DESC:TITLE OF THE INVENTION
RECHARGEABLE BATTERY SYSTEM

TECHNICAL FIELD
[0001] The present invention relates to rechargeable batteries and, more particularly, to a rechargeable battery system for powering applications including, but not limited to, electric automotive vehicles.
BACKGROUND
[0002] Batteries are commonly used in present scenarios to power portable electronic devices, such as mobile phones, computers, digital cameras, digital audio players, and the like. Over time, battery cell technology and manufacturing capacity have improved which has resulted in manufacturing of rechargeable battery cells and/or secondary cells. Further, multiple rechargeable battery cells are electrically coupled to be used as energy storage devices for high power applications, such as in the electric vehicles (EV), hybrid electric vehicles (HEV), and the like.
[0003] In conventional rechargeable battery, electrodes are configured to be terminal output points of the rechargeable battery. The conventional rechargeable battery is electrically connected to a control module via harness routing which forms a conductive path between the rechargeable battery and an external device. Traditionally, electrical connection between each battery cell of the rechargeable battery, and each battery cell to the control module are done by either welding metallic tabs or by wire bonding technique. In such configurations, both terminal surfaces (i.e., positive terminal, and negative terminal) of the battery cell are required to be welded or wire bonded for the electrical connection.
[0004] However, the conventional interconnection design may also prevent the removal of heat in a thermal runaway process from a battery cell of the rechargeable battery due to welding on both terminal surfaces of the battery cell. Therefore, the battery cell may prematurely damage due to trapped thermal energy which in turn results in damaging other battery cells connected in parallel. Moreover, integrity of electrical signal of each series battery module of the rechargeable battery transmitted to the control module results in usage of separate wires for communicating signals. As a result, this inherently, makes the whole apparatus a cumbersome, expensive, and time-consuming process in manufacturing and may require periodic maintenance which is undesirable.
[0005] Therefore, there is a need for techniques which can overcome one or more limitations stated above, in addition to providing other technical advantages.
SUMMARY
[0006] This summary is provided only for the purposes of introducing the concepts presented in a simplified form. This is not intended to identify essential features of the claimed invention or limit the scope of the invention in any manner.
[0007] Various embodiments of the present disclosure provide a battery system. The battery system includes a battery pack and a printed circuit board (PCB) assembly. The battery pack includes a plurality of battery cells. Further, each battery cell of the plurality of battery cells includes at least a positive terminal and a negative terminal. The printed circuit board (PCB) assembly includes a top surface and a bottom surface. The printed circuit board (PCB) further includes a plurality of first polarity conducting traces and a plurality of second polarity conducting traces. The plurality of first polarity conducting traces and the plurality of second polarity conducting traces correspond to conducting tracks for interconnecting each battery cell of the plurality of battery cells. The printed circuit board (PCB) assembly includes a plurality of first type conducting feeders and a plurality of second type conducting feeders mounted at the bottom surface. Further, each first type conducting feeder of the plurality of first type conducting feeders and each second type conducting feeder of the plurality of second type conducting feeders are electrically connected to corresponding first polarity conducting trace of the plurality of first polarity conducting traces, and corresponding second polarity conducting traces of the plurality of second polarity conducting traces respectively. Further, each first type conducting feeder of the plurality of first type conducting feeders and each second type conducting feeder of the plurality of second type conducting feeders are electrically connected to the positive terminal and the negative terminal of corresponding battery cell of the plurality of battery cells respectively.
[0008] In another embodiment, a battery system with an integrated battery management system (BMS) is provided. The battery system includes a battery pack including a plurality of battery cells. Each battery cell of the plurality of battery cells includes at least a positive terminal and a negative terminal. The battery system includes a printed circuit board (PCB) assembly. The printed circuit board (PCB) assembly includes a top surface and a bottom surface. Further, the printed circuit board (PCB) assembly includes a plurality of first polarity conducting traces and a plurality of second polarity conducting traces. The plurality of first polarity conducting traces and the plurality of second polarity conducting traces correspond to conducting tracks for interconnecting each battery cell of the plurality of battery cells. The printed circuit board (PCB) assembly includes a plurality of first type conducting feeders and a plurality of second type conducting feeders mounted at the bottom surface. Further, each first type conducting feeder of the plurality of first type conducting feeders, and each second type conducting feeder of the plurality of second type conducting feeders are electrically connected to corresponding first polarity conducting trace of the plurality of first polarity conducting traces, and corresponding second polarity conducting traces of the plurality of second polarity conducting traces respectively. Further, each first type conducting feeder of the plurality of first type conducting feeders and each second type conducting feeder of the plurality of second type conducting feeders are electrically connected to the positive terminal and the negative terminal of corresponding battery cell of the plurality of battery cells respectively. A voltage sensing connector is mounted onto the top surface of the printed circuit board (PCB) assembly. The voltage sensing connector is configured to receive voltage feedback from each battery cell of the plurality of battery cells. Further, the PCB assembly includes the battery management system (BMS) integrated within the printed circuit board (PCB) assembly. The battery management system (BMS) is configured to monitor operating condition of each battery cell of the plurality of battery cells based on input received from the voltage sensing connector.
[0009] In yet another embodiment, a battery system for an automotive vehicle is disclosed. The battery system includes a battery pack including a plurality of battery cells. Each battery cell of the plurality of battery cells includes at least a positive terminal and a negative terminal. Further, the battery system includes a printed circuit board (PCB) assembly. The printed circuit board (PCB) assembly includes a top surface and a bottom surface. Further, the printed circuit board (PCB) assembly includes a plurality of first polarity conducting traces and a plurality of second polarity conducting traces. The plurality of first polarity conducting traces, and the plurality of second polarity conducting traces correspond to conducting tracks for interconnecting each battery cell of the plurality of battery cells. The printed circuit board (PCB) assembly includes a plurality of first type conducting feeders and a plurality of second type conducting feeders mounted at the bottom surface. Further, each first type conducting feeder of the plurality of first type conducting feeders and each second type conducting feeder of the plurality of second type conducting feeders are electrically connected to corresponding first polarity conducting trace of the plurality of first polarity conducting traces and corresponding second polarity conducting trace of the plurality of second polarity conducting traces respectively. Further, the positive terminal, and the negative terminal are located at the first surface of each battery cell of the plurality of battery cells thereby positioning the first surface of each battery cell