DESC:COMPACT POWER PACK ASSEMBLY
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202321020839 filed on 24/03/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to power packs. The present disclosure specifically relates to a power pack assembly. Furthermore, the present disclosure relates to a power pack assembly with thermal isolation.
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 battery pack generates a large amount of heat during the charging and discharging process. If heat generated during the charging and discharging process is not effectively eliminated, heat accumulation may occur inside the battery, which 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. To prevent thermal runaways, the cooling jackets are provided on the battery packs. However, the cooling jackets are ineffective in such scenarios as the faulty battery cell propagates heat inside the battery pack leading to thermal runaway.
Thus, there exists a need for an efficient battery design to prevent thermal runaways and overcomes one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a power pack assembly.
In accordance with an aspect of the present disclosure, there is provided a power pack assembly. The power pack assembly comprises: a plurality of cell arrays comprising a plurality of battery cells; at least one busbar configured to electrically connect a plurality of terminals of the plurality of battery cells; at least one cooling member configured between the plurality of cell arrays; at least one insulation material surrounding the plurality of battery cells; and a housing configured to accommodate the plurality of cell arrays, the at least one busbar, the at least one cooling member and the at least one insulation material.
The present disclosure provides the power pack assembly. The power pack assembly is advantageous in terms of compactness of size. Furthermore, the power pack assembly is advantageous in terms of being lightweight. The power pack assembly as disclosed by the present disclosure is advantageous in terms of reducing the possibility of thermal runaway inside the power pack assembly. The power pack assembly as disclosed by the present disclosure is advantageous in terms of thermally isolating the battery cells from each other. The power pack assembly is advantageous in terms of reducing risk of fire inside the power pack assembly. Beneficially, the power pack assembly is advantageous in terms of reduced vibrations of the plurality of battery cells inside the cell array.
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 sectional perspective view of a power pack assembly, in accordance with an embodiment of the present disclosure.
Figure 2 illustrates a cross section view of the power pack assembly, in accordance with an embodiment 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 power pack assembly 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 term “cooling member” and “thermal cooling member” are used interchangeably and refers to a structure that is used to dissipate heat generated during the operation of the battery cells in the cell array. It would be understood that the cooling member is designed to maintain optimal temperature levels within the cell array, preventing excessive heat build-up that can affect the performance, lifespan, and safety of the battery cells. The cooling member may include a metal heat spreader, liquid cooling plate, finned cooling plate, and so forth.
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 “coolant” refers to a fluid used to regulate the temperature of the power pack assembly. The coolant absorbs heat from the power pack assembly and dissipates it outside the power pack assembly.
As used herein, the terms “cooling channel” and “coolant channel” are used interchangeably and refer to the structure in the cooling member that forms a pathway for the flow of coolant. The flow of coolant is used to dissipate the heat from the plurality of battery cells and ensure optimum operation.
As used herein, the term “busbar” 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 “insulation material” refers to a material used to create thermal isolation between the plurality of battery cells inside the power pack assembly.
As used herein, the term “housing” refers to casing that encloses and protects the internal components of a battery pack. The housing provides at least protection, safety and structural integrity to the components and the power pack assembly. The housing may be made of composites, plastics, metal or a combination thereof.
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 embodiment, describes a sectional perspective view of a power pack assembly 100. The power pack 100 assembly comprises a plurality of cell arrays 102, at least one busbar 104, at least one cooling member 106, at least one insulation material 108, and a housing 110. The plurality of cell arrays 102 comprises a plurality of battery cells 102a. The at least one busbar 104 is configured to electrically connect a plurality of terminals of the plurality of battery cells 102a. The at least one cooling member 106 is configured between the plurality of cell arrays 102. The at least one insulation material 108 is surrounding the plurality of battery cells 102a. The housing 110 is configured to accommodate the plurality of cell arrays 102, the at least one busbar 104, the at least one cooling member 106 and the at least one insulation material 108.
