Description:
OBJECTIVE OF THE INVENTION:
An objective of the present invention is to provide a design and selection of battery packs considering minimized heat generation by using multiple connections.
Another object of the present invention is to provide a process for selection of battery packs considering minimized heat generation by using multiple connections.

SUMMARY OF THE INVENTION:
Accordingly, the present invention provides an process for design and selection of battery packs, wherein the process comprises the steps of a. selecting batteries according to the need of power output requirement in W or KW; selecting the single battery cell type, chemistry, and form factor for designing the battery pack; after selecting a single battery cell, we get its parameters such as nominal voltage (V), current (A), capacity (Ah) and v?????????? ???? single battery cell is in mm3, calculating the number of possible series and parallel connections and getting number of possible connections; after getting the number of possible connections, calculating the average temperature rise from all the battery packs for different C rates with same power output.
In an embodiment, the present invention provides that the (N) number of battery cells from 3-12 and the battery cells include but not limited to battery chemistries comprising Li-ion Battery, Nickel Manganese cobalt Oxide, lithium cobalt Oxide, Lithium Managenese Oxide Litium Titanium Oxide and all form factors of batteries comprising cylindrical battery cells, prismatic battery cells, pouch battery cells.
In an embodiment, the present invention provides that the batteries are connected in series and parallel.
In an embodiment, the present invention provides that for the 12 battery cells and possible connections are 12s1p, 6s2p, 4s3p, 3s4p, 2s6p, and 1s12p from this battery pack the least heat generation is observed in the 12s1p battery pack.
In an embodiment, the present invention provides that the 3 battery cells and possible connections are 3s1p and 1s3p from this battery pack the least heat generation is observed in the 3s1p battery pack.
In an embodiment, the present invention provides that the 4 battery cells and possible connections are 4s1p, 2s2p, and 1s4p from this battery pack the least heat generation is observed in the 4s1p battery pack.

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

Fig. 1: illustrates single battery cell;
Fig. 2: illustrates the 1sNp battery pack;
Fig. 3: illustrates the Ns1p battery pack;
Fig. 4: illustrates the 4s3p battery pack; Fig 4a: - Front, left side view and top view of 4s3p battery pack; Fig 4b: - Isometric top view of 4s3p battery pack; Fig 4c: - Isometric bottom view of 4s3p battery pack;
Fig. 5: illustrates the 3s4p battery pack; Fig 5a: - Front, left side view and top view of 4s3p battery pack; Fig 5b: - Isometric top view of 3s4p battery pack; Fig 5c: - Isometric bottom view of 3s4p battery pack;
Fig. 6: illustrates the 12s1p battery pack: - The 12s1p battery pack consists of 12 battery cells in series so this makes a voltage of 38.4V and 1 in parallel which means 6A. This 12s1p battery pack gives the power of 230.4W;
Fig. 7: illustrates the 6s2p battery pack: - The 6s2p battery pack consists of 12 battery cells in series so this makes a voltage of 19.2V and 2 in parallel which means 12A. This 6s2p battery pack gives the power of 230.4W;
Fig. 8: illustrates the 4s3p battery pack: - The 4s3p battery pack consists of 4 battery cells in series so this makes a voltage of 12.8V and 3 in parallel which means 18A. This 4s3p battery pack gives power of 230.4W.
Fig. 9: illustrates the 3s4p battery pack: - The 3s4p battery pack consists of 3 battery cells in series so this makes a voltage of 9.6V and 4 in parallel which means 24A. This 3s4p battery pack gives power of 230.4W.
Fig. 10: illustrates the 2s6p battery pack: - The 2s6p battery pack consists of 2 battery cells in series so this makes a voltage of 6.4V and 6 in parallel which means 36A. This 2s6p battery pack gives power of 230.4W.
Fig. 11: illustrates the 1s12p battery pack: - The 1s12p battery pack consists of 1 battery cell in series so this makes a voltage of 3.2V and 12 in parallel which means 72A. This 1s12p battery pack gives the power of 230.4W.
Fig. 12: illustrates combined impact of heat generation with the same power output by different series and parallel connection of battery pack.
Fig. 13: illustrates experimental setup with 4 number of battery cells.
Fig. 14 illustrates experimental temperature rise of 2s2p battery pack with 32700 form factors for different C rate such as 0.5C, 1C, 1.5C and 2C. This plot validates our results.
Fig. 15 illustrates a flowchart of the process of the present invention.
Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. Furthermore, the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION:
To promote an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises...a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
Embodiments of the present invention will be described below in detail concerning the accompanying drawings.
It has been observed that in the battery packs heat generation in parallel connections of the battery is higher than the series connection of the battery pack. The battery connection can be optimized without changing the power output of the battery connection. Further, the heat generation can be minimized to improve life of the battery pack.
The connections are optimized in such a way that the battery pack generates a minimum amount of heat which has less heat generation and we can develop a safer battery pack so that less probability of catching fire. Further, we can locate high heat generation zones or hotspots so that the battery thermal management system should be designed accordingly which saves extra auxiliary power consumption.