in a same plane along a longitudinal axis, thus, electrically connecting the positive terminal, and the negative terminal of each battery cell to the corresponding first type conducting feeders and the second type conducting feeders respectively at the bottom surface of the PCB assembly. A plurality of protective elements is mounted onto the top surface of the printed circuit board (PCB) assembly and electrically connected in series with the two or more battery cells. The plurality of protective elements is configured to provide battery cell level short circuit protection. A voltage sensing connector is mounted onto the top surface of the printed circuit board (PCB) assembly. The voltage sensing connector is configured to receive voltage feedback from each battery cell of the plurality of battery cells. The PCB assembly further includes a battery management system (BMS) mounted onto the top surface of the printed circuit board (PCB) assembly. The battery management system (BMS) is configured to monitor and manage operating condition of each battery cell of the plurality of battery cells based on input received from the voltage sensing connector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For understanding of exemplary embodiments of the present disclosure, reference is now made to the following descriptions taken in connection with the accompanying figures in which:
[0011] FIG. 1A is a perspective view of a battery system, in one example embodiment of the present disclosure;
[0012] FIG. 1B is an exploded view of the battery system depicting a battery pack, a printed circuit board (PCB) assembly including a battery management system (BMS), in one example embodiment of the present disclosure;
[0013] FIG. 2A is a top plan view of the PCB assembly, in one example embodiment of the present disclosure;
[0014] FIG. 2B is a bottom plan view of the PCB assembly, in one example embodiment of the present disclosure;
[0015] FIG. 3 is a side view of the PCB assembly and the battery pack depicting an electrical connection of a plurality of battery cells and the PCB assembly, in one example embodiment of the present disclosure;
[0016] FIG. 4, is a schematic view of electrical interconnection of the plurality of battery cells in the PCB assembly, in accordance with an example embodiment of the present disclosure; and
[0017] FIG. 5 is a schematic view of the battery system employed in an automotive vehicle for powering applications, in accordance with an example embodiment of the present disclosure.
[0018] The figures referred to in this description depict embodiments of the disclosure for the purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the systems and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DESCRIPTION
[0019] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a broad understanding of the present disclosure. It will be apparent, however, to one skilled in the art that the present disclosure can be practiced without these specific details. In other instances, systems and methods are shown in block diagram form only in order to avoid obscuring the present disclosure.
[0020] Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.
[0021] Moreover, although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present disclosure. Similarly, although many of the features of the present disclosure are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present disclosure is set forth without any loss of generality to, and without imposing limitations upon, the present disclosure.
OVERVIEW
[0022] Various embodiments of the present disclosure provide a battery system for powering applications. Particularly, the battery system is a rechargeable battery system which is configured to power electrical and electronic components ranging from high power applications to low power applications.
[0023] The battery system includes a printed circuit board (PCB) assembly. The PCB assembly includes a top surface and a bottom surface. The PCB assembly may include at least one circuitry component mounted onto the top surface of the PCB assembly. The PCB assembly further includes a plurality of first type conducting feeders, and a plurality of second type conducting feeders mounted on the bottom surface of the PCB assembly. The plurality of first type conducting feeders and the plurality of second type conducting feeders are electrically connected to a plurality of first polarity conducting traces, and a plurality of second polarity conducting traces of the PCB assembly, respectively.
[0024] The battery system further includes a battery pack which includes a plurality of battery cells. Each battery cell of the plurality of battery cells includes a positive terminal and a negative terminal. The positive terminal and the negative terminal of each battery cell may be located on a first surface of each battery cell of the plurality of battery cells. In this configuration, the first surface of the plurality of battery cells including the positive terminal and the negative terminal may be oriented in a same plane as that of a longitudinal axis, thus ensuring electrical connection on only side of the PCB assembly without requirement of reorientation. More specifically, the positive terminal and the negative terminal of each battery cell are electrically connected to each of the first type conducting feeders and the second type conducting feeders.
[0025] Further, the plurality of battery cells may be electrically interconnected in combination of at least a series configuration, and a parallel configuration. Particularly, the interconnection of the plurality of battery cells may be done by the conducting tracks configured on the PCB assembly by at least the plurality of first polarity conducting traces, and the plurality of second polarity conducting traces. The interconnection of the plurality of battery cells in combination of at least the series configuration and the parallel configuration is required for meeting desired voltage and current ratings, respectively.
[0026] Further, the PCB assembly includes a plurality of protective elements mounted onto the top surface. As such, the plurality of protective elements is electrically connected in series with each battery cell of the plurality of battery cells. The plurality of protective elements is configured to provide battery cell level protection in case of internal fault condition. The PCB assembly further includes voltage sensing connector which is configured to receive feedback pertaining to voltage from each battery cell. Further, the voltage feedback is transferred to a battery management system (BMS) of the PCB assembly. The BMS of the battery system is configured to monitor, manage, and/or control operating condition of each battery cell of the battery pack. In this configuration, the BMS integrated within the PCB assembly which is electrically connected to the battery pack conforms to an integrated battery system.
[0027] For the better understanding of this disclosure, reference will now be made to the embodiments illustrated in greater depth in the accompanying figures and description given below. In the following figures, the same reference numerals are used to identify the same components in various views. It must be noted that the conducting feeders are depicted to be as “a plurality of first type conducting feeders” and a “plurality of second type conducting feeders” throughout the present description for exemplary purposes. As such, “the plurality of first type conducting feeders” and “the plurality of second type conducting feeders” are referred due to their electrical connection with “positive terminal” and “negative terminal” of each battery cell, respectively.
[0028] Similarly, it should be noted that, the conducting traces and/or tracks are depicted to be as “a plurality of first polarity conducting traces” and “a plurality of second polarity conducting traces”. Thus, “the plurality of first polarity conducting traces” and “the plurality of second polarity conducting traces” are referred due to their electrical connection with the “positive terminal” and the “negative terminal” of each battery cell, respectively. Therefore, the aforementioned terms are used herein throughout the present disclosure to differentiate electrical connection of the positive terminal and the negative terminal with corresponding conducting feeders and the traces thereof.
