 108 may include a plurality of slots 114 adapted to receive the plurality of cells 102. The plurality of slots 114 may be integrally formed with the bottom cell holder 108. The plurality of slots 114 may have a profile corresponding to a profile of the plurality of cells 102, such that the plurality of cells 102 may be partially secured in the plurality of slots 114. The first connecting member 110 is adapted to apply one of the radial force and the axial force to secure the cell in a place while also forming the electrical connection with the first terminal 122 of the cell. In an embodiment, the first connecting member 110 may be compliant or rigid in nature. Further, the second connecting member 112 is adapted to apply one of the radial force and the axial force to secure the cell in the place while also forming the electrical connection with the second terminal 124 of the cell.

In the illustrated embodiment, the top cell holder 106 and the bottom cell holder 108 are adapted to be fastened with each other to form the cell holding structure 104. The top cell holder 106 and the bottom cell holder 108 may be fastened with each other by using a plurality of fasteners. In an embodiment, the plurality of fasteners may include a plurality of screws, without departing from the scope of the present disclosure. Herein, the top cell holder 106 may include a first set of holes 116 adapted to receive the plurality of screws. The bottom cell holder 108 may include a second set of holes 118 adapted to be aligned with the first set of holes 116 to receive the plurality of screws. Herein, the first connecting member 110 may be integrated to the top cell holder 106, and the second connecting member 112 may be integrated to the top cell holder 106. The constructional and operational details of the first connecting member 110 and the second connecting member 112 are explained in the subsequent paragraphs.

In another embodiment, the top cell holder 106 may be integrated to the bottom cell holder 108 to form an integrated unit referred to as the cell holding structure 104. In one embodiment, the cell holding structure 104 may be disposed to support the top portion of the cell 102 from among the plurality of cells 102. In one embodiment, the cell holding structure 104 may be disposed to support the bottom portion of the cell 102 from among the plurality of cells 102. Herein, the cell holding structure 104 may include the plurality of slots 114 adapted to receive the plurality of cells 102.

Each of the plurality of slots 114 may include a first connecting member 110 and a second connecting member 112. The first connecting member 110 is adapted to electrically connect with the first terminal 122 of the cell from among the plurality of cells 102. The second connecting member 112 is adapted to electrically connect with the second terminal 124 of the cell from among the plurality of cells 102. The first connecting member 110 and the second connecting member 112 may be integrated with the cell holding structure 104.

The first connecting member 110 and the top cell holder 106 may be formed integrally by using one of an insert moulding process, an over moulding process, and a heat staking process. In another embodiment, the first connecting member 110 may be removably attached to the top cell holder 106 by using one of the plurality of fasteners and a press fitting with pins. The plurality of fasteners may be mechanical fasteners. The mechanical fasteners may include, but are not limited to, screws or bolts. Further, the plurality of fasteners may include, but are not limited to, adhesives, etching, and layering. The first connecting member 110 may be formed of a metallic material. The first connecting member 110 may be embodied as an interconnect adapted to extract the power from the cell 102.

Figure 4(a) illustrates a top view of the second connecting member 112 of the battery pack 100 while Figure 4(b) illustrates the top view of the second connecting member 112 of the battery pack 100. Further, Figure 4(c) illustrates the top view of the second connecting member 112 of the battery pack 100 while Figure 4(d) illustrates the top view of the second connecting member 112 of the battery pack 100. Figure 5 illustrates a perspective view of the battery pack 100 depicting adhesives adapted to attach the second connecting member 112 with the cell holding structure 104.

Referring to Figures 1, 4(a), 4(b), 4(c), and 4(d), the second connecting member 112 may be integrated to the bottom cell holder 108. The second connecting member 112 and the bottom cell holder 108 may be formed integrally by using one of an insert moulding process, an over moulding process, and a heat staking process. In an embodiment, four second connecting members 112 are disposed around the periphery of the cell, and the based cell holder applies the radial force to the cell to secure the four second connecting members112. In another embodiment, as shown in Figure 4(d), the second connecting member 112 may have four protruding members adapted to form the electrical connection with the cell.

