DESC:TECHNICAL FIELD
[0001] The present subject matter relates generally to a power source module. More particularly but not exclusively the present subject matter relates to a power source module management system.
BACKGROUND
[0002] Nowadays, with the advancement in the technology, an electric or hybrid electric vehicle make use of one or more power source to drive the vehicle. The one or more powers source is a battery to provide power to run a motor which in turn runs one or more wheels of the vehicle. The battery pack includes one or more cells and are connected through one or more interconnectors to provide an electrical connection. The one or more cells are arranged in a module consisting of a top casing and a bottom casing. The one or more cells are welded to a metal strip known as the interconnector, forming a battery pack. The one or more interconnector is connected to a BMS (Battery management system). The BMS obtains the individual parameters of the one or more cells to monitor the SoC (state of charge) and SoH (state of health) of the battery pack.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The details are described with reference to an embodiment of a power source module along with the accompanying diagrams. The same numbers are used throughout the drawings to reference similar features and components.
[0004] Figure 1 exemplarily illustrates a side view of a power source module with a power source module casing.
[0005] Figure 2 exemplarily illustrates side view of the power source module with power source module casing omitted and a side exploded view of a power source module management system connected to the power source module.
[0006] Figure 3 exemplarily illustrates an exploded perspective side view of the of the power source module.
[0007] Figure 4 exemplarily illustrates a top view of a base member disposed on the power source module and the side view of the power source module with the base member disposed on it.
[0008] Figure 5 exemplarily illustrates a top view and a side view of the base member.
[0009] Figure 6(a) exemplarily illustrates a side view of a horizontally placed individual cell with a thermal resistor and its connection.
[00010] Figure 6(b) exemplarily illustrates a side view of a vertically placed individual cell with the thermal resistor and its connection.

DETAILED DESCRIPTION

[0001] Generally, the connection between one or more cell and a battery management system (BMS) is very crucial for efficient working of the battery pack. An interconnector plate made up of metal is used to form the connection between the one or more cells and the BMS. The interconnector plate is welded on the one or more cells and is connected to the BMS through wiring harness. The BMS plays a vital role in monitoring the health of the battery pack. The BMS monitors the voltage, charging current, temperature, state of charge, and the like of the one or more cell for ensuring effective working and long life of the battery pack. In most of the battery pack, the one or more cells are connected to the BMS through the wiring harness to ensure the connection between them. However, if a number of rows of cells is increased, it results in increase in number of interconnectors to be connected between the one or more cells and the BMS, thus resulting in increase of number of wires. So, this leads to complex configuration, wire entanglement and also results in increased assembly time.
[0002] Apart from this, at the time of assembly of the battery pack, the BMS is placed on a battery module formed after assembling the one or more cells and the interconnectors. Once the BMS is placed on the battery module, the battery module gets in contact with the BMS. Then each of the interconnectors gets attached at each voltage sensing parts provided on the BMS, thus leading to the problem of hot plugging. Hot plugging may also occur due to improper contact of the interconnector with the BMS during assembly. The voltage sensing part in BMS is connected to an integrated circuit (IC). The variation in voltage may damage the integrated circuit on the BMS. In the known prior arts, the above-mentioned problem is addressed by directly soldering the interconnectors to the BMS by dividing the voltage sensing part into two part to avoid hot plugging. The voltage sensing part is divided into a first part and a second part. The first and the second part are electrically insulated from each other. The first part comes in contact with the interconnector when the BMS is assembled initially and thus does not makes a contact with the second part when it is disposed, thus avoiding the situation of hot plugging to a large extent. But this structure needs to be formed in a sub assembly and then is assembled with the battery pack, leading in difficulty in manufacturing, increasing assembly time, number of part count, cost to the battery pack and there are still chances that the voltage sensing part may come in contact with the interconnector plates.