Batteries of all types, chemistries and form factors, Battery pack series and parallel connections, Battery packs of high capacity or high-power output used in electric vehicles, energy storage applications, power grid applications, heavy-duty electric vehicle batteries such as buses, etc will be benefited from the present invention.
The present invention provides a process that is used to optimize the battery connections in such a way that heat generation is minimized. This concept helps to improve the performance of existing products and new products will be able to be developed on this concept.
REFERENCE NUMERALS
100 Battery cell body
200 Negative Tab
300 Positive Tab
400 Bus bar for series connectors
500 Bus bar for parallel connectors

The comparison of two pairs of battery packs with the same power outputs, it is clearly observed that differences in heat generation and parallel connections generate more heat.
Changing battery connections is obvious thing but changing or giving multiple options of battery connection for selection of battery pack with considering battery connections according to heat generation at same power output of all possible battery pack connections.
The present invention provides a design of battery thermal management systems to locate high heat generation zone or hotspot zones so that they focus on this zone and remove generated heat effectively.
While designing battery packs with desired power output, the process of the present invention is used to connection of battery cells in the battery pack optimize the heat generation, and design BTMS to the packs. The process of the present invention comprises the steps of:
1) Selecting batteries according to the need of power output requirement in W or KW.
2) Select the single battery cell type, chemistry, and form factor for designing the battery pack;
3) After selecting a single battery cell, we get its parameters such as nominal voltage (V), current (A), and capacity (Ah).
4) Now we can calculate the number of possible series and parallel connections from our equation given below in 1, 2: -
Total number of possible battery pack connections
Nb = ap × bq × cr × ds ×………. 8 (1)
Where, a, b, c, and d are the prime number factors, Nb= Number of battery cells in the battery pack, Nc = Number of possible battery pack connections
Nc = (p+1) × (q+1) × (r+1) × (s+1) …………8 (2)
Where, p, q, r, s … 8 are powers of prime number factors.
e.g. 10 cells in the battery pack = Prime number factors = 2, 5, powers are 1, (1+1) i.e. 2, Nc = 2*2= 4, possible connections =2s5p, 5s2p, 10s1p and 1s10p
5) After getting the number of possible connections, we can calculate the Average temperature rise from all the battery packs for different C rates by our equation given below in 3, 4, 5, 6, and 7:
a) Heat generation factor for series connection in the battery pack
Hgs = Vp × Gs (3)
Where, Hgs= Heat generation factor for series connection battery cells, Ns = Number of battery cells in parallel connection in the battery pack, Vp = Battery pack nominal voltage i.e. Vp = Ns × Nominal voltage of single battery cell, and Gs =Heat generation coefficient for series connection.
b) Heat generation factor for parallel connection in the battery pack
Hgp = Ip × Gp (4)
Where, Hgp =Heat generation factor for parallel connection in the battery pack,
Np = Number of battery cells in parallel connection in the battery pack, Ip = Battery pack output current, i.e. Ip = Np × Nominal current of single battery cell, Gp =Heat generation coefficient for parallel connection in the battery pack.
c) Combined heat generation factor for overall battery pack connection
Hg = Hgs + Hgp (5)
Where, Hg = Combined heat generation factor for overall battery pack connection, Hgs= Heat generation factor for series connection in the battery pack, Hgp = Heat generation factor for parallel connection in the battery pack.
d) Capacity packing Factor
Cp = (Capacity of single battery cell)/ (???????????? ???? single battery cell) ×10 (6)
Where, Capacity of single battery cell is in mAh and, ???????????? ???? single battery cell is in mm3.
e) Overall heat generation coefficient of a battery pack
Cg = Cp× C× Hg (7)
Table 2. Calculation of average temperature rise based on various connections of the battery pack at 1C discharge.
In the above table, calculations are done for three different battery packs for their possible connection.
Ns Np Vp Ip Hgs Hgp Hg Cg Tavg
1 1 3.2 6 0.64 7.26 7.9 8.4135 308.4135
12 1 38.4 6 7.68 7.26 14.94 15.9111 315.9111
6 2 19.2 12 3.84 14.52 18.36 19.5534 319.5534
4 3 12.8 18 2.56 21.78 24.34 25.9221 325.9221
3 4 9.6 24 1.92 29.04 30.96 32.9724 332.9724
2 6 6.4 36 1.28 43.56 44.84 47.7546 347.7546
1 12 3.2 72 0.64 87.12 87.76 93.4644 393.4644
1 3 3.2 18 0.64 21.78 22.42 23.8773 323.8773
3 1 9.6 6 1.92 7.26 9.18 9.7767 309.7767
1 4 3.2 24 0.64 29.04 29.68 31.6092 331.6092
4 1 12.8 6 2.56 7.26 9.82 10.4583 310.4583
2 2 6.4 12 1.28 14.52 15.8 16.827 316.827