Further, the second connecting member 112 may be removably attached to the bottom cell holder 108 by using one of the plurality of fasteners. The plurality of fasteners may be mechanical fasteners. The mechanical fasteners may include, but are not limited to, screws or bolts. Further, the plurality of fasteners may include, but are not limited to, adhesives 126, etching, and layering. In the illustrated embodiment, referring to Figure 5, the adhesives 126 may be applied between the second connecting member 112 and the bottom cell holder 108 to secure the second connecting member 112 with the bottom cell holder 108. In an embodiment, the adhesive 126 may be a thermally conductive adhesive which may provide a thermal interface to the second connecting member 112. Further, the heat may be dissipated through the adhesive 126 for thermal management of the cell 102. The second connecting member 112 may be formed of the metallic material. The second connecting member 112 may be embodied as an interconnect adapted to extract the power from the cell 102.

Referring to Figures 1, and 3, the first connecting member 110 and the second connecting member 112 may be connected with each other in a predefined configuration to electrically connect the plurality of cells 102 in one of the series and the parallel configuration. In another embodiment, the predefined configuration may be a parallel configuration and the first connecting member 110 positioned over a slot from among the plurality of slots 114, is electrically connected with the first connecting member 110 positioned over an adjacent slot.

The first connecting member 110 is connected to the top portion to form a positive electrical connection, and the second connecting member 112 is connected to the bottom portion to form a negative electrical connection. Further, the battery pack 100 may include a pair of terminal members 120 adapted to connect each of the first connecting member 110 to the second connecting member 112.

Although not shown, the predefined configuration may be a series configuration in which the first connecting member 110 positioned over a slot from among the plurality of slots 114, is electrically connected with the second connecting member 112 of the adjacent slot.

Figure 6(a) illustrates a perspective view of the cell holding structure 104 of the battery pack 100, according to another embodiment of the present disclosure. Herein, the first connecting member 110 is electrically connected to the top portion of the cell 102 to form the positive connection. The top cell holder 106 may secure and electrically connect the first connecting member 110 with the top portion. Further, the second connecting member 112 is electrically connected to the body in proximity to the top portion of the cell 102 to form the negative connection. The bottom cell holder 108 may secure and electrically connect the second connecting member 112 with the body.

Figure 6(b) illustrates the perspective view of the cell holding structure 104 of the battery pack 100, according to another embodiment of the present disclosure. Herein, the first connecting member 110 is electrically connected to the top portion of the cell 102 to form the positive connection. The top cell holder 106 may secure and electrically connect the first connecting member 110 with the top portion. Further, the second connecting member 112 is electrically connected to the body in proximity to the bottom portion of the cell 102 to form the negative connection. The bottom cell holder 108 may secure and electrically connect the second connecting member 112 with the body.

Figure 6(c) illustrates the perspective view of the cell holding structure 104 of the battery pack 100, according to another embodiment of the present disclosure. Herein, the first connecting member 110 is electrically connected to the top portion of the cell 102 to form the positive connection. The top cell holder 106 may secure and electrically connect the first connecting member 110 with the top portion. Further, the second connecting member 112 is electrically connected to the bottom portion of the cell 102 to form the negative connection. The bottom cell holder 108 may secure and electrically connect the second connecting member 112 with the bottom portion.

Figure 6(d) illustrates the perspective view of the cell holding structure 104 of the battery pack 100, according to another embodiment of the present disclosure. Herein, the first connecting member 110 is electrically connected to the top portion of the cell 102 to form the positive connection. The top cell holder 106 may secure and electrically connect the first connecting member 110 with the top portion. Further, the second connecting member 112 is electrically connected to the bottom portion and the body of the cell 102 to form the negative connection. The bottom cell holder 108 may secure and electrically connect the second connecting member 112 with the bottom portion and the body.

Figure 6(e) illustrates the perspective view of the cell holding structure 104 of the battery pack 100, according to another embodiment of the present disclosure. Herein, the first connecting member 110 is electrically connected to the top portion of the cell 102 to form the positive connection. The top cell holder 106 may secure and electrically connect the first connecting member 110 with the top portion. Further, the second connecting member 112 is electrically connected to the top portion and the body of the cell 102 to form the negative connection. The bottom cell holder 108 may secure and electrically connect the second connecting member 112 with the top portion and the body.

The present disclosure offers the cell holding structure 104 having the first connecting member 110 and the second connecting member 112 as integral components. Thus, the cell holding structure 104 is individually responsible for mechanically securing and electrically connecting the plurality of cells 102 of the battery pack 100. This reduces the number of components of the battery pack 100, as the implementation of separate units for establishing mechanical and electrical connections is eliminated. Further, the number of steps associated with the assembly of the battery pack 100 is also reduced. Therefore, the implementation of the cell holding structure 104 reduces the time and effort associated with the installation of the battery pack 100 which reduces the overall installation cost.