[0003] In addition to this, one or more electrical components are mounted on the BMS for monitoring the performance and efficiency of the battery pack. For example: one of the couplers connected to a thermal resistor which is disposed on the battery module, is to be connected to the BMS. The thermal resistor with its cord set is attached to one or more cells using adhesives, stickers or any other methods. One end of the cord set is connected to the thermal resistor which is in contact with the one or more cell surface and the other end is connected to a coupler that gets connected to the BMS. The thermal resistor wires are routed through the provisions provided in the module to bring the coupler to the top position. Now, if the number of thermal resistors is to be increased, it leads in increase of the BMS board size to accommodate the individual mating couplers. More Precisely, since each of the thermal resistor is to be connected to the BMS individually, this increases the number of wires and difficulty in wire routing, thus leading to wire entanglement, short circuit, which ultimately impacts the life of the battery module.
[0004] In addition to this, if the battery pack has any thermal solution/cooling solution for controlling the heat generated inside the battery pack. There are chances that this solution might not be in proper contact with all cells, so this may lead to temperature variation in the cells. Thus, the limited number of thermal resistors may not be able to trace the above-mentioned problem. Thus, there is a need to overcome the above-mentioned problems and other problems of known art.
[0005] An objective of the present subject matter is to increase life expectancy of the battery module while eliminating hot plug issue and multiple wired connection in the battery module while maintaining the efficiency and capacity of the battery pack. The present subject matter further aims to provide a compact, simple, safe to operate, easy to manufacture, assemble, and service, and also ensures durability of the attachment, freedom to increase the attachment of number of parts on the BMS, without increasing the size of the BMS. The present subject matter is described using an exemplary battery pack which used in the vehicle, whereas the claimed subject matter can be used in any other type of application employing above-mentioned battery pack, with required changes and without deviating from the scope of invention.
[0006] As per an aspect of the present subject matter, a power source module comprising one or more cells; one or more interconnectors electrically connected to the one or more cells; and one or more power source module management system. One or more base member is configured to establish electrical connection between the one or more interconnectors and the one or more power source module management system.
[0007] As per an aspect of the present subject matter, the one or more base member and the one or more power source module management system is disposed on one of a top portion, a bottom portion, a left-hand side, or a right-hand side.
[0008] As per an aspect of the present subject matter, the one or more interconnector is electrically connected to the base member at one or more voltage sensing points.
[0009] As per an aspect of the present subject matter, the one or more base member is detachably attached with the one or more interconnectors with one or more fasteners.
[00010] As per another aspect of the present subject matter, the one or more base member is attached with the one or more interconnectors by one of a welding or soldering.
[00011] As per an aspect of the present subject matter, the base member is provided with one or more first couplers, and the one or more power source module management system is provided with one or more second couplers.
[00012] As per an aspect of the present subject matter, one end of one or more cord set is connected to the one or more first coupler of the base member and the second end of the cord set is connected to the one or more second coupler of the one or more power source module management system to form an electrical connection between the one or more cells and the one or more power source module management system.
[00013] As per an aspect of the present subject matter, the one or more power source module management system is detachably attached within a top casing of the power source module with one or more fastening means.
[00014] As per an aspect of the present subject matter, the one or more electrical components disposed inside the power source module is electrically connected to the power source module management system through the base member.
[00015] As per an aspect of the present subject matter, one of one or more thermal resistors couplers are disposed on the base member.
[00016] As per an aspect of the present subject matter, one end of a thermal resistor cord set is connected to the one or more cells and the other end of the thermal resistor cord set is connected to the thermal resistor coupler disposed on the base member.