Table 3. Calculation of average temperature rise in 32700 cylindrical battery cells based on
various connections of the battery pack at 2C discharge.
Ns Np Vp Ip Hgs Hgp Hg Cg Tavg
1 1 3.2 6 0.64 7.26 7.9 16.827 316.827
12 1 38.4 6 7.68 7.26 14.94 31.8222 331.8222
6 2 19.2 12 3.84 14.52 18.36 39.1068 339.1068
4 3 12.8 18 2.56 21.78 24.34 51.8442 351.8442
3 4 9.6 24 1.92 29.04 30.96 65.9448 365.9448
2 6 6.4 36 1.28 43.56 44.84 95.5092 395.5092
1 12 3.2 72 0.64 87.12 87.76 186.9288 486.9288
1 3 3.2 18 0.64 21.78 22.42 47.7546 347.7546
3 1 9.6 6 1.92 7.26 9.18 19.5534 319.5534
1 4 3.2 24 0.64 29.04 29.68 63.2184 363.2184
4 1 12.8 6 2.56 7.26 9.82 20.9166 320.9166
2 2 6.4 12 1.28 14.52 15.8 33.654 333.654

Table 4. Calculation of average temperature rise in 32700 cylindrical battery cells based on various connections of the battery pack at 3C discharge.
Ns Np Vp Ip Hgs Hgp Hg Cg Tavg
1 1 3.2 6 0.64 7.26 7.9 25.2405 325.2405
12 1 38.4 6 7.68 7.26 14.94 47.7333 347.7333
6 2 19.2 12 3.84 14.52 18.36 58.6602 358.6602
4 3 12.8 18 2.56 21.78 24.34 77.7663 377.7663
3 4 9.6 24 1.92 29.04 30.96 98.9172 398.9172
2 6 6.4 36 1.28 43.56 44.84 143.2638 443.2638
1 12 3.2 72 0.64 87.12 87.76 280.3932 580.3932
1 3 3.2 18 0.64 21.78 22.42 71.6319 371.6319
3 1 9.6 6 1.92 7.26 9.18 29.3301 329.3301
1 4 3.2 24 0.64 29.04 29.68 94.8276 394.8276
4 1 12.8 6 2.56 7.26 9.82 31.3749 331.3749
2 2 6.4 12 1.28 14.52 15.8 50.481 350.481

