Description:[0001] The present subject matter relates to energy storage device. More particularly, end connections of the energy storage device 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 and the like. However, the lead-acid batteries are heavy, bulky, have short cycle life, short 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.
BRIEF DESCRIPTION OF DRAWINGS
[0005] 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.
[0006] Figure. 1 exemplarily illustrates a perspective view of energy storage device.
[0007] Figure. 2 exemplarily illustrates an exploded perspective view of the energy storage device.
[0008] Figures. 3 exemplarily illustrates perspective view of end cover of the energy storage device.
[0009] Figures. 4 exemplarily illustrate perspective views of a first end connection of the energy storage device.
[00010] Figures. 5 exemplarily illustrate perspective views of end cover of the energy storage device with the gliders and clampers.
[00011] Figures. 6A exemplarily illustrate plan view of end cover of the energy storage device.
[00012] Figures. 6B exemplarily illustrate detail view of guiders in end cover of the energy storage device.
DETAILED DESCRIPTION OF THE INVENTION
[00013] 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. Such interconnecting wires have a potential of short circuit while assembly of the energy storage device.
[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 in the energy storage device in addition to the BMS 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, 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 a need for a design of an energy storage device with end connections that ensure safety during assembly, 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, comprising a design of end connections for facilitating connection of the energy storage device to a battery controller, a charging unit, or subsequent energy storage devices in a powered device, for example, a vehicle. An energy storage device has a plurality of cells enclosed in a casing with at least one end cover securely attached to the casing. The BMS is positioned proximal to the end cover in the casing. Plurality of end connections are removably attached to the BMS such that it comprises a first end connection corresponding to power lines of the energy storage device and a second end connection corresponding to signal lines of the energy storage device.
[00017] The first end connections to power lines comprises at least one protection device positioned between the power lines for providing electrical protection to the energy storage device. The first end connection comprises a terminal holder which is removably attached to BMS board. A positive terminal stud and a negative terminal stud extends from the terminal holder for sourcing power to said electrical loads. The positive terminal stud and the negative terminal stud project from the BMS through the end cover. The positive terminal stud and the negative terminal stud have different geometries to avoid interchanging of polarities during manufacturing, assembly, or servicing of the energy storage device.
[00018] However, different geometries can’t ensure that the said objective is attained under certain circumstances such as when the shape of the two terminal studs is same, but their size is different. Interchanging of polarities between the positive and negative terminals of the cells can cause short circuit while assembling the energy storage device There is often a risk of assembling the conductors onto the negative terminal by mistake, because of the proximity of the negative terminal with the positive terminal. Such mistakes would lead to short circuit in the cell, and therefore causing cell failure and negatively impacting the entire energy storage device. Further, in addition to causing serious damage to the energy storage device and the electrical components, it can even harm the human handling the energy storage device. If the polarities are interchanged, the battery will try to compensate and make the negative volts into a positive charge resulting in a huge surge of power and an enormous amount of heat to be produced. It will not be tolerated well by the energy storage device or the components within and will incur damage that is mostly severe and irreparable. The extreme heat produced can melt the insulators on the cables, clamping them forever on the energy storage device. The end cover of the energy storage device can melt and bend. Interchanging the polarities of the terminal studs can also blow the fuse.
[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 BMS (not shown) within the energy storage device 100.
[00022] The BMS 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 device100 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 lines 106a, 106b and signal lines (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 BMS 206 is attached to one of the sides of the battery pack 204. In an embodiment, the BMS 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 BMS 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 fasteners. The battery pack 204 has mounting provisions for the BMS 206. The BMS 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 power lines 106 of the energy storage device 100. The first end connection 103a is mounted on the BMS 206. The second end connection 103b corresponds to signal lines of the energy storage device 100.
