Description:TECHNICAL FIELD
[0001] The present subject matter relates to energy storage devices. More particularly, end connections of the energy storage devices are disclosed. The present application is a patent of addition with respect to the patent application number 202041010274.
BACKGROUND
[0002] Existing research in battery technology is directed to rechargeable energy storage devices, such as sealed, starved electrolyte, lead/acid batteries. Rechargeable energy storage devices are commonly used as power sources in different applications, such as, vehicles module calendar life, and low turn around efficiency, resulting in limitations in applications.
[0003] The problems associated with conventional energy storage devices including the lead-acid batteries, are overcame in lithium-ion batteries as they provide an ideal system for high energy-density applications, improved rate capability, and safety of the system in which the battery is incorporated and the human handling it. Further, the rechargeable energy storage devices - lithium-ion batteries exhibit one or more beneficial characteristics which makes it useable for battery powered devices. Firstly, for safety reasons, the lithium-ion battery is completely constructed using solid components, while still retaining flexibility and compactness. Secondly, the energy storage devices including the lithium-ion battery exhibit similar conductivity characteristics to primary batteries with liquid electrolytes, i.e., deliver high power and energy density with low rates of self-discharge. Thirdly, the lithium-ion battery is capable of being readily manufactured in a reliable and cost-efficient manner. Also, the energy storage devices including the lithium-ion battery can maintain a necessary minimum level of conductivity at sub-ambient temperatures that makes it reliable in varied operating temperatures.
[0004] In a known structure for the energy storage device, one or more energy storage cells including lithium-ion battery cells are disposed in at least one holder structure in series and parallel combinations, using at least one interconnecting structure. The interconnecting structure is adapted for electrically interconnecting the energy storage cells with a battery management system (BMS). An output voltage and an output current generated by the energy storage device is transmitted to one or more electronic and electrical components configured to be powered by the energy storage device via end connections after being monitored and regulated by the BMS. The design of the end connections is critical to the safety, serviceability, functionality and maintainability of the energy storage device.
[0005]
BRIEF DESCRIPTION OF DRAWINGS
[0006] The detailed description is described with reference to the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[0007] Figure. 1 exemplarily illustrates a perspective view of an energy storage device.
[0008] Figure. 2 exemplarily illustrates an exploded perspective view of the energy storage device.
[0009] Figure. 3A exemplarily illustrate perspective view of a female signal connector.
[00010] Figure. 3B exemplarily illustrate perspective view of a male signal connector.
[00011] Figure. 4 exemplarily illustrate perspective view of the end cover of the energy storage device with the gliders and clampers.
DETAILED DESCRIPTION OF THE INVENTION
[00012] The energy storage device is connected to adjoining energy storage devices and electrical and electronic loads of a power supply system via a plurality of end connections. Typically, the output of the energy storage cells is connected to the BMS circuit board by means of wires. The output voltage and the output current from the end connections connect to the electronic and electrical loads in the power supply system by means of wires. Also, the data from the temperature sensor installed on the battery pack, voltage level detector of an individual cell and current measurement of an individual cell in the battery pack is transferred by means of wires. Such interconnecting wires have a potential of loosening at the connecting ends during servicing and replacement of the energy storage device.
[00013]
[00014] To prevent occurrences of such untoward events, in the existing structures of the energy storage device, the end connections are moulded into an end cover of the energy storage device. Such end connections are not removable, requiring replacement of the entire end cover in case of repair of the end connections. In some other structures of the energy storage devices, the end connections are positioned on a printed circuit board (PCB) located within the energy storage device in addition to the Battery Management System in the energy storage device. Such PCBs are inflexible and are under stress during the assembly of the energy storage device, leading to failure of the PCB in the energy storage device. Further, such additional components in the energy storage device increase the weight of the energy storage device and the cost associated with the manufacturing, servicing, and replacement of the energy storage device.
[00015] There exists a need for a design of an energy storage device with end connections that ensure maintainability, and serviceability of the energy storage device overcoming all problems disclosed above as well as other problems of known art.
[00016] The present subject matter is an improvement over the patent application number IN202041010274, herein called as ‘the application’. The application discloses about an energy storage device, that is, an energy storage device comprising a design of end connections. The design facilitates connection of the energy storage device to a battery controller, a charging unit, or subsequent battery energy storage devices in a powered device, for example, a vehicle. An energy storage device has a plurality of cells enclosed within a casing with at least one end cover securely attached to the casing. The Battery Management System board is positioned proximal to the end cover in the casing. Plurality of end connections are removably attached to the Battery Management System board comprising a first end connection corresponding to signal lines of the energy storage device and a second end connection corresponding to power lines of the energy storage device.