[0029] Various exemplary embodiments of a battery system used for power applications are explained in a detailed manner, herein with reference to FIG. 1 to FIG. 5.
[0030] FIG. 1A in one exemplary embodiment of the present disclosure, illustrates a perspective view of a battery system (100). The battery system (100) may be used in electrical applications ranging from high power applications to low power applications. In a non-limiting example, the battery system (100) may be used in electric vehicles, hybrid vehicles and the like. In one configuration, the battery system (100) may be a rechargeable battery system (hereinafter interchangeably referred to as “rechargeable battery system (100)) (i.e., storage battery, or archaically accumulator). In an alternative embodiment, the battery system (100) may be a non-rechargeable battery or a primary battery.
[0031] The battery system (100) includes a printed circuit board (PCB) assembly (102), and a battery pack (104). In general, the PCB used herein throughout the present disclosure refers to a class of circuit electronics which includes at least one conductor element and/or other circuitry elements may be mounted on and/or embedded within thin flexible substrate of the PCB. Further, the PCB assembly (102) may be formed by photolithographic printing (i.e., optical lithography) of conductive tracks on a polyimide film substrate, which provides exposed conducting pads for electrically connecting at least one or more circuitry elements, and interconnecting the PCB assembly (102) with other circuits.
[0032] The PCB assembly (102) includes a top surface (see, (202) of FIG. 2A) and a bottom surface (see, (214) of FIG. 2B). As such, the top surface (202) of the PCB assembly (102) provides platform for securing the at least one conductor element or circuitry elements.
[0033] In one embodiment, the PCB assembly (102) is a double layer PCB assembly as described herein throughout the present disclosure. However, it should be noted that the PCB assembly (102) may be selected to be one of a single-layer PCB, a multi-layer PCBs, a flexible PCBs, a rigid-flex PCBs, an aluminium-backed PCB, and the like as per design feasibility and requirements.
[0034] Further, the PCB assembly (102) includes a battery management system (BMS) (108) mounted onto the top surface (202) of the PCB assembly (102). In other words, the circuitry components of the BMS (108) may be mounted onto the top surface (202) of the PCB assembly (102), thus forming an integrated PCB assembly (102). In this configuration, the BMS (108) may be coupled to (or mounted to) the PCB assembly (102) by suitable means. In one configuration, the BMS (108) may be a separate component of the battery system (100) and may be electrically connected to the PCB assembly (102) of the battery system (100).
[0035] The BMS (108) may include components such as one or more processors and one or more memory elements. More specifically, the one or more processors may include one or more application specific integrated circuits (ASICs), one or more field programmable gate arrays (FPGAs), one or more general purpose processors, or any combination thereof. Additionally, the one or more memory elements may include volatile memory such as random-access memory (RAM), and/or non-volatile memory such as read-only memory (ROM), or solid-state drives. In one embodiment, the one or more processors may include at least one machine learning models.
[0036] The battery pack (104) includes a plurality of battery cells (106). In one configuration, the plurality of battery cells (106) may be an example of a rechargeable battery cell thus forming the rechargeable battery system (100). Further, in the rechargeable battery system (100), the plurality of battery cells (106) may operate as galvanic cells while powering (i.e., in discharging mode) a device and may operate as electrolytic cells when they are being recharged (i.e., in charging mode).
[0037] In one configuration, the plurality of battery cells (106) may be selected to be one of a lithium-ion (Li-ion), nickel-metal hydride (NiMH), nickel-cadmium (NiCd), rechargeable alkaline batteries, and the like as per design feasibility and requirements. In particular, the plurality of battery cells (106) is of a tubular cylindrical shape (e.g., as shown in FIG. 1B). Without limiting the scope of the present invention, the tubular cylindrical shape battery cells are preferred due to ease of manufacturing, good mechanical stability, and their ability to withstand high internal pressure without deforming. In one embodiment, the plurality of battery cells (106) may be selected based on the powering applications and design requirements. For instance, in high power applications, maximum number of battery cells may be required for greater energy storage and power delivery, and in a lower power applications minimum number of battery cells may be selected. It should be understood, however, that the present invention is not limited to either a minimum or maximum number of batteries.
[0038] Further, the plurality of battery cells (106) of the battery pack (104) is electrically connected to the PCB assembly (102). The plurality of battery cells (106) may be electrically interconnected to the PCB assembly (102) in combination of a series configuration and a parallel configuration. In one form, the plurality of battery cells (106) may be electrically coupled in the series configuration to obtain desired voltage rating. Further, such multiple series configuration of the plurality of battery cells (106) may be electrically connected in the parallel configuration to obtain desired current ratings and capacity. The electrical connection between the PCB assembly (102) and the battery pack (104), and the interconnection between each battery cell of the plurality of battery cells (106) are explained in detail in further sections of the present disclosure.
[0039] In some embodiments, multiple battery systems (such as the battery system (100)) may be electrically connected in the series configuration, and the parallel configuration for powering applications (for providing desired voltage and current requirements).
[0040] In this configuration, the electrical connection of the battery pack (104) to the PCB assembly (102) which is integrated with the BMS (108) is referred to as an integrated battery system (i.e., the battery system (100)).
[0041] Referring to FIG. 2A in conjunction with FIGS. 1A and 1B, a top plan view of the PCB assembly (102) is illustrated, in accordance with an example embodiment of the present disclosure. The PCB assembly (102) including the top surface (202) facilitates a platform for mounting the at least one conductor element and/or circuitry elements.
[0042] In one configuration, the PCB assembly (102) may be selected based on conformity to the dimension for accommodating the plurality of battery cells (106) as per design feasibility and requirements. In other words, the PCB assembly (102) may be selected for making electrical connection of the plurality of battery cells (106) selected based on the desired current ratings and voltage ratings.
[0043] The PCB assembly (102) includes a pair of electrode bus bar of opposite polarity (such as a positive electrode bus bar (204a), and a negative electrode bus bar (204b)) mounted at opposite ends on the top surface (202). In other words, the positive electrode bus bar (204a) and the negative electrode bus bar (204b) may be positioned parallel to each other, on the top surface (202) of the PCB assembly (102). In general, the electrode bus bars are placed apart for ensuring minimum electrical clearance which enables safe operating condition of the circuit. In one configuration, the positive electrode bus bar (204a), and the negative electrode bus bar (204b) may be mounted onto the top surface (202) via mounting means selected from one of adhesive bonding, soldering and the like as per design feasibility and requirement. Further, the orientation of the positive electrode bus bar (204a), and the negative electrode bus bar (204b) may be altered as per design feasibility and requirements.