[00027] Figure. 3 exemplarily illustrates perspective view of end cover of the energy storage device with the first end connection. The first end connection 206b carries current from the BMS board 206 (shown in Figure.2) out of the energy storage device 100 to electrical loads. The current from the cells in the battery pack 204 (shown in Figure.2) culminate into a positive terminal and a negative terminal on the BMS board 206. The first end connection 206b comprises a terminal holder 401 removably attached using at least one mounting provision 402a and 402b to the BMS 206 of the energy storage device 100. As exemplarily illustrated, the terminal holder 401 is a bus bar with mounting provisions to mount at least one protection device 404, a positive terminal stud 405a, and a negative terminal stud 405b of the energy storage device 100 (shown in Figure.1). The positive terminal of the BMS 206 is connected to the positive terminal stud 405a and the negative terminal of the BMS 206 is connected to the negative terminal stud 405b. Between the positive terminal stud 405a and the negative terminal stud 405b, the electrical loads of the energy storage device 100 or a charger of the energy storage device 100 to recharge the energy storage device 100 are connected. The positive terminal stud 405a and the negative terminal stud 405b protrude through the front-end cover 102 (shown in Figure.1). The positive terminal stud 405a and the negative terminal stud 405b are located in a depression (not shown) in the front-end cover 102 as exemplarily illustrated in Fig. 1.
[00028] The positive terminal stud 405a and the negative terminal stud 405b are securely attached to the terminal holder 401 at designated locations on the terminal holder 401. As per an embodiment, the positive terminal stud 405a is a bolt 408a (shown in Figure.4) in which a conductor from the positive terminal of the BMS 206 is placed and fastened with a nut, such as, 409 (shown in Figure.4) to the terminal holder 401. Similarly, as per an embodiment, the negative terminal stud 405b is a bolt 408b (shown in Figure.4) in which a conductor from the negative terminal of the BMS 206 (shown in Figure.2) is placed and fastened with a nut, such as, 409 to the terminal holder 401. Each of the positive terminal stud 405a and the negative terminal stud 405b is fastened to the terminal holder 401 using a fastener 409, for example, a screw and a washer from bottom of the terminal holder 401.
[00029] The positive terminal stud 405a and the negative terminal stud 405b extend from the plastic base member (not shown) through the first end cover 102 (shown in Figure.1) for sourcing power to external loads. The positive terminal stud 405a and the negative terminal stud 405b form the first end connection 103a exemplarily illustrated in Fig. 1. As per an embodiment, the positive terminal (405a) stud have a first configuration, and the negative terminal stud (405b) have a second configuration, wherein said first configuration and said second configuration are different from each other.
[00030] In an embodiment, the exterior shapes of at least one of the positive terminal stud 405a and the negative terminal stud 405b include skewed sidewall surfaces.
[00031] In an embodiment, the exterior shapes of at least one of the positive terminal stud 405a and the negative terminal stud 405b is capable of accommodating at least one of a female connector and a male connector in a male-female interface.
[00032] In an embodiment, the exterior shapes of at least one of the positive terminal stud 405a and the negative terminal stud 405b are elongated asymmetrically.As exemplarily illustrated in Figure.5 the first end cover 102 also includes guiders (104a, 104b) for guiding the power lines 106 (shown in figure.1) arising from the positive terminal stud 405a and the negative terminal stud 405b as exemplarily illustrated in Fig. 3. The guiders (104a, 104b) comprises a first guider 104a and a second guider 104b, and said plurality of guiders (104a, 104b) are located in depressions on said at least one end cover 102. The first guider 104a guides cables from the positive terminal stud 405a and the second guider 104b guides cables from the negative terminal stud 405b such that the first guider 104a for said positive terminal stud 405a and said second guider 104b for said negative terminal stud 405b have distinct shape to avoid interchanging of polarities.
