Description: Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

In the context of the present invention, the term "BCU" (27) means a Battery Control unit that controls & monitors the battery state of action as per the requirement of energy flow in an Electric Vehicle.

In the context of the present invention, the term "BMS" (24, 25, 26) means a Battery Management System which manages & monitors the state of condition of battery packs and controls their temperature & condition, and external shares information during faults, hazards & emergency situations.

In the context of the present invention, the term "PDU" (1) means power distribution unit which distributes the power as per the component requirement to the components integrated into the Energy flow system of the Vehicle.

In the context of the present invention, the term "TMS" (28) means a Thermal Management System which controls the cell temperature of the differential battery pack-based priority on the environment and situation.

According to one embodiment of the invention, the differential Battery Pack (2) is integrated with the plurality of sub battery packs, (21, 22, 23), an independent BMS (24, 25, 26) for each sub battery pack, Master BCU (27), TMS (28), and housing.

The components which are integrated into the differential battery pack (2) maintain the fixed capacity of power for each component of the Electric vehicle and supply power to each system separately free from the DC-DC converter (loss enabling system) till stipulated or a specific period of time.

A plurality of sub battery packs that are being integrated into the differential battery pack (2) have different specifications and voltage levels (High & Low) from each other, which are arranged in cluster format separately, based on the voltage and power requirements of different systems of the vehicle and the total use of the vehicle components as well as the situation and condition of the vehicle, these individual battery packs have been chosen for vehicle usage. These selections of battery packs are operated by Battery Control Unit (BCU) (27) and processed by the Power Distribution Unit (PDU) and Vehicle Control Unit (VCU).

While operating these battery packs, analyzing and monitoring the condition of batteries plays a vital role in regulating the flow of energy & power. The BMS (24, 25, 26) unit of different battery packs is responsible for monitoring and managing the conditions of a battery pack. As a whole, each battery pack has a Battery Management System (BMS) (24, 25, 26), which controls both the charging and discharging of the battery, controls the environment Temperature, balances the energy flow of the battery, calculates secondary data, and monitors & reports its state of condition. Besides this, it acts as an external communication data bus for the vehicle.

In order to control and manage these battery conditions, the BMS (24, 25, 26) takes command from the BCU (27), which makes decisions based on the report of battery pack conditions and the usage of vehicle power. This BCU (27) is determined as the MBCU (Master Battery Control Unit) (27) of the differential battery pack which manages functions like monitoring battery packs, data logging, cell balancing, cell voltage, temperature, & safety device, hardware interlock, and controlling the mode of operation like state flow and relay pre-charge to ensure the battery pack healthy condition & flow of energy. Furthermore, the controller plays a key role in connecting to other controllers and transmitting reports about the battery pack's health.

FIG1. Illustrates a block diagram of a Differential Battery Pack System which highlights the integrated components in the Battery Pack and shows the process flow of communication medium between components to a Battery pack (21, 22, 23) & MBCU (27), It also highlights energy power flow medium between components.

FIG1A. Illustrates a process flow of communication medium & data transfer to MBCU (27) & Logical circuit (27D), which analysis the battery pack condition like temperature, state of flow, and safety conditions, these data analyzed helps PUC & VCU to decide the required amount of energy to be consumed to operate the vehicle till the stipulated period of time.

FIG1B. Illustrates a process flow of power supply medium between Battery Pack (21, 22, 23) to PDU (1). Based on the battery pack condition the system regulates the charging/discharging of the battery, safety operation, controlling its environment, balancing it, calculating secondary data, and monitoring & reporting its state of condition, including these, it also acts as an external communication data bus for a Vehicle. These managing operations help PDU (1) & BCU (27) to regulate the energy flow required to operate the vehicle till the stipulated period of time.

While operating the battery pack system it’s important they regulate atmosphere & battery temperature of a battery pack, for controlling these TMS unit is been integrated into the system which regulates the temperature of the battery pack to normal as per command and data analyses report from BCU (27) & BMS (24, 25, 26) respectively. This unit also ensures the life cycle & efficiency of the battery pack which might be affected due to overheating of the battery.

For ensuring safety & optimal arrangement of the system to suit the road and environmental conditions of components housing are integrated into the differential battery pack system which also helps adhesives to mount all other units too in the system.

FIG2. Illustrates a layout of the Differential Battery Pack System which regulates & analyses both the charging and discharging of the battery, controls the environment Temperature, balances the energy flow of the battery, calculates secondary data, and monitors & reports its state of condition. Besides this, it acts as an external communication data bus for the vehicle. These managing operations help PDU & BCU to regulate the energy flow required to operate the vehicle till the stipulated period of time. The components integrated into Battery Pack System are MBCU – Master Battery Control Unit (27), Sub Battery Packs (21, 22, 23), TMS - Thermal Management System (28), BMS - Battery Management System (24, 25, 26), Fuse (27C), Board - Wire - Board Connectors [1 way & 2 ways] (27B), Switch (27A), and logical circuit (27D).

