[0001] The present invention relates to an energy storage apparatus, and more
particularly relates to an energy storage apparatus which is compact and lightweight.
BACKGROUND OF THE INVENTION
[0002] With rise in pollution, environmental hazards caused by the usage of fossil
fuels, and depletion of fossil fuels, batteries are predominantly being used as energy
storages in applications to power vehicles.
[0003] In most cases, multiple batteries or battery cells are connected to one
another in one of series, parallel and a combination thereof and placed within a
battery pack. The number of battery cells is dependent on one of application and
requirement of a user. In addition to the battery cells, the battery pack is provided
with multiple components required for ensuring efficient and safe operation of the
battery pack. The multiple components include one of, but is not limited to, thermal
pads, electrical insulators, a plurality of sensors, a controlling unit and connectors.
The multiple components are arranged in various combination along with the battery
cells within the battery pack. Further, size and weight of the battery pack is directly
proportional to the arrangement of the multiple components and the battery cells.
[0004] The battery pack is one of coupled or retrofitted to the electric vehicles.
The electric vehicle may be one of, but not limited to, an electric two-wheeler, threewheeler, and heavy duty vehicles. In case the electric vehicle is the electric twowheeler, the battery back may be disposed within a boot space of the electric vehicle.
The battery pack may be disposed also be disposed at any suitable location of the
electric vehicle. However, the boot space is generally used as a storage space for the
user of the electric vehicle, and restrictions in storage space is a cause of concern for
the user. Reducing the size and/or weight of the battery pack by removal of one or
more of the multiple components or by reducing the number of the battery cells will
impact the safety and the efficiency of the battery pack, respectively. Also, heavy
battery packs effect the portability of the battery pack and performance of the electric
two-wheeler.
3
[0005] Accordingly, it is required to provide a battery pack that is portable,
lightweight and compact, without compensating for the efficiency and performance
of the battery pack.
SUMMARY OF THE INVENTION
[0006] One or more embodiments of the present invention provide an energy
storage apparatus and a method for providing the energy storage apparatus.
[0007] In one aspect of the invention, an energy storage apparatus is provided.
The apparatus includes a housing having at least one open end and a rear end
opposite to the at least one open end. The apparatus further includes a casing
disposed along a longitudinal axis of the housing via the at least one open end of the
housing. The casing includes multiple sheets coupled to each other and in contact
with the housing to define a hollow space within the casing. A plurality of cell packs
is thereafter arranged within the casing and adjacent to the rear end of the housing.
Each of the plurality of cell core packs is positioned parallel to each other and further
at an offset from the longitudinal axis of the housing. The apparatus further includes
a Battery Management System (BMS) coupled to each of the plurality of cell core
packs. The BMS is disposed within the casing via the at least one open end of
housing and adjacent to the plurality of cell core packs. The apparatus further
includes a top cover detachably coupled to a periphery of the at least one open end of
the housing.
[0008] In another aspect of the invention, a method for providing an energy
storage apparatus is provided. The method includes the step of disposing a casing
along a longitudinal axis of a housing via an at least one open end of the housing.
The casing includes multiple sheets coupled to each other and in contact with the
housing to define a hollow space within the housing. The method includes
interconnecting each of a plurality of cells via at least a first bus bar to one of couple
the plurality of cells and isolate at least one of the plurality of cells during one of an
event of thermal runaway and short circuit. Each of the plurality of cells is
interconnected to each other in one of a series connection, a parallel connection, and
a combination thereof. The plurality of cells is thereafter arranged within a plurality
4
of cell core packs. The method includes arranging a plurality of cell core packs
within the casing and adjacent to a rear end of the housing. The plurality of cell
packs is interconnected to each other via at least a second bus bar to one of couple
the plurality of cell core packs and isolate at least one of the plurality of cell core
packs during one of an event of thermal runaway and short circuit.
[0009] The method further includes positioning at least one insulation sheet
between the plurality of cell core packs to electrically insulate the plurality of cell
core packs, and further encompassing the plurality of cell core packs within a
plurality of intermediate plates to thermally insulate the plurality of cell core packs
within the battery pack. Thereafter, the method includes coupling a Battery
Management System (BMS) to each of the plurality of cell core packs, the BMS
disposed within the casing and adjacent to the plurality of cell core packs via the at
least one open end of the housing. The method further includes detachably coupling
a top cover to a periphery of the at least one open end of the housing.