Further, each of the first connecting member 110 and the second connecting member 112 may apply the radial forces and the axial forces to secure the cell 102. This eliminates the implementation of existing welding techniques to attach the first connecting member 110 and the second connecting member 112 to the cell 102, which affects the performance of the first connecting member 110 and the second connecting member 112. Thus, the performance of the first connecting member 110 and the second connecting member 112 is also improved, as it is not affected by any existing technique such as welding. Unlike welding, even a person with limited skillsets may connect the first connecting member 110 and the second connecting member 112 to the plurality of cells 102 by using the cell holding structure 104. This also results in a quicker assembly of the battery pack 100. Therefore, the cell holding structure 104 of the present disclosure is operationally effective, cost-effective, easy to implement and has better serviceability.

While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
, Claims:1. A cell holding structure adapted to electrically connect a plurality of cells, comprising:
a. a plurality of slots (114) adapted to receive the plurality of cells (102), each of the plurality of slots (114) comprising:
i. a first connecting member (110) adapted to electrically connect with a first terminal (122) of a cell from among the plurality of cells (102); and
ii. a second connecting member (112) adapted to electrically connect with a second terminal (124) of the cell from among the plurality of cells (102),
wherein the first connecting member (110) and the second connecting member (112) are connected with each other in a predefined configuration to electrically connect the plurality of cells (102) in one of a series or a parallel configuration.

2. The cell holding structure (104) as claimed in claim 1, wherein the predefined configuration is a series configuration and the first connecting member (110) of a slot from among the plurality of slots (114), is electrically connected with the second connecting member (112) of an adjacent slot.

3. The cell holding structure (104) as claimed in claim 1, wherein the predefined configuration is a parallel configuration and the first connecting member (110) of a slot from among the plurality of slots (114), is electrically connected with the first connecting member (110) of an adjacent slot.

4. A battery pack comprising:
a. a plurality of cells (102) adapted to be connected with each other in one of a series and a parallel configuration,
b. a cell holding structure (104) adapted to secure and electrically connect the plurality of cells (102), the cell holding structure (104) comprising:
i. a top cell holder (106) adapted to support a top portion of the cell from among the plurality of cells (102);
ii. a bottom cell holder (108) adapted to support a bottom portion of the cell, the bottom cell holder (106) comprising a plurality of slots (114) adapted to receive the plurality of cells (102);
iii. a first connecting member (110) integrated to the top cell holder (106), and adapted to electrically connect to a first terminal (122) of the cell; and
iv. a second connecting member (112) integrated to the bottom cell holder (108), and adapted to electrically connect to a second terminal (124) of the cell,
wherein the first connecting member (110) and the second connecting member (112) are connected with each other in a predefined configuration to electrically connect the plurality of cells (102), and
the top cell holder (106) and the bottom cell holder (108) secure and electrically connect the first connecting member (110) and the second connecting member (112) with the cell.

5. The battery pack (100) as claimed in claim 4, wherein the predefined configuration is a series configuration and the first connecting member (110) positioned over a slot from among the plurality of slots (114), is electrically connected with the second connecting member (112) of an adjacent slot.

6. The battery pack (100) as claimed in claim 4, wherein the predefined configuration is a parallel configuration and the first connecting member (110) positioned over a slot from among the plurality of slots (114), is electrically connected with the first connecting member (110) positioned over an adjacent slot.

7. The battery pack (100) as claimed in claim 4, comprising a pair of terminal members (120) adapted to connect each of the first connecting member (110) to the second connecting member (112).

8. The battery pack (100) as claimed in claim 4, wherein:
the first connecting member (110) is connected to the top portion to form a positive electrical connection; and
the second connecting member (112) is connected to the bottom portion to form a negative electrical connection.

9. The battery pack (100) as claimed in claim 8, wherein:
the first connecting member (110) is adapted to apply one of a radial force and an axial force to secure the cell and electrically connected with the first terminal (122) of the cell; and
the second connecting member (112) is adapted to apply one of the radial force and the axial force to secure the cell and electrically connected with the second terminal (124) of the cell.

10. The battery pack (100) as claimed in claim 4, wherein:
the first connecting member (110) is removably attached to the top cell holder (106) via a plurality of fasteners; and
the second connecting member (112) is removably attached to the bottom cell holder (108) via the plurality of fasteners.

11. The battery pack (100) as claimed in claim 4, wherein each of the first connecting member (110) and the second connecting member (112) is formed of a conductive metallic material.