DESC:BUSBAR FOR CELL ARRAY OF BATTERY PACK
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202321020836 filed on 24/03/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to battery packs. The present disclosure specifically relates to a busbar unit for a cell array of a battery pack. Furthermore, the present disclosure relates to a cell array of a battery pack.
BACKGROUND
Recently, there has been a rapid development in battery packs because of their use as clean energy storage solution for various uses ranging from domestic use to transportation use. The battery pack comprises a set of any number of identical batteries or individual battery cells. The battery cells are assembled as cell arrays and multiple cell arrays are combined to form the battery packs.
Each battery pack comprises a plurality of cells and cell holders for securing the plurality of cells. These battery cells are electrically connected to form cell arrays and multiple cell arrays can be stacked together to form the battery pack, being used as a single unit for meeting high voltage and current requirements. However, the if even one battery cell of the battery pack becomes faulty, it may harm the entire battery pack. Furthermore, such battery packs with faulty battery cell also pose safety risk. The faulty battery cell may results in thermal runaway inside the battery pack. Furthermore, a faulty cell may suddenly increase the temperature inside the battery pack. Moreover, such sudden increase in the temperature due to the faulty battery cell may increase the temperature of the surrounding cell leading to the thermal runaway. Once the thermal runaway starts, it is difficult to control and stops only when the whole battery pack is destroyed. Moreover, such thermal runaways pose a safety risk for the user. Therefore, it is necessary to electrically isolate such battery cell. Generally, fuses are provided in strings of the battery cells, however, such fuses increase the complexity inside the battery pack. Moreover, such fuses do not prevent heat transfer between the cells through the heating of the busbar due to the faulty battery cell.
Thus, there exists a need for an improved busbar that electrically isolates faulty battery cell and overcomes one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a busbar unit for a cell array of a battery pack.
Another object of the present disclosure is to provide a cell array for a battery pack.
In accordance with first aspect of the present disclosure, there is provided a busbar unit for a cell array of a battery pack. The busbar unit comprises at least one elongated conductive strip comprising a plurality of cell sections, wherein each of the plurality of cell sections comprises a positive terminal connector and a negative terminal connector connected to the elongated conductive strip via at least one fuse strip.
The present disclosure provides the busbar unit for the cell array of the battery pack. The busbar unit of the present disclosure is advantageous in terms of compactness of size. Furthermore, the busbar unit is advantageous in terms of being lightweight. The busbar unit as disclosed by the present disclosure is advantageous in terms of reducing the possibility of thermal runaway inside the battery pack. The busbar unit as disclosed by the present disclosure is advantageous in terms of electrically isolating a faulty battery cell from other battery cells. The busbar unit is advantageous in terms of enabling direct welding of the busbar unit on terminals of the battery cell eliminating need of any additional cell tab. Beneficially, the busbar unit of the present disclosure enables easier assembly of the cell array.
In accordance with second aspect of the present disclosure, there is provided a cell array for a battery pack. The cell array comprises a plurality of battery cells and a busbar unit. The busbar unit comprises at least one elongated conductive strip comprising a plurality of cell sections, wherein each of the plurality of cell sections comprises a positive terminal connector and a negative terminal connector connected to the elongated conductive strip via at least one fuse strip.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates a top view of a section of a busbar unit, in accordance with an aspect of the present disclosure.
Figure 2 illustrates a top view of the busbar unit, in accordance with an embodiment of the present disclosure.
Figure 3 illustrates a perspective view of a cell array, in accordance with another aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a busbar unit and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “power pack”, “battery pack”, and “power pack assembly” are used interchangeably and refer to multiple individual battery cell arrays connected to provide a higher combined voltage or capacity than what a single battery cell array can offer. The power pack assembly is designed to store electrical energy and supply it as needed to various devices or systems. Power pack assembly, as referred herein may be used for various purposes such as power electric vehicles and other energy storage applications. Furthermore, the power pack assembly may include additional circuitry, such as a battery management system (BMS), to ensure the safe and efficient charging and discharging of the battery cells. The battery pack comprises a plurality of battery cell arrays which in turn comprises a plurality of battery cells.
