Description:FIELD OF THE INVENTION
[001] The present invention relates to a battery pack. More particularly, the present invention relates to a Battery Management System of the battery pack.

BACKGROUND OF THE INVENTION
[002] Conventional battery packs are operated on low voltages, for example below 60 volts for which a single Battery Management System (BMS) acting as master and slave, both master and slave are used for functioning of the battery pack. In case of battery packs with higher voltages such as 400 volts, a single BMS is not feasible. The battery packs with higher voltage are used in various high end applications such as, not being limited to, electric vehicles or premium vehicles. The use of a single BMS in high voltage battery packs faces high risk of short circuit while assembling of the battery pack. Moreover, single BMS in high voltage battery packs is also difficult to handle and dangerous to operate. It is difficult to isolate the signals and communication in the single BMS used for high voltage battery packs.
[003] Also, in conventional battery packs, the BMS is not mounted on a battery module. The BMS is mounted on a battery pack level, meaning the entire battery module is assembled and, thereafter, the BMS is mounted and the connections of the BMS with the modules are made using wires. These wire connections, many a times, get jumbled up and get damaged. Further, the wire connections are also difficult to handle, and routing of wires is also troublesome. Apart from this, in the conventional low voltage battery packs, a multilayer Printed Circuit Board (PCB) is used. The multilayer PCB is a solid PCB which cannot be bent to accommodate in an existing space due to less flexibility. The multilayer PCB takes more space in the battery pack. Also, to mount the multilayer PCB, a large number of fasteners are used, making mounting difficult and time consuming. Moreover, fasteners add weight to the battery pack, which is undesirable.
[004] In view of the foregoing, there is a need-felt to overcome the above-mentioned disadvantages of the prior arts.

SUMMARY OF THE INVENTION
[005] In one aspect of the present invention, a battery pack is disclosed. The battery pack comprises one or more battery modules. Each of the battery module comprises one or more battery cells. Each of the battery modules in the battery pack is provided with a Printed Circuit Board wherein the Printed Circuit Board is arranged on the battery module. Each of the battery module is provided with one or more Battery Management Modules of a Battery Management System wherein the one or more Battery Management modules are mounted on the Printed Circuit Board.
[006] In an embodiment, the one or more Battery Management Modules are slave modules. The slave modules are communicatively coupled to a master module.
[007] In an embodiment having plurality of Battery Management Modules, one of the Battery Management Modules is a master module and remaining Battery Management modules are slave modules wherein the slave modules are operably connected to the master module.
[008] In an embodiment, the Printed Circuit Board is a flexible Printed Circuit Board. In one non-limiting example, the Printed Circuit Board is made of flexible materials such as, not being limited to, Polyethylene terephthalate (PET).
[009] In an embodiment, the battery module comprises a top holder, a bottom holder, a top plate and a bottom plate. The top holder and the bottom holder are adapted to receive end portions of the one or more battery cells. The top plate comprises one or more first interconnectors. The one or more first interconnectors are adapted to enable contact with terminals on one end portion of the one or more battery cells. The bottom plate comprises one or more second interconnectors. The one or more second interconnectors are adapted to enable contact with terminals on another end portion of the one or more battery cells. Each of the one or more battery modules define at least four sides between the top holder and the bottom holder. The Printed Circuit Board is arranged on at least three sides of each of the one or more battery modules. The Printed Circuit Board comprises a first set of connectors and a second set of connectors. The first set of connectors are adapted to establish contact with the one or more first interconnectors and the one or more second interconnectors. The first set of connectors comprises nickel strips to establish contact with the one or more first interconnectors and the one or more second interconnectors. The first set of connectors are spot welded onto the one or more first interconnectors and the one or more second interconnectors. The second set of connectors are adapted to establish contact with the one or more Battery Management Modules.