Where, Cg =Overall heat generation coefficient of a battery pack, Cp =Capacity packing Factor, C =Discharge rate, Hg= Combined heat generation factor for overall battery pack connection.
f) Average temperature rise in battery pack
Tavg = Cg + Tamb (8)
Where, Tavg = Average temperature rise in the battery pack for various connections (K or ?), Cg =Overall heat generation coefficient of a battery pack, Tamb = Ambient temperature (taken as 300K or 26.85?),
First row shows heat generation for single cell 1s1p. Further, for 12 battery cells and possible connections are 12s1p, 6s2p, 4s3p, 3s4p, 2s6p, and 1s12p from this battery pack the least heat generation is observed in the 12s1p battery pack. Moreover, for 3 battery cells and possible connections are 3s1p and 1s3p from this battery pack the least heat generation is observed in the 3s1p battery pack.
For 4 battery cells and possible connections are 4s1p, 2s2p, and 1s4p from this battery pack the least heat generation is observed in the 4s1p battery pack. From the above calculation we get heat generation in terms of average temperature rise from the battery pack at different discharge rates, we can learn to select the battery pack with the least heat generation according to the requirement of the application. From the above process we get the best-suited battery pack with minimized heat generation in the design stage leads to an increase in the life of the battery pack.
Experimental analysis: -
We have taken 4 number of battery cells and possible battery pack connections are 3 that is 4s1p, 1s4p and 2s2p. We have don battery cycling at different discharge rate to analyses heat generation in these three battery packs.
Advantages of the Invention:
• The present invention optimizes the connections in such a way that the battery pack generates a minimum amount of heat which has less heat generation and we can develop a safer battery pack so that less probability of catching fire.
• The present invention locates high heat generation zones or hotspots so that the battery thermal management system should be designed accordingly which saves extra auxiliary power consumption.
• The present invention gives the minimized heat generation by using optimizing battery pack connections in design stage or giving multiple option to select the battery pack at same power output with lesser heat generation.
• The present invention is dropping the battery pack heat generation by our inventive process which leads to increases battery life and safety.
, Claims:We Claim:
1. A process for design and selection of battery packs, wherein the process comprises the steps of:
a. selecting batteries according to the need of power output requirement in W or KW;
b. selecting the single battery cell type, chemistry, and form factor for designing the battery pack;
c. after selecting a single battery cell, we get its parameters such as nominal voltage (V), current (A), capacity (Ah) and v?????????? ???? single battery cell is in (mm3).
d. calculating the number of possible series and parallel connections and getting number of possible connections;
e. after getting the number of possible connections, calculating the average temperature rise from all the battery packs for different C rates with same power output.
2. The process as claimed in claim 1, wherein the number of battery cells ranges for n number of battery cells, and wherein the battery cells include but not limited to battery chemistries comprising Li-ion Battery, Nickel Manganese cobalt Oxide, lithium cobalt Oxide, Lithium Managenese Oxide Litium Titanium Oxide and all form factors of batteries comprising cylindrical battery cells, prismatic battery cells, pouch battery cells.
3. The process as claimed in claim 1, wherein the number of battery cells will vary as per power output requirement in W or KW.
4. The process as claimed in claim 1, wherein the possible combination of (NC) number of series and parallel connections.
5. The process as claimed in claim 1, wherein the batteries are connected in series and parallel.
6. The process as claimed in claim 1, wherein the process minimizes heat generation which leads to enhancement in efficiency and life of battery packs.
7. The process as claimed in claim 1, wherein for the 12 battery cells and possible connections are 12s1p, 6s2p, 4s3p, 3s4p, 2s6p, and 1s12p from this battery pack the least heat generation is observed in the 12s1p battery pack.
8. The process as claimed in claim 1, wherein for 3 battery cells and possible connections are 3s1p and 1s3p from this battery pack the least heat generation is observed in the 3s1p battery pack.
9. The process as claimed in claim 1, wherein for 4 battery cells and possible connections are 4s1p, 2s2p, and 1s4p from this battery pack the least heat generation is observed in the 4s1p battery pack.
10. The process as claimed in claim 1, wherein for the N number of battery cells and possible connections are Nc from this battery pack and able to calculate least heat generation in terms of average temperature rise by the equation.

Dated this 21st day of March 2024