[0044] The positive electrode bus bar (204a) and the negative electrode bus bar (204b) are configured to concentrate power from each battery cell of the plurality of battery cells (106). More specifically, the positive electrode bus bar (204a) and the negative electrode bus bar (204b) may be configured as distribution elements which are electrically connected to the battery pack (104). Further, the positive electrode bus bar (204a) and the negative electrode bus bar (204b) may be selected from at least one current conducting material such as, but not limited to, copper, brass, and aluminium. In an embodiment, the positive electrode bus bar (204a) and the negative electrode bus bar (204b) may be plated with a metallic material such as tin, or any other metallic material.
[0045] Further, the PCB assembly (102) includes a plurality of broached studs (206a, 206b, and 206c) mounted onto the positive electrode bus bar (204a), the negative electrode bus bar (204b), and onto the top surface (202) of the PCB assembly (102) respectively. In the illustrated embodiment, the broached studs (206a) and (206b) correspond to positive terminal output points and negative terminal output points of the battery system (100), respectively. Further, the broached studs (206c) correspond to a ground terminal point of the battery system (100). The ground terminal (i.e., broached studs (206c)) of the battery system (100) may be configured to suppress electrical noise when electrically connected to a metallic part of an external electrical device.
[0046] In this configuration, a plurality of protective elements (208) may be mounted onto the top surface (202) of the PCB assembly (102). The plurality of protective elements (208) is configured to provide protection for each battery cell of the plurality of battery cells (106). For instance, the plurality of protective elements (208) is configured to provide a battery cell level protection in the battery pack (104) in case of internal faults in the battery pack (104). The protective elements (208) may be selected based on the rating and/or capacity of each battery cell of the plurality of battery cells (106). In the illustrated configuration, the protective elements (208) may be a surface mount fuse (hereinafter interchangeably referred to as “SMD Fuse”), such as but not limited to, FLAT PAK fuse, Nano 2 fuse, PICO® Fuses, AECQ-Compliant Fuses and the like. Alternatively, or additionally, the plurality of protective elements (208) may be selected based on a current interrupt device (CID), a pressure temperature current (PTC) and the like, as per design requirements. The electrical connection of each protective element of the plurality of protective elements (208) in the PCB assembly (102) is described with reference to FIG. 4.
[0047] The PCB assembly (102) further includes a voltage sensing connector (210) mounted onto the top surface (202) of the PCB assembly (102). As such, the PCB assembly (102) including conductive tracks enables electrical connection of each of the battery cell to the voltage sensing connector (210). Thus, the voltage sensing connector (210) is configured to receive feedback from each battery cell of the plurality of battery cells (106) electrically connected to the PCB assembly (102). The feedback from each battery cell corresponds to operating conditions (i.e., voltage levels) of each battery cell.
[0048] In one form, the voltage sensing connector (210) may be electrically connected to the BMS (108) which is integrated within the PCB assembly (102) as described with reference with FIG. 1. The BMS (108) of the battery system (100) may be configured to receive inputs from the voltage sensing connector (210) and monitor the operating conditions of the battery system (100) and/or output commanded by the BMS (108). In particular, the BMS (108) may be configured to monitor voltage levels of each battery cell of the plurality of battery cells (106) in response to feedback provided by each battery cell to the voltage sensing connector (210).
[0049] In an embodiment, the BMS (108) and the voltage sensing connector (210) may include pin connector (not shown in Figures) for mounting onto the top surface (202) of the PCB assembly (102). As such, the pin connector of the BMS (108) and the voltage sensing connector (210) may be selected based on plurality of battery cells (106) used in the battery system (100). For instance, if the battery system (100) includes 14 cells in series, a 20-pin connector configuration may be selected for the BMS (108) and the voltage sensing connector (210).
[0050] In one form, the positive electrode bus bar (204a), the negative electrode bus bar (204b), the plurality of protective elements (208), and the voltage sensing connector (210), and the BMS (108) may be electrically connected with each other by conductive tracks and/or conducting path fabricated on the PCB assembly (102). For instance, these conductive tracks correspond to the wiring patterns of the circuitry connection in the PCB assembly (102). As such, these conducting tracks may be traced based on the design requirements in the manufacturing process of the PCB assembly (102).
[0051] Further, the PCB assembly (102) and the BMS (108) including at least one electronic component as described above may be provided with a conformal coating. As such, the conformal coating provided over the electronic components protects from at least moisture, dust, and chemicals.
[0052] Referring to FIG. 2B in conjunction with FIGS. 1A and 1B, a bottom plan view of the PCB assembly (102) is illustrated, in accordance with an example embodiment of the present disclosure. In this configuration, the PCB assembly (102) includes a plurality of first type conducting feeders (216a) and a plurality of second type conducting feeders (216b) mounted to the bottom surface (214) of the PCB assembly (102). In particular, each of the first type conducting feeders (216a), and the second type conducting feeders (216b) is electrically connected to a plurality of first polarity conducting traces and a plurality of second polarity conducting traces of the PCB assembly (102) respectively (e.g., as shown in FIG. 3). Further, each of the first type conducting feeders (216a) and the second type conducting feeders (216b) may be oriented at 0 degree or 180 degree at the bottom surface (214) for ease of electrically connecting to the PCB assembly (102). Further, each of the first type conducting feeders (216a) and the second type conducting feeders (216b) may be aligned in alternate fashion (e.g., successive to each other) as shown in FIG. 2B.
[0053] In one embodiment, the plurality of first type conducting feeders (216a) and the plurality of second type conducting feeders (216b) may be mounted onto the top surface (202) of the PCB assembly (102).
[0054] In one form, the plurality of first type conducting feeders (216a) and the plurality of second type conducting feeders (216b) may be fabricated using a tin-plated nickel material or any other conducting material as per design feasibility and requirements. In one embodiment, tin may be partially plated on at least one surface of the plurality of first type conducting feeders (216a) and the plurality of second type conducting feeders (216b) made of nickel. In an alternate embodiment, the tin may be completely plated to the plurality of first type conducting feeders (216a) and the plurality of second type conducting feeders (216b) made of nickel. As such, plating on the conducting feeders may prevent corrosion and may provide better soldering surface for electrically connecting each of the first type conducting feeders (216a) and the second type conducting feeders (216b) to the PCB assembly (102).
[0055] In one embodiment, the first type conducting feeders (216a) and the second type conducting feeders (216b) may conform to a horseshoe shape (e.g., as shown in FIG. 2B). Further, the shape of the conducting feeders (216a) and (216b) may be altered based on the design configurations.
[0056] Referring now to FIG. 3 in conjunction with FIG. 2B, an example representation of electrical connection of the plurality of battery cells (106) to the PCB assembly (102) is illustrated. In this configuration, the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b) may be fabricated at the top surface (202) and the bottom surface (214) of the PCB assembly (102). Particularly, due to double layer configuration of the PCB assembly (102), the plurality of first and second polarity conducting traces (302a), (302b) may be configured at the top surface (202) and the bottom surface (214). As such, this configuration provides both the surfaces as a platform for electrical connection. The first polarity conducting traces (302a) and the second polarity conducting traces (302b) may also be referred to as conducting tracks and/or conducting path. In one form, the first and second polarity conducting traces (302a), (302b) may be made of a copper material or any other conducting materials as per design feasibility and requirement.