BRIEF DESCRIPTION OF THE DRAWINGS
[010] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 is an exploded view of a battery module with a Printed Circuit Board and a Battery Management Module, in accordance with an embodiment of the present invention.
Figure 2 and Figure 3 are perspective view of the battery module with the Printed Circuit Board and the Battery Management Module, in accordance with the embodiment of the present invention.
Figure 4 is a perspective view of a flexible Printed Circuit Board, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[011] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[012] Figure 1 is an exploded view of a battery module 100 (shown in Fig. 2) with a Printed Circuit Board 102 and a Battery Management Module 104, in accordance with an embodiment of the present invention. Figure 2 and Figure 3 are perspective view of the battery module 100 with the Printed Circuit Board 102 and the Battery Management Module 104, in accordance with the embodiment of the present invention.
[013] The present invention relates to a battery pack comprising one or more battery modules 100. The battery module 100 comprises one or more battery cells 106. The battery module 100 comprises a top holder 108, a bottom holder 110, a top plate 112, and a bottom plate 114. The top holder 108 and the bottom holder 110 are adapted to receive end portions of the one or more battery cells 106. The top plate 112 comprises one or more first interconnectors 116 adapted to enable contact with terminals on one end portion of the one or more battery cells 106. The bottom plate 114 comprises one or more second interconnectors 118 adapted to enable contact with terminals on another end portion of the battery cells 106. As shown, the battery module 100 is rectangular in shape and defines four sides between the top holder 108 and the bottom holder 110. However, rectangular shape of battery module 100 should not be construed as limiting and other shapes between the top holder 100 and the bottom holder 110 are also feasible.
[014] Each battery module 100 of the battery pack is provided with the Printed Circuit Board 102. The Printed Circuit Board 102 is arranged on the battery module 100. In one non-limiting example, the Printed Circuit Board 102 is flexible. In other words, the Printed Circuit Board 102 can be folded to confirm to the shape and size of at least three sides of the battery module 100 between the top holder 108 and the bottom holder 110. Flexible Printed Circuit Boards 102 are generally made of polymers such as, not being limited to, Polyethylene terephthalate (PET). In another non-limiting example, the Printed Circuit Board 102 can be manufactured in standard shape and size to confirm to the shape and size of at least three sides of the battery module 100 between the top holder 108 and the bottom holder 110. In another non-limiting example, the Printed Circuit Board 102 is arranged on the at least three sides of the battery module 100 with an adhesive material or double sided tape. In another non-limiting example, the thickness of Printed Circuit Board 102 is in a range of 0.3 to 0.6 mm.
[015] The Printed Circuit Board 102 comprises a first set of connectors 120 (shown in Figure 4) and a second set of connectors 122. The first set of connectors 120 are adapted to establish contact with the one or more first interconnectors 116 of the top plate 112 and the one or more second interconnectors 118 of the bottom plate 114. The first set of connectors 120 comprises nickel strips to establish contact with the one or more first interconnectors 116 and the one or more second interconnectors 118. The second set of interconnectors 118 establishes connection with one or more Battery Management Modules 104 of a Battery Management System (BMS).
[016] The BMS comprises the plurality of Battery Management Modules 104. Each battery module 100 is provided with one or more Battery Management Modules 104. The Battery Management Modules 104 are mounted on the Printed Circuit Board 102. As already stated, the Printed Circuit Board 102 comprises the first set of connectors 116 and the second set of connectors 118. The first set of connectors 116 establishes contact with terminals of the one or more battery cells 106 and the second set of connectors 122 establishes connection with the one or more Battery Management Modules 104 mounted on the Printed Circuit Board 104. Owing to said connections, different parameters of the battery module 100 are received by the one or more Battery Management Modules 104. The different parameters include State of Charge (SoC), State of Health (SoH), temperature, voltage, and current of the battery module, and the like.
[017] In one non-limiting example, the one or more Battery Management Modules 104 mounted on the Printed Circuit Board 102 are slave modules communicatively coupled to a master module. In such a scenario, the parameters of the battery module 100 received by the slave modules are transmitted to a master module. The master module may be arranged at the battery pack level or outside the battery pack such as at a vehicle level. The parameters received by the master module are processed to control operation of the one or more battery modules 100 such as, not being limited to, charging and discharging of the battery modules 100.
[018] In another non-limiting example, one of the Battery Management Module 100 in the battery pack is a master module and the remaining Battery Management Modules in the battery pack are slave module wherein the slave module(s) are communicatively couped to the master module. In other words, of all the Battery Management Modules 104 received in one or more battery modules 100, one of the Battery Management Module 104 is a master modules and remaining Battery Management Modules 104 are slave modules and all the slave modules are communicatively coupled to the master module. In such a scenario, the parameters of the battery modules 100 are received by the master module and the slave modules for their respective battery modules. The parameters of the slave modules are transmitted to the master module which processes the transmitted data of the slave modules as well as the received data to control operation of the one or more battery modules such as, not being limited to, charging and discharging of the battery modules.
[019] It is to be understood that master module and slave modules are communicatively coupled via network. The network may include Controller Area Network, wireless networks, Ethernet AVB networks, or combinations thereof. Further, the network may be a public network, such as the Internet, a private network, such as an intranet, or combinations thereof, and may utilize a variety of communication protocols now available or later developed.