The present disclosure provides the power pack assembly 100. The power pack assembly 100 is advantageous in terms of compactness of size. Furthermore, the power pack assembly 100 is advantageous in terms of being lightweight. The power pack assembly 100 as disclosed by the present disclosure is advantageous in terms of reducing the possibility of thermal runaway inside the power pack assembly 100. The power pack assembly 100 as disclosed by the present disclosure is advantageous in terms of thermally isolating the battery cells from each other. The power pack assembly 100 is advantageous in terms of reducing risk of fire inside the power pack assembly 100. Beneficially, the power pack assembly 100 is advantageous in terms of reduced vibrations of the plurality of battery cells 102a inside the cell array 102.
In an embodiment, the at least one cooling member 106 comprises a plurality of cooling channels for flow of a coolant therein. Beneficially, the cooling member 106 is advantageous in terms of efficiently extracting heat from inside the power pack assembly 100. Beneficially, the cooling member 106 is located inside the power pack assembly 100 to extract heat from inside the power pack assembly 100. Furthermore, beneficially the cooling member 106 is in physical contact with the plurality of battery cells 102a of the power pack assembly 100 for efficient heat transfer from the plurality of battery cells 102a to outside the power pack assembly 100.
In an embodiment, the at least one insulation material 108 is configured to create a thermal isolation and an electrical isolation between the plurality of battery cells 102a. Beneficially, the thermal isolation between the plurality of battery cells 102a enables protection against thermal runaway inside the power pack assembly 100 as the heat generated by one faulty battery cell does not transfer to or impact other nearby battery cells inside the power pack assembly 100.
In an embodiment, the at least one insulation material 108 comprises: a high-density insulation material 108a and a low-density insulating material 108b. Beneficially, the high-density insulation material 108a and a low-density insulating material 108b together provide a complete thermal isolation between the plurality of battery cells 102a inside the power pack assembly 100.
In an embodiment, the high-density insulation material 108a is configured to surround a surface area along length of the plurality of battery cells 102a. Beneficially, the high-density insulation material 108a creates a thermal isolation between the surface area along length of the plurality of battery cells 102a to prevent any heat transfer between the plurality of battery cells 102a inside the power pack assembly 100.
In an embodiment, the high-density insulation material 108a is configured to completely fill a vacant space between the plurality of battery cells 102a. Beneficially, the high-density insulation material 108a provides mechanical support to the plurality of battery cells 102a by filling the vacant space between the plurality of battery cells 102a inside the power pack assembly 100. More beneficially, the high-density insulation material 108a reduces vibration of the inside the plurality of battery cells 102a inside the power pack assembly 100.
In an embodiment, the low-density insulation material 108b is configured to cover a surface along the plurality of terminals of the plurality of battery cells 102a. Beneficially, the low-density insulation material 108b may cover the surface along the plurality of terminals of the plurality of battery cells 102a to create the thermal isolation between the plurality of battery cells 102a. More beneficially, the low-density insulation material 108b may act as a shock absorber in case of venting of the faulty battery cell. It is to be understood that the low-density insulation material 108b may absorb the mechanical shock while allowing the harmful gases to pass through. More beneficially, the low-density insulation material 108b may prevent damaging of the housing 110 due to the venting of the faulty battery cell.
In an embodiment, the high-density insulation material 108a comprises at least one of: a high-density polyurethane foam, a high-density polystyrene foam, or a high-density polyethylene foam. Beneficially, the high-density insulation material 108a may strong and dense.
In an embodiment, the low-density insulation material 108b comprises at least one of: a low-density polyurethane foam, a low-density polystyrene foam, or a low-density polyethylene foam. Beneficially, the low-density insulation material 108b may be flexible and provide cushioning.
In an embodiment, the high-density insulation material 108a and the low-density insulation material 108b further comprises a fire-retardant material. It is to be understood that the fire-retardant material is mixed with the high-density insulation material 108a and the low-density insulation material 108b to create fire-retardant high-density insulation material 108a and fire-retardant low-density insulation material 108b. The fire-retardant high-density insulation material 108a and the fire-retardant low-density insulation material 108b may prevent fire inside the power pack assembly 100 in case of venting of the faulty battery cell. Optionally, the fire-retardant material may include melamine based fire-retardant material. More optionally, the high-density insulation material 108a and the low-density insulation material 108b may comprise any other suitable fire-retardant material.