[0057] The conducting tracks configured by the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b) form the wiring patterns of the circuitry connection of the PCB assembly (102). The conducting tracks of the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b) may provide interconnection of the plurality of battery cells (106) in the PCB assembly (102). The electrical interconnection of the plurality of battery cells (106) in the PCB assembly (102) is described in detail in further sections of the present disclosure.
[0058] In this configuration, the plurality of first type conducting feeders (216a), and the plurality of second type conducting feeders (216b), made of the tin-plated nickel material, may be electrically coupled to the PCB assembly (102) at the bottom surface (214). For example, the tin-plated nickel conducting feeders (i.e., the plurality of first type conducting feeders (216a) and the plurality of second type conducting feeders (216b)) may be placed onto the bottom surface (214) of the PCB assembly (102) by a tape and reel apparatus. Further, each of the first type conducting feeders (216a) and the second type conducting feeders (216b) may be electrically coupled to the corresponding first polarity conducting traces (302a) and the second polarity conducting traces (302b) respectively.
[0059] In one implementation, the electrical coupling may be done by a surface mount technology (SMT) reflow technique or any other techniques as per design feasibility and requirements. Additionally, in the SMT reflow technique, a solder paste may be applied onto each of the first type conducting feeders (216a) and the second type conducting feeders (216b). Thereafter, the PCB assembly (102) is subjected to controlled heat. Thus, the tin plating on each of the first type conducting feeders (216a) and the second type conducting feeders (216b) enables creation of permanent solder joints which enables each of the first type conducting feeders (216a) and the second type conducting feeders (216b) to be electrically connected to the corresponding first polarity conducting traces (302a) and the second polarity conducting traces (302b), respectively.
[0060] In one embodiment, each of the first type conducting feeders (216a), and the second type conducting feeders (216b) may be electrically connected by using conventional means such creating individual solder joints with a desoldering hot air gun.
[0061] Further, each battery cell of the plurality of battery cells (106) electrically connected to the PCB assembly (102) includes a first surface (304a) and a second surface (304b). In one configuration, each battery cell of the plurality of battery cells (106) is configured with a projecting nub (i.e., positive terminal (306a)) at the first surface (304a), and can or casing of each battery cell is selected to be the negative terminal (306b). It is understood, that for each battery cell, the positive terminal (306a) is located centrally on the first surface (304a), and the negative terminal (306b) is located at periphery (which is at zero potential) of the first surface (304a).
[0062] In this configuration, the first surface (304a) of each battery cell of the plurality of battery cells (106) may be aligned in a same plane as that of a longitudinal axis ‘X’ (e.g., as shown in FIG. 3). Such arrangement ensures electrical connection of the plurality of battery cells (106) to the PCB assembly (102) on only one side of PCB assembly (102) without the requirement of reorientation. In other words, the first surface (304a) of each battery cell is oriented towards the bottom surface (214) of the PCB assembly (102). The second surface (304b) of each battery cell is oriented away from the bottom surface of the PCB assembly (102). Accordingly, such configuration mitigates the flip flop arrangement of the plurality of battery cells (106) for electrically connecting the battery pack (104) to the PCB assembly (102).
[0063] In one embodiment, the second surface (304b) of each battery cell of the plurality of battery cells (106) may be coated with an insulating material (not shown in Figures). The insulating material coated onto the second surface (304b) may be configured to regulate heat during a thermal runaway condition. Further, the insulating material may also enhance other properties of the plurality of battery cells (106), such as chemical resistance, adhesion strength, and the like. In a non-limiting example, the insulating material may be selected to be one of an epoxy resin, ceramic, liquid silicone as per design feasibility and requirements.
[0064] In one configuration, each battery cell of the plurality of battery cells (106) may be electrically connected to the PCB assembly (102) by using conventional technique i.e. by a spot welding technique or any other techniques as per design feasibility and requirements. For instance, in the spot welding technique, electrodes of the spot welding apparatus, may be used to weld the positive terminal (306a) and the negative terminal (306b) of each battery cell to each of the first type conducting feeders (216a) and the second type conducting feeders (216b), respectively. As such, the electrodes may be accessed through at least one weld cut-outs (see, 212 of FIG. 2A) extending from the top surface (202) to the bottom surface (214) of the PCB assembly (102) for welding. Thus, the weld coupling of the positive terminal (306a) and the negative terminal (306b) of each battery cell to each of the first type conducting feeders (216a), and the second type conducting feeders (216b), respectively, ensures electrically connection with the PCB assembly (102).
[0065] FIG. 4 is a schematic view of electrical interconnection of the plurality of battery cells (106) in the PCB assembly (102), in accordance with an example embodiment of the present disclosure. The plurality of battery cells (106) electrically connected to the PCB assembly (102) via the plurality of first type conducting feeders (216a) and the plurality of second type conducting feeders (216b) is already described with reference to FIG. 3. Further, as shown in FIG. 4, the plurality of battery cells (106) is electrically interconnected in combination of the series configuration and the parallel configuration. In one implementation, the series configuration and the parallel configuration which are the circuitry connection may be traced on the PCB assembly (102) during the manufacturing of the PCB assembly (102) as per the design requirements. Thus, the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b) may electrically interconnect each battery cell of the plurality of battery cells (106) by way of a combination of series and parallel configurations.
[0066] In the series configuration, at least one battery cell of the plurality of battery cells (106) may be electrically connected in series with each other. Generally, in the series configuration, the positive terminal of one battery cell is electrically connected to the negative terminal of another battery cell. As such, electrically connecting the positive terminal of one battery cell to the negative terminal of another battery cell may be done by the conducting path traced in the PCB assembly (102). Further, electrically connecting at least one battery cell of the plurality of battery cells (106) in series with other may form a battery cell group (402). The battery cell group (402) includes two or more battery cells (106) connected in series. In other words, the plurality of battery cells (106) of the battery cell group (402) in series configuration is aligned in the same plane as of the longitudinal axis ‘X’ (e.g., as shown in FIG. 4). Further, each battery cell group (402) of the series configuration is electrically connected in the parallel configuration to one another and oriented along a vertical axis ‘Y’. In an example, the plurality of battery cells (106) can be understood to be arranged in a set of battery cell groups (402). For example, if there are 100 number of battery cells (106), it can be arranged in a configuration of 25*4 battery cells (106), where 25 number of battery cell groups (402) are connected in parallel, where each battery cell group (402) include 4 number of battery cells (106).