[020] The construction and operation of the slave module and the master module of the Battery Management System are already known in the art and have not been discussed in detail for the sake of brevity. The present invention essentially relates to mounting of the Printed Circuit Boards and one or more Battery Management Modules i.e., slave module and/or master module on the battery module 100 rather than mounting the Printed Circuit Boards and Battery Management Modules at the battery pack level.
[021] In Figure 2 and Figure 3, the Flexible Printed Circuit Board 102 is arranged on the battery module 100 and the Battery Management Module 104 is mounted on the Printed Circuit Board 102. In Figure 3, a cover 124 (also shown in Figure 1) has been shown to cover the Battery Management Module 104.
[022] Figure 4 is a perspective view of a flexible Printed Circuit Board 102, in accordance with the present invention.
[023] As shown, a U-shaped Printed Circuit Board 102 is shown which is adapted to be arranged on three sides of the battery module 100. As already stated, in one non-limiting example, the Printed Circuit Board 102 can be made of a flexible material which is capable of being folded to form a U-shaped structure as shown in Figure 4. Also, in another non-limiting example, the Printed Circuit Board 102 can be manufactured in U-shape to confirm with the shape and size of the battery module 100. In another non-limiting example, the Printed Circuit Board 102 can cover all four sides of the battery module 100, based on the design of the battery pack. The Printed Circuit Board 102 is arranged on the battery module 100. The term “arrange” in the present context means that the Printed Circuit Board 102 are stuck on the sides of the battery modules using adhesives or double sided tape. The Printed Circuit Board 102 comprises the first set of connectors 120 and the second set of connectors 122. The first set of connectors 120 are adapted to establish connection with the first and second interconnectors 118, 120 of the battery module 100. In Figure 4, the first set of connectors 120 are L-shaped wherein the part which contacts the interconnectors 116, 118 are made of nickel strips or comprises nickel. However, this shape of the first set of connectors 120 should not be construed as limiting and other shapes which are able to establish connection with first interconnectors 116 and the second interconnectors 118 are within the scope of the present invention.
[024] The second set of connectors 122 are for connecting the Battery Management Module 104 to the battery module 100. In Figure 4, two connectors 122 are shown which can be used to receive two battery management modules 104. However, this number should not be construed as limiting and the second set of connectors 122 can comprise one connector (for receiving only one battery management module) or more than two connectors to receive more than two Battery Management Module 104.
[025] The claimed features/method steps of the present invention as discussed above are not routine, conventional, or well understood in the art, as the claimed features/steps enable the following solutions to the existing problems in conventional technologies. Specifically, the technical problem of efficiently mounting the Printed Circuit Board and the one or more Battery Management Modules in high voltage battery packs is solved by the present invention.
[026] In the present invention, both the Printed Circuit Board and the Battery Management Module are arranged/mounted at the battery module level which facilitates ease in assembling of the battery pack.
[027] In the present invention, as the Printed Circuit Board and the Battery Management Module are arranged/mounted at the battery module level, distance between the interconnectors and the Battery Management Module is less as compared to conventional battery packs and, therefore, need for wire connections between said above-mentioned components are eliminated which facilitates safe operation of high voltage battery packs as well as ease of assembling above-mentioned components in the battery pack.
[028] In the present invention, the Printed Circuit Board is adapted to conform to shape and size of the battery module which saves space in the battery pack and provides flexibility in mounting the PCB on the battery module.
[029] In the present invention, the thickness of the Printed Circuit Board ranges from 0.3 to 0.6 mm which is substantially less that the thickness of Printed Circuit Board used in conventional battery packs. In conventional battery packs, the thickness of Printed Circuit Board is at least 10mm. Therefore, the present invention results in saving space in the battery pack, which also provides flexibility to the Printed Circuit Board to be mounted on the battery module.
[030] In the present invention, the Printed Circuit Board are made to stick on the battery module, thereby completely eliminating the need of fasteners. The elimination of fasteners simplifies assembly process and reduces the cost, space requirement, and weight of the battery pack. As the Printed circuit Board is made to stick on the battery module, chances of failure of the connections between the Printed Circuit Board and the battery module are also eliminated.
[031] In the present invention, the first set of connectors of the Printed Circuit Board are spot welded on the first interconnectors and the second interconnectors of the battery module. In conventional battery packs, Printed Circuit Boards were fastened through fasteners which had more resistance. In the present invention, as the spot welding is used to establish connection between the interconnectors of the battery module and the first set of connectors, resistance path is decreased which reduces the losses and increases the performance, efficiency, and safety of the battery pack.
[032] In the present invention, the assembling of the Printed Circuit Board and the Batter Management Module on the battery module is simple, thereby reducing the assembly cost. Also, mounting of Printed Circuit Board and the Batter Management Module at the batter pack level in conventional battery packs required mounting means, wiring harness and the like. which are eliminated in the present invention, thereby, reducing cost as well as weight of the battery pack.
[033] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