[00017] As per an aspect of the present subject matter, the power source module management system being configured to establish an external connection with the power source module through the base member. The embodiments of the present invention will now be described in detail with reference to a power source module along with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[00018] Fig.1 exemplarily illustrates a side view of a power source module 100a with a power source module casing 102. Fig.2 exemplarily illustrates a side view of the power source module 100a with power source module casing 102 omitted and a side exploded view of a power source module management system 110 connected to the power source module 100a. Fig.1 and Fig.2 shall be discussed together. The power source module casing 102 protects the power source module 100a from outside environment and prevents it’s from getting damage. The power source module 100a includes one or more cells (not shown) disposed in one or more holder 104 to hold it still in its required position, during the operation of the vehicle (not shown) and also to maintain the required cell arrangement and cell spacing. The power source module 100a includes the one or more cells (not shown), one or more cell holder 104, and one or more interconnectors 106. The one or more cells provides the electric energy to drive a vehicle (not shown). In the present embodiment, the power source module casing 102 includes a first casing 102a (shown in fig.3), a second casing 102b (shown in fig.3), and a top casing 102c (shown in fig.3). The first casing 102a supports a front portion of the one or more cells. The second casing 102b supports a back portion of the one or more cells. The top casing 102c covers the power source module 100a from a top portion of the power source module 100a. In an embodiment, the one or more casing 102 can be one of the aluminum casing. The one or more cell holder 104 includes provisions (not shown) for one or more interconnector 106 to be housed. The one or more interconnectors 106 are used to make electrical connection between the one or more cells. The one or more cells are welded to the interconnector 106 to form a power source module 100a. The one or more interconnectors 106 are placed above the module 100a and provisions are provided on the module 100a to hold the one or more interconnectors 106 in place.
[00019] Fig.3 exemplarily illustrates an exploded perspective side view of the of the power source module 100a. Fig.4 exemplarily illustrates a top view of a base member 108 disposed on the power source module 100a and the side view of the power source module 100a with the base member 108 disposed on it. Fig.3 and Fig.4 shall be discussed together. The power source module 100a includes the one or more base member 108, the power source module management system 110, and one or more cord set 126. In the present embodiment, the base member 108 is disposed on a top portion of the power source module 100a, when the power source pack 100 is placed vertically. The power source module management system 110 is disposed on the top of the base member 108. In the present embodiment, the power source module management system 110 is a single part. However, the one or more base member 108 and the one or more power source module management system 110 can be disposed on one of a top portion, a bottom portion, a left-hand side, or a right-hand side of the power source module 100a. In the present embodiment, the base member 108 includes one or more electrical component connected and placed on a portion of the base member 108. The one or more base member 108 is sandwichedly disposed between the one or more interconnectors 106 and the one or more power source module management system 110. In the present embodiment, the base member 108 can be a printed circuit board (PCB) acting as an insulation member between the power source module 100a and the power source module management system 110. However, any other material can be used exhibiting similar properties than the PCB. One side of the base member is non conducting, and the non-conducting side of the base member 108 is faced towards the power source module 100a, acting as an insulator between the power source module 100a and the power source module management system 110. The other side of the base member 108 is faced towards the power source module management system 110 and accommodates one or more electrical connections. However, in another embodiment, the power source module management system 110 can be a two-part component placed one above the other, based on the height of the power source pack 100. In an embodiment, the power source module management system 110 is positioned in the top casing 102c to reduce the height of the power source pack 100. In the present embodiment, the one or more power source module management system 110 is detachably attached within the top casing 102c of the power source module 100a with one or more fastening means (not shown). An output port 112 and a socket 114 are provided in the top casing 102c to bring out the connection to the outside of the power source pack 100 from the power source module management system 110.
[00020] In the present embodiment, the base member provides connection for a thermal resistor 132 (shown in fig.6(a)), so as to be connected with the power source module management system 110. The one or more interconnectors 106 are connected to the power source module management system 110 by means of the base member 108. The base member 108 includes one or more voltage sensing points 118, where each of the one or more interconnectors 106 are getting attached. In the best embodiment, the interconnectors 106 are detachably attached by means of one or more fasteners 120 at the voltage sensing points 118 located at the base member 108. However, the attachment means can include welding, soldering and the like. The base member 108 gets connected to the power source module management system 110 by means of one or more couplers (122, 124) (shown in fig.2 and fig.3) and one or more cord sets 126. The base member 108 is provided with one or more first coupler 122 (shown in fig.2), and the one or more power source module management system 110 is provided with one or more second coupler 124 (shown in fig.2). One end of one or more cord set 126 is connected to the one or more first coupler 122 of the base member 108 and the second end of the cord set 126 is connected to the one or more second coupler (122, 124) of the one or more power source module management system 110 to form an electrical connection between the one or more cells (not sown) and the one or more power source module management system 110. A first set of voltage values are obtained from the terminals of a signal interconnector 106a (shown in fig.2) and is given to the power source module management system 110 and a second set of voltage values are obtained from the terminals of a power interconnectors 106b (shown in fig.2).