[0067] In one implementation, the positive terminal (306a) of end battery cell (i.e., a battery cell of the plurality of battery cells (106)) of each battery cell group (402) is electrically connected to the positive electrode bus bar (204a). Further, the negative terminal (306b) of other end battery cell of each battery cell group (402) is electrically connected to the negative electrode bus bar (204b). Thus, it is evident that the power from the plurality of battery cells (106) from each battery cell group (402) is concentrated at the positive electrode bus bar (204a) and the negative electrode bus bar (204b) for distribution.
[0068] Referring back to FIG. 2A, the plurality of protective elements (208) is mounted onto the top surface (202) of the PCB assembly (102). As such, each protective element is electrically connected between the positive terminal (e.g., the positive terminal (306a)) of a battery cell and the negative terminal (e.g., the negative terminal (306b)) of another battery cell. In particular, each protective element of the plurality of protective elements (208) is electrically connected in series with each battery cell of the plurality of battery cells (106) for example, as shown in FIG. 4. In one configuration, electrical connection of the plurality of protective elements (208) may also be traced on the PCB assembly (102) which is already described in reference with FIG. 2A.
[0069] Each protective element of the plurality of protective elements (208) is configured to provide battery cell level protection in case of internal fault condition in the battery pack (104). For instance, electrical resistance of an individual battery cell of the battery cell group (402) may drop, or any internal failure may occur in the individual cell. In this scenario, the battery cell of each battery cell group (402) electrically connected in parallel may also exhibit increase in temperature leading to a thermal runaway due to significant increase in electric current. Thus, BMS (such as the BMS (108)) may be configured to detect the fault condition (e.g., overcurrent due to overloads and short circuits), and may provide a command to the protective element (208). Therefore, the protective element (such as the plurality of protective elements (208)) connected to the short circuited battery cell may operate (i.e., blow off) thereby protecting the battery cells of each battery cell group (402) connected in the parallel configuration. For example, in an event of overcurrent leading to overheating, each protective element is designed to melt and break the electrical connection. Thus, isolating the short-circuited cell from the entire battery pack (such as the battery pack (104)) prevents the thermal runaway event from initiating or from propagating.
[0070] In one example embodiment, the short-circuited cell of the plurality of battery cells (106) may be replaced by a normally operating battery cell. Thus, a normally operating battery cell may be spot welded to the corresponding first type conducting feeders (216a) and the second type conducting feeders (216b) upon disconnecting the short-circuited battery cell from the battery pack (104).
[0071] FIG. 5 is a schematic view of the rechargeable battery system (100), employed in an automotive vehicle (500) for powering applications, in accordance with an example embodiment of the present disclosure. For example, the automotive vehicle (500) may be an example of an “electric vehicle (500)” (such as a 2-wheeler as shown in FIG. 5). For illustrative purpose, the electric vehicle (500) (hereinafter interchangeably referred to as “EV vehicle (500)”) is depicted which includes the battery system (100) for powering of the EV vehicle (500) for inducing motive power. Thus, it is understood to a person skilled in the art, that the battery system (100) may be used in any of the powering applications in the electrical and electronics field without deviating from the scope of invention.
[0072] The battery system (100) may further include a housing (not shown in Figures) for encasing the components of the battery system (100) (i.e., battery pack (104), and the PCB assembly (102) etc.). Further, the battery system (100) may be configured for powering one or more electrical components of the EV vehicle (500). Particularly, the battery system (100) may power at least one component (e.g., lights, consoles, etc.), as well as electric motor of the EV vehicle (500). As such, powering at least one component of the EV vehicle (500) may result in a motive power.
[0073] More specifically, the BMS (e.g., the BMS (108)) may be configured to monitor voltage levels of each battery cell of the plurality of battery cells (106) of the battery pack (104) in the EV vehicle (500). Thus, ensuring safety and efficient operation of the battery system (100). Further, the BMS (108) may control one or more operational parameters such as, but not limited to, discharging control, charging control, state-of-charge (SOC) determination, cell balancing, thermal control, and the like. Further, the BMS (108) acts as a bridge between the battery pack (104) and the electronic control unit (ECU) (not shown in Figures) of the EV vehicle (500). As such, the information collected by the BMS (108) may be communicated to the ECU.
[0074] In an embodiment of the present disclosure, the battery system (100) is provided. The battery system (100), provided using a PCB board (such as PCB assembly (102) integrated with the BMS (108)) is a single integrated solution of battery cell interconnection leading to usage of fewer components. Thus, making the battery system (100), compact and performing multiple functions of feeding battery cell current into terminal bus bar, providing termination point for power connections, cell level short circuit protection, providing voltage sense connections to the BMS (108), eliminating use of bus bars and harness to connect battery power terminal to the BMS (108). Further, the PCB assembly (102) used in the battery system (100) has better performance in signal integrity. Further, the plurality of battery cells (106) having the positive terminal (306a) and the negative terminal (306b) on the same side ensures welding on only one side of PCB without the requirement of reorientation for cell interconnection.
[0075] Although the invention has been described with reference to specific exemplary embodiments, it is noted that various modifications and changes may be made to these embodiments without departing from the broad spirit and scope of the invention.
[0076] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the invention.
,CLAIMS:We claim:
1. A battery system (100), comprising:
a battery pack (104) including a plurality of battery cells (106), each battery cell of the plurality of battery cells (106) including at least a positive terminal (306a) and a negative terminal (306b); and
a printed circuit board (PCB) assembly (102) including a top surface (202) and a bottom surface (214), the printed circuit board (PCB) assembly (102) comprising:
a plurality of first polarity conducting traces (302a) and a plurality of second polarity conducting traces (302b), wherein the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b) correspond to conducting tracks for interconnecting each battery cell of the plurality of battery cells (106), and
a plurality of first type conducting feeders (216a) and a plurality of second type conducting feeders (216b) mounted at the bottom surface (214), wherein each first type conducting feeder of the plurality of first type conducting feeders (216a) and each second type conducting feeder of the plurality of second type conducting feeders (216b) are electrically connected to corresponding first polarity conducting trace of the plurality of first polarity conducting traces (302a), and corresponding second polarity conducting trace of the plurality of second polarity conducting traces (302b) respectively,
wherein, each first type conducting feeder of the plurality of first type conducting feeders (216a) and each second type conducting feeder of the plurality of second type conducting feeders (216b) are electrically connected to the positive terminal (306a) and the negative terminal (306b) of corresponding battery cell of the plurality of battery cells (106), respectively.