List of Reference Numerals:
100- battery module
102- Printed Circuit Board
104-Battery Management Module
106- battery cells
108- top holder
110- bottom holder
112- top plate
114- bottom plate
116- first interconnectors
118- second interconnectors
120- first set of connectors
122- second set of connectors
124- cover , Claims:WE CLAIM:

1. A battery pack comprising:
one or more battery modules (100), each of the one or more battery modules (100) comprising one or more battery cells (106);
wherein each of the one or more battery modules (100) being provided with a Printed Circuit Board (102) and one or more Battery Management Modules (104) of a Battery Management System (BMS),
the Printed Circuit Board (102) being arranged on the battery module (100) and the one or more Battery Management Modules (104) being mounted on the Printed Circuit Board (102).

2. The battery pack as claimed in claim 1, wherein the one or more Battery Management Modules (104) being slave modules communicatively coupled to a master module.

3. The battery pack as claimed in claim 1, wherein one Battery Management Module (104) in the battery pack being a master module and remaining Battery Management Modules (104) in the battery pack being slave modules, the slave modules being communicatively coupled to the master module.

4. The battery pack as claimed in claim 2 or 3, wherein the Printed Circuit Board (102) being a flexible Printed Circuit Board.

5. The battery pack as claimed in claim 4, wherein the Printed Circuit Board (102) being made of Polyethylene terephthalate (PET).

6. The battery pack as claimed in claim 1, wherein each of the one or more battery modules (100) comprises:
- a top holder (108) and a bottom holder (110) adapted to receive end portions of the one or more battery cells (106);
- a top plate (112) having one or more first interconnectors (116) to enable contact with terminals on one end portion of the one or more battery cells (106); and
- a bottom plate (114) having one or more second interconnectors (118) to enable contact with terminals on another end portion of the one or more battery cells (106).

7. The battery pack as claimed in claim 6, wherein each of the one or more battery modules (100) define at least four sides between the top holder (108) and the bottom holder (110), the Printed Circuit Board (102) being arranged on at least three sides of each of the one or more battery modules (100).

8. The battery pack as claimed in claim 7, wherein the Printed Circuit Board (102) being arranged on each of the one or more battery modules (100) with an adhesive material.

9. The battery pack as claimed in claim 8, wherein the Printed Circuit Board (102) comprises a first set of connectors (120), the first set of connectors (120) being adapted to establish contact with the one or more first interconnectors (116) and the one or more second interconnectors (118).

10. The battery pack as claimed in claim 9, wherein the first set of connectors (120) comprises nickel strips to establish contact with the one or more first interconnectors (116) and the one or more second interconnectors (118).

11. The battery pack as claimed in claim 10, wherein the first set of connectors (120) are spot welded onto the one or more first interconnectors (116) and the one or more second interconnectors (118).

12. The battery pack as claimed in claim 11, wherein the flexible Printed Circuit Board (102) comprises a second set of connectors (122), the second set of connectors (122) being adapted to establish contact with the one or more Battery Management Modules (104).

Dated this 23rd day of March 2023
TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471