[00021] The voltage sensing points 118 at the base member 108 are connected to the corresponding interconnectors 106 at the power source module management system 110 and further are internally connected to the couplers (122, 124). When the voltage sensing points 118 are connected to the corresponding interconnectors 108, unintentional contact between the voltage sensing points 118 occur, the power source module management system 110 and its associated components may get damage due to the repeated unintentional contact between the voltage sensing points 118 and the corresponding interconnectors 106, if they are connected directly to the power source module management system 110. To prevent this from happening, the base member 108 is used as an intermediary between interconnectors 106 and the power source module management system 110. This configuration eliminates the problem of hot plugging because when the coupler (122, 124) on the base member 108 gets connected to the coupler (122, 124) on power source module management system 110, only then the voltage sensing points 118 gets electrically connected to an integrated circuit (IC) (not shown) of the power source module management system 110, during the time of the assembly. The base member 108 collects one or more signal from each interconnector 106 and transfers to the power source module management system 110 by means of one or more cord set 126 and couplers (122, 124). The power source module management system 110 includes the integrated circuit (IC) (not shown) that gets electrically connected to the coupler internally. The integrated circuit is the vital part of the power source module management system 110 as the integrated circuit monitors and measures the one or more cell voltages to control the operation of the power source module 100a. The present invention thus provides a modular power source module management system 110 and eliminates use of wires to connect the one or more interconnectors 106 with the power source module management system 110, thus reducing the complexity in connections. Also, facilitates in easy replacement of the power source module management system 110, in case of component failure. This provides a simple design, eliminates complexity due to wire and removal of wires improves the aesthetic appearance of the power source module 100a.
[00022] Fig.5 exemplarily illustrates a top view and a side view of the base member 108. In the present embodiment, the base member 108 is rectangular in shape with a U-shape cut section 128 provided at one of the sides of the rectangular base member. However, the base member 108 can be of any other shape based on the structural requirement of the power source pack 100. The base member 108 includes the one or more voltage sensing points 118 for establishing the electrical connection with the one or more interconnectors 106 (shown in fig. 4) and the one or more couplers (122,124) for facilitating connections between the base member 108 and the power source module management system 110. The base member 108 includes one or more thermal resistor couplers 130 (shown in fig. 4 and fig.5). In an embodiment, all electrical connections from the one or more electrical components in the power source module (100a) goes to the power source module management system 110 through the base member 108. In the present embodiment, a thermal resistor 132 is an electrical component. However, above mentioned electrical connection can be established between any other type of electrical components placed in the power source module (100a) and the power source module management system 110. In another embodiment, the power source module management system 110 being configured to establish an external connection with the power source module 100a through the base member 108. The external connection may include any connection from any other component external to the power source module 100a or it may be an external power source module (not shown), or any other connections, and the like.
[00023] Fig.6(a) exemplarily illustrates a side view of a horizontally placed individual cell with a thermal resistor 132 and its connection. Fig.6(b) exemplarily illustrates a side view of a vertically placed individual cell with the thermal resistor 132 and its connection. Fig.6(a) and Fig.6(b) shall be discussed together. In the present embodiment, the thermal resistor 132 with its cord set 134 is attached to the cell by means of adhesives, stickers, and the like. However, any other means can be used to attach it to the cell of the power source module 100a. One end of the thermal resistor cord set 134 is connected to the cell and the other end of the thermal resistor cord set 134 is connected to the thermal resistor couplers 130 (shown in fig.5) disposed on the base member 108 to form a connection. The thermal resistor couplers 130 are internally connected. The base member 108 collects the signal from each interconnector 106 and thermal resistors 132 and transfers to the power source module management system 110 by means of the cord set 134 and the couplers 130. The power source module management system 110 consists of a temperature sensing circuit (not shown) that gets electrically connected to the coupler internally that monitors and measures the cell temperatures to control the power source module 100a operations.