[0010] Other features and aspects of this invention will be apparent from the
following description and the accompanying drawings. The features and advantages
described in this summary and in the following detailed description are not allinclusive, and particularly, many additional features and advantages will be apparent
to one of ordinary skill in the relevant art, in view of the drawings, specification, and
claims hereof. Moreover, it should be noted that the language used in the
specification has been principally selected for readability and instructional purposes,
and may not have been selected to delineate or circumscribe the inventive subject
matter, resort to the claims being necessary to determine such inventive subject
matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Reference will be made to embodiments of the invention, examples of
which may be illustrated in the accompanying figures. These figures are intended to
be illustrative, not limiting. The accompanying figures, which are incorporated in
and constitute a part of the specification, are illustrative of one or more embodiments
of the disclosed subject matter and together with the description explain various
5
embodiments of the disclosed subject matter and are intended to be illustrative.
Further, the accompanying figures have not necessarily been drawn to scale, and any
values or dimensions in the accompanying figures are for illustration purposes only
and may or may not represent actual or preferred values or dimensions. Although
the invention is generally described in the context of these embodiments, it should be
understood that it is not intended to limit the scope of the invention to these
particular embodiments.
[0012] FIG. 1 is a block diagram of an environment to which an energy storage
apparatus is implemented, according to one or more embodiments of the present
invention;
[0013] FIG. 2A is a housing of the energy storage apparatus of FIG. 1, in
accordance with one or more embodiments of the present invention;
[0014] FIG. 2B is a top cover of the energy storage apparatus of FIG. 1, in
accordance with one or more embodiments of the present invention;
[0015] FIG. 2C is the energy storage apparatus, in accordance with one or more
embodiments of the present invention;
[0016] FIG. 3A is a casing of the energy storage apparatus of FIG. 2C, in
accordance with one or more embodiments of the present invention;
[0017] FIG. 3B is a plurality of intermediate plates to be positioned within the
casing of the energy storage apparatus of FIG. 2C, in accordance with one or more
embodiments of the present invention;
[0018] FIG. 4A is a cell holder tray to position a plurality of cells of the energy
storage apparatus of FIG. 2C, in accordance with one or more embodiments of the
present invention;
[0019] FIG. 4B is a first bus bar to interconnect each of the plurality of cells of the
energy storage apparatus of the FIG. 2C, in accordance with one or more
embodiments of the present invention;
[0020] FIG. 4C is a first cell core pack of the energy storage apparatus of FIG.
2C, in accordance with one or more embodiments of the present invention;
6
[0021] FIG. 5 is a plurality of cell core packs of the energy storage apparatus of
FIG. 2C, in accordance with one or more embodiments of the present invention;
[0022] FIG. 6 is an at least one insulation sheet adapted to be disposed between
the plurality of cell core packs of the energy storage apparatus of FIG. 2C, in
accordance with one or more embodiments of the present invention;
[0023] FIG. 7A is a schematic representation of a Battery Management System
(BMS) of the energy storage apparatus of FIG. 2C, in accordance with one or more
embodiments of the present invention;
[0024] FIG. 7B is a mounting plate of the BMS of FIG. 7A of the energy storage
apparatus of FIG. 2C, in accordance with one or more embodiments of the present
invention;
[0025] FIG. 8 is a rear plate of the housing of FIG. 2A of the energy storage
apparatus of FIG. 2C, in accordance with one or more embodiments of the present
invention;
[0026] FIG. 9 is an exploded view of the energy storage apparatus of FIG. 1, in
accordance with one or more embodiments of the present invention; and
[0027] FIG. 10 is a flow chart of a method of providing the energy storage
apparatus of FIG. 1, according to one or more embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Reference will now be made in detail to specific embodiments or features,
examples of which are illustrated in the accompanying drawings. Wherever
possible, corresponding or similar reference numbers will be used throughout the
drawings to refer to the same or corresponding parts. References to various elements
described herein, are made collectively or individually when there may be more than
one element of the same type. However, such references are merely exemplary in
nature. It may be noted that any reference to elements in the singular may also be
construed to relate to the plural and vice-versa without limiting the scope of the
invention to the exact number or type of such elements unless set forth explicitly in
the appended claims. Moreover, relational terms such as first and second, and the
7
like, may be used to distinguish one entity from the other, without necessarily
implying any actual relationship or between such entities.