[00017] The first end connection to the signal lines comprises at least one female signal connector with at least one hollow pin securely attached to the Battery Management System. The male signal connector comprises at least one plug removably engaged with at least one hollow pin of at least one female signal connector for connecting the energy storage device to a battery controller. The male signal connector comprises at least one locking elements or at least one clip on both sides for enabling ease in insertion and removal of the male signal connector. This also enables mating and disengaging of the male signal connector with the female signal connector.
[00018] However, the snap fit fails to provide required pressure in the connection and leaves certain entry points which can allow dust and water entry into the energy storage device through the end connections which may cause the controller to short circuit. Usually, the metal components in the energy storage device starts rusting in the place where water has come in contact with it. Further, if water seeps into the energy storage device, it can start formation of hydrogen gas which may cause thermal runaway.
[00019] Hence, there is a need of addressing the above circumstances and problems of the known arts.
[00020] The present subject matter has been devised in view of the above circumstances as well as solving other problems of the known art.
[00021] Figure. 1 exemplarily illustrates perspective view of a energy storage device 100. The energy storage device 100 comprises a plurality of cells arranged in a particular sequence in a cell holder. The cells are electrically connected in series and/or parallel configuration to form an array of cells. Such arrays of cells are electrically connected to a Battery Management System 206 within the energy storage device 100.
[00022] The Battery Management System is a printed circuit board with one or more integrated circuits integrally built on it as exemplarily illustrated in Figure.2.
[00023] As exemplarily illustrated, the energy storage device 100 comprises an external casing 101 with a dovetail pattern that is vibration proof and shock resistant, a first end cover 102, a second end cover 203 (shown in Figure.2), and a battery pack. The external casing 101 encloses the battery pack from top and bottom. The second end cover 203(shown in Figure.2) and the front-end cover 102 enclose the battery pack from the rear and the front respectively.
[00024] The terminal studs of a plurality of end connections 103a and 103b extend from the first end cover 102 as exemplarily illustrated. The first-end cover 102 further comprises at least one guider 104 and a holding clamper 105 to route power cables (not shown) and signal cables (not shown) connected to the end connections 103a and 103b of the energy storage device 100.
[00025] Figure.2 exemplarily illustrates an exploded perspective view of the energy storage device 100. As exemplarily illustrated, the battery pack 204 is enclosed between the second end cover 203, the external casing 101, the first-end cover 102. The Battery Management System 206 is attached to one of the sides of the battery pack 204. In an embodiment, the Battery Management System 206 is located between the battery pack 204 and the first end cover 102. The end connections 103a and 103b are removably attached to the Battery Management System 206. The external casing 101 has mounting provisions for the second end cover 203 and the first end cover 102. The second end cover 203 and the first end cover 102 are fastened to the external casing 101 using a plurality of attachment means 202 and 209 respectively. As per a preferred embodiment, the attachment means can be fastening meanss. The battery pack 204 has mounting provisions for the Battery Management System 206. The Battery Management System 206 is screwably attached to the cell holder 204a of the battery pack 204.
[00026] The plurality of end connections (103a, 103b) includes a first end connection 103a and a second end connection 103b. The first end connection 103a exemplarily illustrated in Figure. 1 corresponds to the signal lines of the energy storage device 100. The first end connection 103a is mounted on the Battery Management System 206. The second end connection 103b corresponds to power lines of the energy storage device 100.
[00027] The first end connection 103a facilitates parallel connection of the energy storage device 100 with other energy storage devices of similar type. Also, the first end connection 103a and the corresponding signal lines signal lines aids in communication of the energy storage device 100 to the battery controller in the powered device, for example, a vehicle. The signal lines originate from at least one of a temperature sensor installed on the battery pack 204, a current level detector of an individual cell in the battery pack 204, or a voltage level detector of an individual cell in the battery pack 204, etc. The first end connection 103a is a two-part signal connector including a female signal connector 207 and a male signal connector 208.