[00024] The above-mentioned configuration helps in replacing a greater number of 2 pin couplers with a single 34 or more pin coupler on the power source module management system 110 and thus increases the space on the base member 108 and avoids cluttering of loose wires. As the base member 108 has no electrical components, thus providing space to keep more couplers, thus allowing increased number of thermal resistors 132 in the power source pack 100. This also reduces the cost of the power source module management system 110 and helps in reducing the power source module management system 110 size and makes the design modular and compatible with different configuration of packs. In an embodiment, one or more rubber damper (not shown) is positioned between the interconnectors 106 and the power module casing 102. The rubber dampers insulate the power line from casing 102 which is made up of aluminum and arrest the vibrations generated on the one or more interconnectors 106. Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention.

List of Reference numerals
100: Power source pack
100(a): Power source module
102: Power source module casing
102(a): First casing
102(b): Second casing
102(c): Top casing
104: One or more cell holder
106: One or more interconnectors
106(a): Signal interconnector
106(b): Power interconnector
108: One or more base member
110: One or more power source module management system
112: Output port
114: Socket
116: One or more thermal resistor
118: One or more voltage sensing points
120: One or more fasteners
122: First coupler
124: Second coupler
126: One or more cord set
128: U-shape cut-section
130: Thermal resistor couplers
132: Thermal resistors
134: Thermal resistor cord set

,CLAIMS:We claim:
1. A power source module (100a) comprising:
one or more cells (not shown);
one or more interconnectors (106) electrically connected to the one or more cells; and
one or more power source module management system (110);
one or more base member (108); and
wherein, the one or more base member (108) being configured to establish electrical connection between the one or more interconnectors (106) and the one or more power source module management system (110).
2. The power source module (100a) as claimed in claim 1, wherein the one or more base member (108) and the one or more power source module management system (110) being disposed on one of a top portion, a bottom portion, a left-hand side, or a right-hand side of the power source module (100a).
3. The power source module (100a) as claimed in claim 1, wherein the one or more interconnector (106) being electrically connected to the base member (108) at one or more voltage sensing points (118).
4. The power source module (100a) as claimed in claim 3, wherein the one or more base member (108) being detachably attached with the one or more interconnectors (106) with one or more fasteners (120).
5. The power source module (100a) as claimed in claim 1, wherein the one or more base member (108) being attached with the one or more interconnectors (106) by one of a welding or soldering.
6. The power source module (100a) as claimed in claim 1, wherein the base member (108) being provided with one or more first couplers (122), and the one or more power source module management system (110) being provided with one or more second couplers (124).
7. The power source module (100a) as claimed in claim 6, wherein one end of one or more cord set (126) being connected to the one or more first coupler (122) of the base member (108) and the second end of the cord set (126) being connected to the one or more second coupler (124) of the one or more power source module management system (110) to form an electrical connection between the one or more cells (not shown) and the one or more power source module management system (110).
8. The power source module (100a) as claimed in claim 1, wherein the one or more power source module management system (110) being detachably attached within a top casing (102c) of the power source module (100a) with one or more fastening means (not shown).
9. The power source module (100a) as claimed in claim 1, wherein one or more electrical components (132), disposed inside the power source module (100a), being electrically connected to the power source module management system (110) through the base member (108).
10. The power source module (100a) as claimed in claim 9, wherein one or more thermal resistor coupler (130) being disposed on the base member (108), wherein One end of a thermal resistor cord set (134) being connected to the one or more cells and the other end of the thermal resistor cord set (134) being connected to the thermal resistor coupler (130).
11. The power source module (100a) as claimed in claim 1, wherein the power source module management system (110) being configured to establish an external connection with the power source module (100a) through the base member (108).