As used herein, the term “battery cell array” refers to an assembled unit of a plurality of cylindrical battery cells that are connected physically and electrically to form a larger energy storage system. Each cell within the battery cell array is typically a discrete unit capable of storing electrical energy. The battery cell array can be arranged in series or parallel configuration depending on the desired voltage and capacity requirements. It is understood that connecting the battery cell array in series increases the overall voltage of the battery pack while connecting them in parallel increases the capacity. The electrical connections in the battery cell array are formed by connecting the terminals of the battery cells with bus bars. Furthermore, in addition to the individual cells, a battery pack may also include circuitry for balancing the charge levels of the cells, managing the charging and discharging processes, and providing safety features such as overcharge and over-discharge protection. The battery cell array, along with the associated electronics and packaging, forms the core component of a battery pack, enabling the efficient and reliable storage and delivery of electrical energy.
As used herein, the terms “battery cell”, “cells” and “battery-cell” are used interchangeably and refer to a basic energy storage unit that stores electrical energy. The battery cells may be comprised of different chemistry including lithium-ion cells, solid-state cells, zinc-carbon and alkaline cells, nickel metal hydride, nickel-cadmium, and so forth. Furthermore, the battery cells may include various types (based on the shape) of cells including cylindrical cells, prismatic cells, pouch cells, coin cells, or any customized shape cells.
As used herein, the term “busbar unit” refers to a conductive metal strip or plate used to facilitate the distribution of electrical power or signals within the cell arrays of the power pack assembly. The busbar serves as a common electrical connection point for multiple battery cells.
As used herein, the term “elongated conductive strip” refers to strip-like structure of the busbar unit for creating a string of series and/or parallel connection between the plurality of battery cells. The elongated conductive strip may be made up of metal. Beneficially, the elongated conductive strip may be made up of insulator pieces infused metal strip to create distinct electrical connections.
As used herein, the term “cell section” refers to a section on the elongated conductive strip on which a battery cell is connected. The cell sections may provide mechanical support to the plurality of battery cells.
As used herein, the term “positive terminal connector” refers to a connector element of the cell section which is connected to the positive terminal of the battery cell. The positive terminal connector may complement a shape of the positive terminal of the battery cell.
As used herein, the term “negative terminal connector” refers to a connector element of the cell section which is connected to the negative terminal of the battery cell. The negative terminal connector may complement a shape of the negative terminal of the battery cell.
As used herein, the term “fuse strip” refers to metal strip connection the positive terminal connector and the negative terminal connector to the elongated conductive strip. The fuse strip may be designed to melt and electrically isolate a battery cell. The fuse strip may be made of metal and/or suitable alloys.
As used herein, the term “thermal cooling pad” and “cooling pad” are used interchangeably and refers to a soft, compressible material used to enhance heat transfer between two surfaces. It is to be understood that the thermal cooling pad fills in microscopic air gaps and uneven surfaces between the heat source and the heat sink, ensuring efficient heat transfer and minimizing thermal resistance. By improving the contact between the two surfaces, the thermal cooling pad enhances the conduction of heat from the heat-generating component to the heat sink, allowing for more effective cooling.
Figure 1, in accordance with an aspect, describes a busbar unit 100 for a cell array of a battery pack. The busbar unit 100 comprises at least one elongated conductive strip 102 comprising a plurality of cell sections 104, wherein each of the plurality of cell sections 104 comprises a positive terminal connector 106 and a negative terminal connector 108 connected to the elongated conductive strip 102 via at least one fuse strip 110.
The present disclosure provides the busbar unit 100 for the cell array of the battery pack. The busbar unit 100 of the present disclosure is advantageous in terms of compactness of size. Furthermore, the busbar unit 100 is advantageous in terms of being lightweight. The busbar unit 100 as disclosed by the present disclosure is advantageous in terms of reducing the possibility of thermal runaway inside the battery pack. The busbar unit 100 as disclosed by the present disclosure is advantageous in terms of electrically isolating a faulty battery cell from other battery cells. The busbar unit 100 is advantageous in terms of enabling direct welding of the busbar unit 100 on terminals of the battery cell eliminating need of any additional cell tab. Beneficially, the busbar unit 100 of the present disclosure enables easier assembly of the cell array.