[00033] The guiders (104a, 104b) are located in depressions on the first-end cover 102 to guide the power lines 106 through the depressions in the first end cover 102. The first end cover 102 has projections over the positive terminal stud 405a and the negative terminal stud 405b beyond which the positive terminal stud 405a and the negative terminal stud 405b do not extend. The guiders (104a, 104b) and the projections ensure the power lines 106 extending from the positive terminal stud 405a and the negative terminal stud 405b are press fit into the guiders (104a, 104b) and do not bulge from the surface of the front-end cover 102 avoiding stress and damage on the power lines 106 (shown in figure.1), when the energy storage device100 is to be compactly positioned in a powered device, for example, a vehicle. The holding clamper (505a, 505b) holds the guided cables and prevents dangling of the power lines 106 (shown in figure.1) to avoid damage to the cables. The guider 104a guides the first power lines 106a (shown in figure.1) arising from the positive terminal stud 405a and the guider 104b guides the second power lines 106b (shown in figure.1) arising from the negative terminal stud 405b. The first guider (104a) for said positive terminal stud have a first configuration (405a) and the second guider (104b) for the negative terminal stud (405b) have a second configuration, wherein the first configuration and the second configuration are different from each other.
[00034] In an embodiment, the guider (104a, 104b) is located in depressions on the first-end cover 102 to guide the cable through the depressions in the first end cover 102.
[00035] In an embodiment, the interior shapes of at least one of the positive terminal stud 405a and the negative terminal stud 405b include skewed sidewall surfaces.
[00036] In an embodiment, the interior shapes of at least one of the positive terminal stud 405a and the negative terminal stud 405b provide a male connector of a male-female interface.
[00037] In an embodiment, the interior shapes of at least one of the positive terminal stud 405a and the negative terminal stud 405b is capable of accommodating at least one of a female connector and a male connector in a male-female interface.
[00038] In an embodiment, the interior shapes of at least one of the positive terminal stud 405a and the negative terminal stud 405b are elongated asymmetrically.
[00039] The end connections in the energy storage device provide several technical advancements in battery technology. The different shapes of the terminal studs and the guiders in the end connections prevents interchanging of the polarities of the terminal studs and eases assembly and servicing of the energy storage device. This saves manhours in assembly, servicing, and maintenance of the energy storage device. Such energy storage devices allow uninterrupted supply to drive the powered device as the end connections facilitate interconnection of multiple such energy storage devices.
[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 NUMERAL

100: Energy storage device
101: External casing
102: End cover
103a: First end connection
103b: Second end connection
104a: First guider
104b: Second guider
106a, 106b: Power lines
206: Battery management system (BMS)
203: Plurality of cells
204: Battery pack
204a: Cell holder
305a, 305b: Holding clampers
401: Terminal holder
405a: Positive terminal stud
405b: Negative terminal stud

, Claims:We claim:
1. An energy storage device (100), said energy storage device (100) comprising:
a plurality of cells being enclosed in a casing (101);
at least one end cover being securely attached to said casing (101);
a battery management system (206);
a plurality of end connections (103a,103b) being capable of removably attached to said battery management system (206);
one or more power lines (106a, 106b), wherein each power line (106a, 106b) of said one or more power lines (106a, 106b) corresponds to at least one end connection (103a) of said plurality of end connections (103a, 103b);
wherein said plurality of end connections (103a, 103b) comprising:
a first end connection (103a) corresponding to at least one power line (106a, 106b) of said one or more power lines (106a, 106b) and wherein said first end connection (103a) comprises:
a terminal holder (401), said terminal holder (401) being removably attached to said battery management system (206); wherein said terminal holder (401) comprises:
a positive terminal stud (405a) having a first configuration, and
a negative terminal stud (405b) having a second configuration,
wherein said first configuration and said second configuration are different from each other.

2. The energy storage device (100) as claimed in claim 1, wherein said energy storage device (100) can be used in a powered device.
3. The energy storage device (100) as claimed in claim 1, wherein said first end connection (103a) carries a current from said battery management system (206) to a plurality of electrical loads.
4. The energy storage device (100) as claimed in claim 1, wherein said positive terminal stud (405a) and said negative terminal stud (405b) extend outwardly from said terminal holder (401).