Figure 2, in accordance with an embodiment, describes a cross section of the power pack assembly 100. The power pack 100 assembly comprises the plurality of cell arrays 102, the at least one busbar 104, the at least one cooling member 106, the at least one insulation material 108, and the housing 110. The plurality of cell arrays 102 comprises the plurality of battery cells 102a. The at least one busbar 104 is configured to electrically connect the plurality of terminals of the plurality of battery cells 102a. The at least one cooling member 106 is configured between the plurality of cell arrays 102. The at least one insulation material 108 is surrounding the plurality of battery cells 102a. The housing 110 is configured to accommodate the plurality of cell arrays 102, the at least one busbar 104, the at least one cooling member 106 and the at least one insulation material 108. Furthermore, the at least one cooling member 106 comprises a plurality of cooling channels for flow of a coolant therein. Furthermore, the at least one insulation material 108 is configured to create a thermal isolation and an electrical isolation between the plurality of battery cells 102a. Furthermore, the at least one insulation material 108 comprises: a high-density insulation material 108a and a low-density insulating material 108b. Furthermore, the high-density insulation material 108a is configured to surround a surface area along length of the plurality of battery cells 102a. Furthermore, the high-density insulation material 108a is configured to completely fill a vacant space between the plurality of battery cells 102a. Furthermore, the low-density insulation material 108b is configured to cover a surface along the plurality of terminals of the plurality of battery cells 102a. Furthermore, the high-density insulation material 108a comprises at least one of: a high-density polyurethane foam, a high-density polystyrene foam, or a high-density polyethylene foam. Furthermore, the low-density insulation material 108b comprises at least one of: a low-density polyurethane foam, a low-density polystyrene foam, or a low-density polyethylene foam. Furthermore, the high-density insulation material 108a and the low-density insulation material 108b further comprises a fire-retardant material.
In an embodiment, the power pack assembly 100 comprises thermal cooling pads, and wherein each of the thermal cooling pad is mounted over each of the busbars 104 to for cooling of the busbar 104 and terminals of the plurality of battery cells 102a.
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 power pack assembly (100), wherein the power pack (100) assembly comprises:
- a plurality of cell arrays (102) comprising a plurality of battery cells (102a);
- at least one busbar (104) configured to electrically connect a plurality of terminals of the plurality of battery cells (102a);
- at least one cooling member (106) configured between the plurality of cell arrays (102);
- at least one insulation material (108) surrounding the plurality of battery cells (102a); and
- a housing (110) configured to accommodate the plurality of cell arrays (102), the at least one busbar (104), the at least one cooling member (106) and the at least one insulation material (108).
2. The power pack assembly (100) as claimed in claim 1, wherein the at least one cooling member (106) comprises a plurality of cooling channels for flow of a coolant therein.
3. The power pack assembly (100) as claimed in claim 1, wherein the at least one insulation material (108) is configured to create a thermal isolation and an electrical isolation between the plurality of battery cells (102a).
4. The power pack assembly (100) as claimed in claim 1, wherein the at least one insulation material (108) comprises: a high-density insulation material (108a) and a low-density insulating material (108b).
5. The power pack assembly (100) as claimed in claim 4, wherein the high-density insulation material (108a) is configured to surround a surface area along length of the plurality of battery cells (102a).
6. The power pack assembly (100) as claimed in claim 5, wherein the high-density insulation material (108a) is configured to completely fill a vacant space between the plurality of battery cells (102a).
7. The power pack assembly (100) as claimed in claim 4, wherein the low-density insulation material (108b) is configured to cover a surface along the plurality of terminals of the plurality of battery cells (102a).
8. The power pack assembly (100) as claimed in claim 4, wherein the high-density insulation material (108a) comprises at least one of: a high-density polyurethane foam, a high-density polystyrene foam, or a high-density polyethylene foam.
9. The power pack assembly (100) as claimed in claim 4, wherein the low-density insulation material (108b) comprises at least one of: a low-density polyurethane foam, a low-density polystyrene foam, or a low-density polyethylene foam.
10. The power pack assembly (100) as claimed in claim 1, wherein the high-density insulation material (108a) and the low-density insulation material (108b) further comprises a fire-retardant material.