In an embodiment, the at least one elongated conductive strip 102 is shaped in a zigzag form to reduce distance between a plurality of battery cells 212 connected to the busbar unit 100. Beneficially, the zigzag form of the at least one elongated conductive strip 102 enhance the packing efficiency of the cell array i.e. more plurality of battery cells 212 may be accommodated in the cell array. More beneficially, the zigzag form of the at least one elongated conductive strip 102 improves the compactness of the cell array.
In an embodiment, the positive terminal connector 106 is configured in electrical connection with a positive terminal of the battery cell 212. Beneficially, the positive terminal connector 106 is shaped to complement a shape of the positive terminal of the battery cell 212 to maximize an electrical area of contact between the positive terminal connector 106 and the positive terminal of the battery cell 212.
In an embodiment, the negative terminal connector 108 is configured in electrical connection with a negative terminal of the battery cell 212. Beneficially, the negative terminal connector 108 is shaped to complement a shape of the negative terminal of the battery cell 212 to maximize an electrical area of contact between the negative terminal connector 108 and the negative terminal of the battery cell 212.
In an embodiment, the positive terminal connector 106 and the negative terminal connector 108 are directly connected to the positive terminal and the negative terminal of the battery cell 212 respectively. Beneficially, the positive terminal connector 106 and the negative terminal connector 108 may eliminate the need of any additional cell tab (cell cap) to connect to the positive terminal and the negative terminal of the battery cell 212 respectively. Beneficially, the positive terminal connector 106 may be directly welded on the positive terminal of the battery cell 212. Similarly, the negative terminal connector 108 may be directly welded on the negative terminal of the battery cell 212.
In an embodiment, the at least one elongated conductive strip 102 forms parallel connection between the plurality of battery cells 212 connected to the positive terminal connector 106 and the negative terminal connector 108. Beneficially, such arrangement of the plurality of battery cells 212 enables easier assembly of the cell array. In an embodiment, the at least one elongated conductive strip 102 may be insulator strips infused to create distinct electrical connection between the plurality of battery cells 212. Beneficially, positions of the insulator strips in the at least one elongated conductive strip 102 may be defined according to requirement of electrical connection between the plurality of battery cells 212.
In an embodiment, each of the cell section 104 of adjacent elongated conductive strip 102 forms series connection between the plurality of battery cells 212 connected to the positive terminal connector 106 and the negative terminal connector 108. Beneficially, such arrangement of the plurality of battery cells 212 enables easier assembly of the cell array.
In an embodiment, the at least one fuse strip 110 melts to electrically isolate a particular battery cell, when a current greater than a threshold current flows through the at least one fuse strip 110. Beneficially, the at least one fuse strip 110 eliminates the need of any additional fuse element in the cell array to electrically isolate any faulty battery cell. More beneficially, the at least one fuse strip 110 is integrated in the design of the busbar unit 100, thus, enabling easier assembly of the cell array. More beneficially, the at least one fuse strip 110 enables easier assembly of the cell array.
In an embodiment, the threshold current is linked with at least one of: dimensions of the at least one fuse strip 110, and a shape of the at least one fuse strip 110. Beneficially, the at least one fuse strip 110 may be designed according to the current rating and other requirements of the cell array.