5. The energy storage device (100) as claimed in claim 1, wherein said positive terminal stud (405a) and said negative terminal stud (405b) extend outwardly from said battery management system (206) through at least one end cover (102).
6. The energy storage device (100) as claimed in claim 1, wherein said plurality of end connections (103a and 103b) comprises a second end connection (103b), said second end connection (103b) corresponds to one or more signal lines of said energy storage device (100).
7. The energy storage device (100) as claimed in claim 1, wherein the exterior shapes of at least one of said positive terminal stud (405a) and said negative terminal stud (405b) include skewed sidewall surfaces.
8. The energy storage device (100) as claimed in claim 1, wherein the exterior shapes of at least one of said positive terminal stud (405a) and said negative terminal stud (405b) is capable of accommodating at least one of a female connector and a male connector in a male-female interface.
9. The energy storage device (100) as claimed in claim 1, wherein the exterior shapes of at least one of said positive terminal stud (405a) and said negative terminal stud (405b) are elongated asymmetrically extending outwardly from end cover (102, 203).
10. An energy storage device (100), said energy storage device (100) comprising:
a battery management system board (206); a positive terminal stud (405a) and a negative terminal stud (405b);
one or more power lines (106a, 106b), wherein each power line (106a, 106b) of said one or more power lines (106a, 106b) corresponds to at least one end connection (103a) of said plurality of end connections (103a, 103b);
at least one end cover (102), said at least one end cover (102) being securely attached to a casing (101); said at least one end cover (102) comprising:
plurality of guiders (104a, 104b), said plurality of guiders (104a, 104b) comprising a first guider (104a) and a second guider (104b), wherein said plurality of guiders (104a, 104b) are located in depressions on said at least one end cover (102), and wherein said first guider (104a) guides power line (106a) from said positive terminal stud (405a) and said second guider (104b) guides power line (106b) from said negative terminal stud (405b),
wherein said first guider (104a) for said positive terminal stud having a first configuration (405a) and said second guider (104b) for said negative terminal stud (405b) having a second configuration,
wherein said first configuration and said second configuration are different from each other.
11. The energy storage device (100) as claimed in claim 10, wherein said energy storage device (100) can be used in a powered device.
12. The energy storage device (100) as claimed in claim 10, wherein said positive terminal stud (405a) and said negative terminal stud (405b) project from said battery management system (206) through at least one of said end cover (102).
13. The energy storage device (100) as claimed in claim 10, wherein said at least one end cover (102) has a plurality of holding clampers (305a, 305b) wherein said holding clampers (305a) secures power lines (106a, 106b) arising from said positive terminal stud (405a) and said holding clampers (305b) secure cables arising from said negative terminal stud (405b) onto said end cover (102).
14. The energy storage device (100) as claimed in claim 10, wherein the interior shapes of at least one of said positive terminal stud (405a) and said negative terminal stud (405b) include skewed sidewall surfaces.
15. The energy storage device (100) as claimed in claim 10, wherein the interior shapes of at least one of said positive terminal stud (405a) and said negative terminal stud (405b) is capable of accommodating at least one of a female connector and a male connector in a male-female interface.
16. The energy storage device (100) as claimed in claim 10, wherein the interior shapes of at least one of the positive terminal stud (405a) and the negative terminal stud (405b) are elongated asymmetrically.
17. The energy storage device (100) as claimed in claim 10, wherein said energy storage device (100) has a plurality of end connections (103a,103b) being capable of removably attached to said battery management system (206), wherein said plurality of end connections (103a and 103b) comprises a terminal holder (401), said terminal holder (401) being removably attached to said battery management system board (206), wherein said terminal holder (401) comprising said positive terminal stud (405a) and said negative terminal stud (405b).
18. The energy storage device (100) as claimed in claim 17, wherein said first end connection corresponds at least one of the power lines of said energy storage device (100).
19. The energy storage device (100) as claimed in claim 17, wherein said positive terminal stud (405a) and said negative terminal stud (405b) extend outward from said terminal holder (401).