[00028] Figures. 3A-3B exemplarily illustrate perspective view of the first end connection 103a (shown in Figure.1) of the energy storage device 100. The first end connection 103a comprises the female signal connector 207 and the corresponding male signal connector 208. The female signal connector 207 comprises at least one hollow pin 301 centrally located in its body. The female signal connector 207 is fastened on the Battery Management System 206 (shown in Figure.2) using at least one of first fastening means 205 (shown in Figure.2). The at least one hollow pin 301 are moulded into the body of the female signal connector 207. Corresponding to the hollow pins 301, the Battery Management System 206 comprises corresponding at least one mounting provisions, such as, holes 206a (shown in Figure.2) to removably attach the female signal connector 207 with the hollow pins 301 to the Battery Management System 206 using at least one of first fastening means 205. The female signal connector 207 with hollow pins 301 is attached to the Battery Management System 206 at least one of first fastening means 205, wherein said at least one of first fastening means fastening means 205 pass through said at least one mounting provisions 206a of the Battery Management System 206, in a direction normal to a fourth surface 211 of the Battery Management System 206 and fasten with the hollow pins 301 of female signal connector 207.
[00029] The corresponding male signal connector 208 removably engages with the female signal connector 207. The male signal connector 208 comprises at least one second engaging means 302 (shown in Figure.4) protruding from a second surface 208a to engage with at least one pin 301 in the female signal connector 207. The hollow pin 301 of the female signal connector 207 engages with the second engaging means 302 of the male signal connector 208. On a first surface 208b of the male signal connector 208, at least one second engaging means 302 facilitate signal lines of the battery pack 204 (shown in Figure.2) to be accessed. The signal lines of the battery pack 204 are soldered or crimped into at least one second engaging means 302.
[00030] In an embodiment, the male signal connector 208 comprising at least one second engaging means 302 removably engages with hollow pins 301 of the female signal connector 207 for connecting the energy storage device 100 to the battery controller (not shown).
[00031] In an embodiment, at least one female signal connector (207) comprises of a first engaging means (301) and said at least one male signal connector (208) comprises of a second engaging means (302).
[00032] In an embodiment, for mating of the second engaging means 302 with the hollow pins 301, the inner diameter of the hollow pins 301 are greater than or engageably conforming with the diameter of the second engaging means 302 and the second engaging means 302 are inserted into the hollow space of the hollow pins 301 to achieve an operable & stable electrical contact cum connection. The pins 301 correspond to the signals from the Battery Management System 206.
[00033] In an embodiment, the male signal connector 208 comprises at least one second fastening provision 303 having internal mating threads, with at least one thread groove bordered by thread flanks to be fastened by means of a second fastening means 401. The end cover 102 comprises one or more third surface 402 with at least one first fastening provision 403 configured to receive at least one second fastening means 401. The one or more third surface 402 with at least one fastening provision 403 have internal threads, with at least one thread groove bordered by flanks. At least one male signal connector 208 is fastened to the end cover 102 by means of at least one second fastening means 401 with said at least one female signal connector 207 is engaged with said at least one male signal connector 208.
[00034] In an embodiment, the second fastening means 401 ensure secure and tight locking of the second engaging means 302 with the hollow pins 301. The hollow pins 301 correspond to the signals from the Battery Management System 206 (shown in Figure.2). The first end connection 103b facilitates parallel connection of the energy storage device 100 with other energy storage devices of similar type. Also, the first end connection 103a aids in communication of the energy storage device 100 to the battery controller (not shown) in the powered device, for example, a vehicle.
[00035] Figure. 4 exemplarily illustrate perspective view of the end cover of the energy storage device with the gliders and clampers.
[00036] In an embodiment, the second fastening means 401 for engaging and disengaging the male signal connector 208 and female signal connector 207 has a front end, a back end and an external thread.
[00037] In an embodiment, at least one gasket is placed between said male signal connector 208, female signal connector 207 and said first end cover 102.
[00038] In an embodiment, at least at least one O-ring is placed between said male signal connector 208, female signal connector 207 and said first end cover 102.
[00039] The end connections in the energy storage device provide several technical advancements in battery technology. The energy storage device with such end connection avoids interference of the signal lines with the power lines. The end connections are rugged in construction allowing multiple times of engagement and disengagement of the cables from the end connections, improving durability and reliability of the energy storage device. The end connections prevent dust and water entry into the energy storage device through the end connections resulting in a waterproof and dust resistant energy storage device.