[0029] FIG. 1 illustrates a block diagram of an environment 100 to which an
energy storage apparatus 105 is implemented, according to one or more
embodiments of the present invention. The energy storage apparatus 105 is adapted
to be utilized as source of power in electric vehicles, telecom, household appliances,
and the like. Further, the energy storage apparatus 105 is one of, but not limited to, a
battery pack, a renewable energy storage system, and the like. Further, for the
purpose of description and understanding the energy storage apparatus 105 is
hereinafter referred to as “the battery pack 105” and will be explained with respect to
the battery pack 105, without limiting and deviating from the scope of the present
disclosure.
[0030] The environment 100 includes a vehicle 110 powered and propelled by the
battery pack 105, as also illustrated in FIG. 2C. In the illustrated embodiment, the
vehicle 110 is an electric two-wheeler. It should, however, be noted that the vehicle
110 is depicted as the electric two-wheeler only for the purpose of description and
explanation, and should nowhere be construed as limiting the scope of the
description. As such, the vehicle 110 may be one of, but not limited to, a threewheeler, a four-wheeler, and a heavy duty vehicle. Further, although the description
is provided with respect to the vehicle 110, it is to be understood that the battery
pack 105 may be employed as an energy source for any other application such as
telecom, household appliances, smart homes and the like.
[0031] The vehicle 110 is provided with a boot space 115 underneath a seat 120 of
the vehicle 110. In the preferred embodiment, the battery pack 105 is positioned
within the boot space 115. In alternate embodiments, the battery pack 105 may be
positioned on one of a platform 125 and any other suitable location of the vehicle
110. The vehicle is further provided with a set of ground engaging elements 130.
[0032] The battery pack 105 further transmits data pertaining to multiple
operational parameters of the battery pack 105 to a server 135 via a network 140.
The multiple operational parameters are one of, but not limited to, current, voltage,
8
and temperature of the battery pack 105. In one embodiment, the battery pack 105
includes a Battery Management System 705 (as shown in FIG. 7A) for receiving and
temporarily storing the data pertaining to multiple operational parameters of the
battery pack 105. It may be understood that the server 135 may be implemented in a
variety of computing systems, such as a mainframe computer, a network server,
cloud, and the like.
[0033] The server 135 is in communication with the BMS 705 of the battery pack
105 via the network 140. In one embodiment, a Secure Hardware Extension (SHE)
unit is embedded within the battery pack 105. The SHE unit ensures that a secure
communication of data takes place between the battery pack 105 and the server 135,
thereby preventing third party access to data. In an embodiment, the network 140
can include wired and/or wireless connections such as, but not limited to, local area
network (LAN), Bluetooth, Near Field Communication (NFC), infrared, WIFI,
GPRS, LTE, Edge and the like.
[0034] In addition, the battery pack 105 is in communication with a user device
145 via the network 140. As such, the user device 145 receives notifications
pertaining to the multiple operational parameters of the battery pack 105. In certain
embodiments, the user device 145 enables the user to manually switch off the battery
pack 105 from a remote location in case of an emergency. In addition, the user
device 145 is communicably coupled to the server 135. Further, one of the server
135 and the BMS 705 is configured to provide the user with periodic reports
regarding health of the battery pack 105. The user device 145 is one of, but not
limited to, a mobile phone, a portable computer, a personal digital assistant, a
handheld device, a laptop computer, and a display unit in the electric vehicle.
[0035] Referring to FIGS. 2A-2B, FIG. 2A illustrates a housing 205 of the battery
pack 105, according to the one or more embodiments of the present invention. The
housing 205 is a hollow enclosure within which multiple components essential to
operation of the battery pack 105 is arranged. The multiple components are arranged
in such a way so as to ensure compactness of the battery pack 105 without
compromising on safety and efficiency of the battery pack 105. The arrangement of
9
the components within the housing 205 will be explained in detailed with respect to
the following figures. The housing 205 includes at least one open end 207 and a rear
end 209 opposite and distal to the at least one open end 207.