2. The battery system (100) as claimed in claim 1, wherein the plurality of battery cells (106) electrically connected to the printed circuit board (PCB) assembly (102) are electrically interconnected in a combination of a series configuration and a parallel configuration by conducting tracks configured by the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b), wherein the plurality of battery cells (106) are arranged in a set of battery cell groups (402) connected in parallel to each other, wherein each battery cell group (402) includes two or more battery cells (106) connected in series.

3. The battery system (100) as claimed in claim 2, further comprising:
a plurality of protective elements (208) mounted onto the top surface (202) of the printed circuit board (PCB) assembly (102), wherein each protective element of the plurality of protective elements (208) is electrically connected in series with the two or more battery cells (106),
wherein, the plurality of protective elements (208) is configured to provide short circuit protection.

4. The battery system (100) as claimed in claim 2, wherein the printed circuit board (PCB) assembly (102) further comprises:
a voltage sensing connector (210) mounted onto the top surface (202) of the printed circuit board (PCB) assembly (102), the voltage sensing connector (210) configured to receive voltage feedback from each battery cell of the plurality of battery cells (106); and
a battery management system (BMS) (108) electrically connected to the printed circuit board (PCB) assembly (102), the battery management system (BMS) (108) configured to monitor and manage operating condition of each battery cell of the plurality of battery cells (106) based on input received from the voltage sensing connector (210).
5. The battery system (100) as claimed in claim 2, wherein the printed circuit board (PCB) assembly (102) further comprises:
a voltage sensing connector (210) mounted onto the top surface (202) of the printed circuit board (PCB) assembly (102), the voltage sensing connector (210) configured to receive voltage feedback from each battery cell of the plurality of battery cells (106); and
a battery management system (BMS) (108) integrated within the printed circuit board (PCB) assembly (102), the battery management system (BMS) (108) configured to monitor and manage operating condition of each battery cell of the plurality of battery cells (106) based on input received from the voltage sensing connector (210).

6. The battery system (100) as claimed in claim 2, further comprising:
a positive electrode bus bar (204a) and a negative electrode bus bar (204b) mounted onto the top surface (202), wherein the positive terminal (306a) of an end battery cell of each battery cell group (402) is electrically connected to the positive electrode bus bar (204a), and the negative terminal (306b) of other end battery cell of each battery cell group (402) is electrically connected to the negative electrode bus bar (204b).

7. The battery system (100) as claimed in claim 2, wherein the positive terminal (306a), and the negative terminal (306b) are located at a first surface (304a) of each battery cell of the plurality of battery cells (106), thereby positioning the first surface (304a) of each battery cell in a same plane along a longitudinal axis for electrically connecting the positive terminal (306a), and the negative terminal (306b) of each battery cell to the corresponding first type conducting feeders (216a) and the second type conducting feeders (216b) respectively at the bottom surface (214).

8. The battery system (100) as claimed in claim 2, wherein each battery cell of the plurality of battery cells (106) comprises a second surface (304b), wherein the second surface (304b) of each battery cell is potted with an electrically insulating material which is configured to extract thermal energy from the second surface (304b) of each battery cell of the plurality of battery cells (106) during operation and protecting the battery cell against a thermal runaway condition.

9. The battery system (100) as claimed in claim 1, wherein the plurality of first type conducting feeders (216a) and the plurality of second type conducting feeders (216b) are fabricated by a tin-plated nickel material.

10. The battery system (100) as claimed in claim 1, wherein each battery cell of the plurality of battery cells (106) is a lithium (Li) ion battery cell.

11. The battery system (100) as claimed in claim 1, wherein electrical connection of each of the first type conducting feeders (216a) and the second type conducting feeders (216b) with the positive terminal (306a) and the negative terminal (306b) of the corresponding battery cell of the plurality of battery cells (106), respectively comprise a weld coupling.