[00040] Many modifications and variations of the present subject matter are possible in the light of above disclosure. Therefore, within the scope of claims of the present subject matter, the present disclosure may be practiced other than as specifically described.

LIST OF REFERENCE NUMERALS
100: Energy storage device
101: Casing
102: End cover
103a: First end connection
103b: Second end connection
104a, 104b: Guiders
106: Cables
203: Plurality of cells
204: Battery pack
204a: Cell holder
205: First fastening means
206: Battery management system (BMS)
206a: Mounting provisions
207: Female signal connector
208: Male signal connector
208b: First surface
211: Fourth surface
301: First engaging means
302: Second engaging means
303: Second fastening provision
401: Second Fastening means
402: Third surface
403: Fastening provision

, Claims:We Claim:
1. An energy storage device (100) comprising:
a plurality of cells (501) being enclosed within a casing (101);
a Battery Management System (206) comprising at least one mounting provision (206a);
at least one end cover (102), said at least one end cover (102) being securely attached to said casing (101) and at least a portion of said at least one end cover (102) comprising one or more third surface (402) having at least one first fastening provision (403);
a plurality of end connections (103a,103b), at least one of said plurality of end connections (103a,103b) comprising at least one female signal connector (207), and at least one male signal connector (208),
wherein one side of said at least one female signal connector (207) being fastened to said Battery Management System (206) by means of at least one of first fastening means (205), and the other side of said at least one female signal connector (207) being removably engaged with said at least one male signal connector (208),
wherein said at least one male signal connector (208) being securely attached with said third surface 402 of said end cover (102), by means of interaction of at least one second fastening means (401) with said one or more fastening provision (403) of said end cover (102), to enable tight sealing between said end cover (102) and said at least one male signal connector (208).
2. The energy storage device (100) as claimed in claim 1, wherein said energy storage device (100) being used in a powered device.
3. The energy storage device (100) as claimed in claim 1, wherein said plurality of end connections (103a, 103b) comprising a first end connection (103a) corresponding to at least one signal line of said energy storage device (100) and a second end connection (103b) corresponding to at least one power line of said energy storage device (100), wherein said plurality of end connections (103a,103b) being capable of removably attached to said Battery Management System (206).
4. The energy storage device (100) as claimed in claim 1, wherein said at least one female signal connector (207) comprising of a first engaging means (301) and said at least one male signal connector (208) comprising of a second engaging means (302).
5. The energy storage device (100) as claimed in claim 1, wherein said at least one female signal connector (208) comprising at least one first engaging means (301), wherein said at least one first engaging means (301) being used in removably engaging said at least one female signal connector (208) with a second engaging means (302) of said at least one male signal connector (208).
6. The energy storage device (100) as claimed in claim 1, wherein said second engaging means (302) being a banana plug.
7. The energy storage device (100) as claimed in claim 1, wherein said first engaging means (301) being a hollow pin shaped structure.
8. The energy storage device (100) as claimed in claim 1, wherein said at least one of first fastening means (205) pass through said at least one mounting provisions (206a) of said Battery Management System (206) in a direction normal to fourth surface (211) of said Battery Management System (206).
9. The energy storage device (100) as claimed in claim 1, wherein said at least one male signal connector (208) comprises at least one second fastening provision (303) having internal mating thread, and at least one thread groove bordered by thread flanks to screwably receive at least one second fastening means (401).
10. The energy storage device (100) as claimed in claim 1, wherein the inner diameter of said at least one first engaging means (301) is engageably conforming with the diameter of said at least one second engaging means (302).
11. The energy storage device (100) as claimed in claim 1, wherein on a first surface (208b) of said male signal connector (208), at least one second engaging means (302) facilitate signal lines of said battery pack (204) to be accessed.
12. The energy storage device (100) as claimed in claim 1, wherein said at least one corresponding male signal connector (208) comprising at least one second engaging means (302), said at least one second engaging means (302) being removably engaged with said at least one hollow pin (301) of said at least one female signal connector (207) for connecting said energy storage device (100) to a battery controller.
13. The energy storage device (100) as claimed in claim 1, wherein said fastening means has a front end, a back end and an external thread.
14. The energy storage device (100) as claimed in claim 1, wherein at least one gasket is placed between said male signal connector (208), female signal connector (207) and said first end cover (102).
15. The energy storage device (100) as claimed in claim 1, wherein at least one O-ring is placed between said male signal connector (208), female signal connector (207) and said first end cover (102).