Figure 2, in accordance with an embodiment, describes the busbar unit 100 for the cell array of the battery pack. The busbar unit 100 comprises the at least one elongated conductive strip 102 comprising the plurality of cell sections 104, wherein each of the plurality of cell sections 104 comprises the positive terminal connector 106 and the negative terminal connector 108 connected to the elongated conductive strip 102 via the at least one fuse strip 110. Furthermore, the at least one elongated conductive strip 102 is shaped in the zigzag form to reduce distance between the plurality of battery cells 212 connected to the busbar unit 100. Furthermore, the positive terminal connector 106 is configured in electrical connection with the positive terminal of the battery cell 212. Furthermore, the negative terminal connector 108 is configured in electrical connection with the negative terminal of the battery cell 212. Furthermore, the positive terminal connector 106 and the negative terminal connector 108 are directly connected to the positive terminal and the negative terminal of the battery cell 212 respectively. Furthermore, the at least one elongated conductive strip 102 forms the parallel connection between the plurality of battery cells 212 connected to the positive terminal connector 106 and the negative terminal connector 108. Furthermore, each of the cell section 104 of adjacent elongated conductive strip 102 forms the series connection between the plurality of battery cells 212 connected to the positive terminal connector 106 and the negative terminal connector 108. Furthermore, the at least one fuse strip 110 melts to electrically isolate the particular battery cell, when the current greater than the threshold current flows through the at least one fuse strip 110. Furthermore, the threshold current is linked with the at least one of: the dimensions of the at least one fuse strip 110, and the shape of the at least one fuse strip 110.
Figure 3, in accordance with another aspect, describes a cell array 200 for a battery pack. The cell array 200 comprises a plurality of battery cells 212 and a busbar unit 100. The busbar unit 100 comprises at least one elongated conductive strip 102 comprising a plurality of cell sections 104, wherein each of the plurality of cell sections 104 comprises a positive terminal connector 106 and a negative terminal connector 108 connected to the elongated conductive strip 102 via at least one fuse strip 110.
In an embodiment, the cell array 200 comprises thermal cooling pads, and wherein each of the thermal cooling pad is mounted over the busbar unit 100 for cooling of the busbar unit 100 and terminals of the plurality of battery cells 212.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases by those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A busbar unit (100) for a cell array of a battery pack, wherein the busbar unit (100) comprises at least one elongated conductive strip (102) comprising a plurality of cell sections (104), wherein each of the plurality of cell sections (104) comprises a positive terminal connector (106) and a negative terminal connector (108) connected to the elongated conductive strip (102) via at least one fuse strip (110).
2. The busbar unit (100) as claimed in claim 1, wherein the at least one elongated conductive strip (102) is shaped in a zigzag form to reduce distance between a plurality of battery cells (212) connected to the busbar unit (100).
3. The busbar unit (100) as claimed in claim 1, wherein the positive terminal connector (106) is configured in electrical connection with a positive terminal of the battery cell (212).
4. The busbar unit (100) as claimed in claim 1, wherein the negative terminal connector (108) is configured in electrical connection with a negative terminal of the battery cell (212).
5. The busbar unit (100) as claimed in claim 1, wherein the positive terminal connector (106) and the negative terminal connector (108) are directly connected to the positive terminal and the negative terminal of the battery cell (212) respectively.
6. The busbar unit (100) as claimed in claim 1, wherein the at least one elongated conductive strip (102) forms parallel connection between the plurality of battery cells (212) connected to the positive terminal connector (106) and the negative terminal connector (108).
7. The busbar unit (100) as claimed in claim 1, wherein each of the cell section (104) of adjacent elongated conductive strip (102) forms series connection between the plurality of battery cells (212) connected to the positive terminal connector (106) and the negative terminal connector (108).
8. The busbar unit (100) as claimed in claim 1, wherein the at least one fuse strip (110) melts to electrically isolate a particular battery cell, when a current greater than a threshold current flows through the at least one fuse strip (110).
9. The busbar unit (100) as claimed in claim 8, wherein the threshold current is linked with at least one of: dimensions of the at least one fuse strip (110), and a shape of the at least one fuse strip (110).
10. A cell array (200) for a battery pack, wherein the cell array (200) comprises:
- a plurality of battery cells (212); and
- a busbar unit (100) comprising at least one elongated conductive strip (102) comprising a plurality of cell sections (104), wherein each of the plurality of cell sections (104) comprises a positive terminal connector (106) and a negative terminal connector (108) connected to the elongated conductive strip (102) via at least one fuse strip (110).