In a preferred embodiment of the invention, A printed circuit board is used in the differential battery pack with a logical circuit (27D) for functions like deciding the charging and discharging condition of each said sub battery pack, analyzing the data, and deciding whether to send out faults or cut off the circuit from the power distribution unit of the vehicle, charge and discharge the sub battery packs, monitor pack and cell level voltage and temperature, estimate state-of-charge (SOC) and state-of-health (SOH) of each sub battery pack, limit power input and output for thermal and overcharge protection, control the battery charging profile, balance the state of charge of individual cells, isolate the battery pack from the source and load when necessary, control and regulate the battery temperature based on pack level and cell level values to maintain the pack temperature within the optimal set range.

After analyzing the information energy flow of the battery pack is customized as per the report and state of condition of the battery pack by MBCU (27) and deliver’s the power source to PDU (1) which ensures the disturbing of power supply to components of the vehicle to operate the vehicle smoothly and more efficiently with minimum consumption of energy till the stipulated period of time.

FIG3. Illustrates a block diagram of an Energy flow system that highlights the units in the energy flow system of the vehicle and shows the energy power flow medium between units of the vehicle. The components integrated into Energy Flow System are Battery Pack (2), PDU – Power Distribution unit (1), Charging Socket (3), High Voltage System (4), and Low Voltage System (5).

In a preferred embodiment of the invention, the sub battery pack (21, 22, 23) has a fixed capacity of power as mentioned previously, these battery packs ensure their power supplies to each system separately based on the high & low voltage of component usage free from the DC-DC converter (loss enabling system) till stipulated or a specific period of time.

Systems and methods have been described in general terms as an aid to understanding the details of the invention. In some instances, well-known structures, materials, and/or operations have not been specifically shown or described in detail to avoid obscuring aspects of the invention. In other instances, specific details have been given in order to provide a thorough understanding of the invention. One skilled in the relevant art will recognize that the invention may be embodied in other specific forms, for example, to adapt to a particular system or apparatus or situation or material or component, without departing from the spirit or essential characteristics thereof. Therefore, the disclosures and descriptions herein are intended to be illustrative, but not limiting, of the scope of the invention.
, Claims: 1. An electric vehicle Differential battery pack system comprises of
A Plurality of Sub-battery packs;
An Independent BMS for each battery pack,
A Master Battery Control Unit,
A Thermal management system; and
A housing.

2. According to claim 1, the plurality of Individual sub-battery packs having different Specifications and voltage levels (High & Low) from each other is arranged in cluster format separately. These individuals arranged battery packs will be selected based on the voltage and power requirements of different systems of the vehicle.

3. A plurality of sub-battery packs includes an output connector of a bus bar type that is connected to an independent battery management system.

4. The battery pack system of claim 1, wherein the plurality of sub battery packs each have a wire-to-board connector plug with a plurality of wires that carry information and power to the independent battery management system.

5. The battery pack system of claim 1 wherein said plurality of sub battery packs has a plurality of mounting brackets that bolts to the said housing.
6. According to claim 1, the battery pack system includes an independent battery management system for each sub battery pack, which includes a printed circuit board with terminals and a connector block that plugs into the bus bar type output connector of claim 3 and to a wire-to-board connector plug of claim 4 respectively.

7. The battery pack system of claim 1 wherein said independent battery management system of each sub battery pack has a printed circuit board with a logical circuit for functions that are not limited to charging and discharging the battery pack, monitoring cell voltage and temperature, estimating state-of-charge (SOC) and state-of-health (SOH), limit power input and output for thermal and overcharge protection, control the battery charging profile, balance the state-of-charge of individual cells, isolate the battery pack from source and load when necessary.

8. As claimed in claim 1, the said independent battery management system for each sub battery pack is rigidly fixed to the respective sub battery packs.

9. In the battery pack system of claim 1, wherein said master battery control unit is a printed circuit board that is not limited to fuses or switches for controlling the power from each individual sub battery pack respectively but also serves as a bridge between the independent battery management system and the power distribution unit of the vehicle.

10. The battery pack system of claim 1, wherein said master battery control unit comprises a printed circuit board that transmits and receives data points between the independent battery management system and the vehicle master control unit.

11. The battery pack system of claim 1, wherein said master battery control unit is a printed circuit board having controls for controlling and regulating fluid flow through the thermal management system.

12. The battery pack system of claim 1 wherein said master battery control unit is a printed circuit board with the logical circuit for functions that are not limited to deciding the charging and discharging condition of each said sub battery packs, analyzing the data from the claim 7 and decide whether to send out faults or cut off the circuit from the power distribution unit of the vehicle, charge and discharge the sub battery packs, monitor pack and cell level voltage and temperature, estimate state-of-charge (SOC) and state-of-health (SOH) of each sub battery pack, limit power input and output for thermal and overcharge protection, control the battery charging profile, balance the state-of-charge of individual cells, isolate the battery pack from source and load when necessary, control and regulate the battery temperature based on pack level and cell level values to maintain the pack temperature within the optimal set range.

13. The battery pack system of claim 1 wherein said thermal management system is meant for circulating fluid inside the battery pack to maintain and regulate the battery temperature.

14. The battery pack system of claim 1 wherein said housing has means not limited to brackets, adhesives to mount all other systems mentioned in the apparatus in a manner that ensures the safety and optimal arrangement of the system to suit the road and environmental conditions.