12. A battery system (100) with an integrated battery management system (BMS) (108), the battery system (100) comprising:
a battery pack (104) including a plurality of battery cells (106), each battery cell of the plurality of battery cells (106) including at least a positive terminal (306a) and a negative terminal (306b);
a printed circuit board (PCB) assembly (102) including a top surface (202) and a bottom surface (214), the printed circuit board (PCB) assembly (102) comprising:
a plurality of first polarity conducting traces (302a) and a plurality of second polarity conducting traces (302b), wherein the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b) correspond to conducting tracks for interconnecting each battery cell of the plurality of battery cells (106),
a plurality of first type conducting feeders (216a) and a plurality of second type conducting feeders (216b) mounted at the bottom surface (214), wherein each first type conducting feeder of the plurality of first type conducting feeders (216a) and each second type conducting feeder of the plurality of second type conducting feeders (216b) are electrically connected to corresponding first polarity conducting trace of the plurality of first polarity conducting traces (302a), and corresponding second polarity conducting trace of the plurality of second polarity conducting traces (302b) respectively,
wherein, each first type conducting feeder of the plurality of first type conducting feeders (216a) and each second type conducting feeder of the plurality of second type conducting feeders (216b) are electrically connected to the positive terminal (306a) and the negative terminal (306b) of corresponding battery cell of the plurality of battery cells (106), respectively, and
a voltage sensing connector (210) mounted onto the top surface (202) of the printed circuit board (PCB) assembly (102), the voltage sensing connector (210) configured to receive voltage feedback from each battery cell of the plurality of battery cells (106); and
the battery management system (BMS) (108) electrically connected to the printed circuit board (PCB) assembly (102), the battery management system (BMS) (108) configured to monitor and manage operating condition of each battery cell of the plurality of battery cells (106) based on input received from the voltage sensing connector (210).

13. The battery system (100) as claimed in claim 11, wherein the plurality of battery cells (106) electrically connected to the printed circuit board (PCB) assembly (102) are electrically interconnected in a combination of a series configuration and a parallel configuration by conducting tracks configured by the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b), wherein the plurality of battery cells (106) are arranged in a set of battery cell groups (402) connected in parallel to each other, wherein each battery cell group (402) includes two or more battery cells (106) connected in series.

14. The battery system (100) as claimed in claim 12, further comprising:
a plurality of protective elements (208) mounted onto the top surface (202) of the printed circuit board (PCB) assembly (102), wherein each protective element of the plurality of protective elements (208) is electrically connected in series with the two or more battery cells (106),
wherein, the plurality of protective elements (208) is configured to provide battery cell level short circuit protection.

15. The battery system (100) as claimed in claim 12, further comprising:
a positive electrode bus bar (204a) and a negative electrode bus bar (204b) mounted onto the top surface (202), wherein the positive terminal (306a) of an end battery cell of each battery cell group (402) is electrically connected to the positive electrode bus bar (204a), and the negative terminal (306b) of other end battery cell of each battery cell group (402) is electrically connected to the negative electrode bus bar (204b).

16. The battery system (100) as claimed in claim 12, wherein the positive terminal (306a), and the negative terminal (306b) are located at a first surface (304a) of each battery cell of the plurality of battery cells (106), thereby positioning the first surface (304a) of each battery cell in a same plane along a longitudinal axis for electrically connecting the positive terminal (306a), and the negative terminal (306b) of each battery cell to the corresponding first type conducting feeders (216a) and the second type conducting feeders (216b) respectively at the bottom surface (214).

17. The battery system (100) as claimed in claim 12, wherein each battery cell of the plurality of battery cells (106) comprises a second surface (304b), wherein the second surface (304b) of each battery cell is potted with an electrically insulating material which is configured to extract thermal energy from the second surface (304b) of each battery cell of the plurality of battery cells (106) during operation and protecting the battery cell against a thermal runaway condition.

18. The battery system (100) as claimed in claim 11, wherein the plurality of first type conducting feeders (216a), and the plurality of second type conducting feeders (216b) are fabricated by a tin-plated nickel material.

19. The battery system (100) as claimed in claim 11, wherein each battery cell of the plurality of battery cells (106) is a lithium (Li) ion battery cell.

20. The battery system (100) as claimed in claim 11, wherein electrical connection of each of the first type conducting feeders (216a) and the second type conducting feeders (216b) with the positive terminal (306a) and the negative terminal (306b) of the corresponding battery cell of the plurality of battery cells (106), respectively comprise a weld coupling.

21. A battery system (100) for an automotive vehicle (500), comprising:
a battery pack (104) including a plurality of battery cells (106), each battery cell of the plurality of battery cells (106) including at least a positive terminal (306a) and a negative terminal (306b);
a printed circuit board (PCB) assembly (102) including a top surface (202) and a bottom surface (214), the printed circuit board (PCB) assembly (102) comprising:
a plurality of first polarity conducting traces (302a) and a plurality of second polarity conducting traces (302b), wherein the plurality of first polarity conducting traces (302a) and the plurality of second polarity conducting traces (302b) correspond to conducting tracks for interconnecting each battery cell of the plurality of battery cells (106),
a plurality of first type conducting feeders (216a), and a plurality of second type conducting feeders (216b) mounted at the bottom surface (214), wherein each first type conducting feeder of the plurality of first type conducting feeders (216a) and each second type conducting feeder of the plurality of second type conducting feeders (216b) are electrically connected to corresponding first polarity conducting trace of the plurality of first polarity conducting traces (302a), and corresponding second polarity conducting trace of the plurality of second polarity conducting traces (302b) respectively,
wherein, the positive terminal (306a), and the negative terminal (306b) are located at a first surface (304a) of each battery cell of the plurality of battery cells (106), thereby positioning the first surface (304a) of each battery cell in a same plane along a longitudinal axis, thus electrically connecting the positive terminal (306a), and the negative terminal (306b) of each battery cell to the corresponding first type conducting feeders (216a) and the second type conducting feeders (216b), respectively at the bottom surface (214) of the printed circuit board (PCB) assembly (102),
a plurality of protective elements (208) mounted onto the top surface (202) of the printed circuit board (PCB) assembly (102), wherein each protective element of the plurality of protective elements (208) is electrically connected in series with the two or more battery cells (106) wherein, the plurality of protective elements (208) is configured to provide battery cell level short circuit protection, and
a voltage sensing connector (210) mounted onto the top surface (202) of the printed circuit board (PCB) assembly (102), the voltage sensing connector (210) configured to receive voltage feedback from each battery cell of the plurality of battery cells (106); and
a battery management system (BMS) (108) integrated within the printed circuit board (PCB) assembly (102), the battery management system (BMS) (108) configured to monitor operating condition of each battery cell of the plurality of battery cells (106) based on input received from the voltage sensing connector (210).