[0036] A shape and size of the housing 205 may vary based on an application in
which the battery pack 105 is required to utilized. In the illustrated embodiment, the
battery pack 105 is of rectangular shape. However, in alternate embodiments, the
battery pack 105 may be, but not limited to, a square shape without deviating from
the scope of the present disclosure. The housing 105 is preferably made of materials
which are thermally conductive to enable heat dissipation from within and thereby
prevent damage to the battery pack 105. In alternate embodiments, the housing 205
is made of thermally insulating materials, such as plastic.
[0037] The battery pack 105 further includes a top cover 210, as illustrated in FIG.
2B. The top cover 210 is detachably coupled to a periphery of the at least one open
end 207 of the housing 205 via fasteners. Shape of the top cover 210 is required to
be in proportion with the shape of the housing 205 in order to ensure accurate
coupling of the housing 205 and the top cover 210. The top cover 210 is preferably
made of materials which are thermally conductive and flame retardant.
[0038] In the preferred embodiment, a telematics unit 215 is mounted and coupled
onto the top cover 210 of the battery pack 105 via fasteners. The telematics unit 215
is configured to provide a display interface unit to a user of the battery pack 105.
The telematics unit 215 displays information pertaining to, but not limited to, a State
of Charge (SOC) of the battery pack 105, time remaining for the battery pack 105 to
drain, low SOC level of the battery pack 105 alert, and emergency alerts. In an
alternate embodiment, the telematics unit 215 may be coupled to the vehicle 110 in a
position visually accessible by the user.
[0039] The top cover 210 further includes a handle bar 220 coupled to thereon.
More specifically, the handle bar 220 is coupled to an outer surface 225 of the top
cover 210 via one of fasteners, press joining, and clinching. Further, a groove 227 is
defined on the top cover 210. The groove 227 is adapted to seat the handle bar 220
therein when the handle bar 220 is in a rest position.
10
[0040] The handle bar 220 is adapted to aid in lifting the battery pack as per
requirement of the user. For example, in a scenario where SOC of the battery pack
105 is critically low, the user may lift the battery pack 105 using the handle bar 220.
Accordingly, the handle bar 220 is positioned in line with a center of gravity of the
battery pack 105 to aid in an uncomplicated lifting of the battery pack 105. In
another embodiment, the housing 205 is further provided with rails and guides to
ensure safe and accurate position the battery pack 105 within the vehicle 110.
[0041] The top cover 210 of the housing further includes a venting apparatus 230
machined onto the battery pack 105. The venting apparatus 230 includes a venting
membrane (not shown). The venting membrane is adapted to rupture to allow gases
to escape from within the battery pack 105 to atmosphere during instances of
pressure build up within the battery pack 105. During instances of thermal runaway,
inflammable gases are generated within the battery pack 105, and there is a pressure
build up therein. Failure of timely release of the gases generated therein leads to
explosion of the battery pack 105. As the pressure builds up within the battery pack
105, ruptures are formed on the venting membrane of the venting apparatus 230. As
such, the gases generated within the battery pack 105 escapes quickly to the
atmosphere.
[0042] The top cover 210 further includes an opening 235 extending between the
outer surface 225 and an inner surface (not shown) of the top cover 210. One or
more battery connectors are routed through the opening 235 to aid in coupling the
battery pack 105 with one of the vehicle 110 and a charging station. The one or
more battery connectors aid in transferring power from the battery pack 105 to
propel and power the vehicle 110.
[0043] As mentioned earlier, multiple components essential for the safe and
efficient operation of the battery pack 105 is arranged within the hollow enclosure of
the housing 205. Accordingly, the battery pack 105 includes a casing 305, as
illustrated in FIG. 3A. The casing is formed by coupling multiple sheets 310 to each
other. More specifically, the multiple sheets include a first, a second, a third, and a
fourth sheet 310a-d coupled to each other and to a rear sheet (not shown) to define a
11
hollow space within the casing 305. Shape of the casing 305 is adapted to
correspond with the shape of the housing 205 of the battery pack 105. The casing
305 is adapted to ensure electrical insulation of the housing 205 of the battery pack
105. The casing 305 is further adapted to ensure thermal isolation of the housing
205 of the battery pack 105. Accordingly, the casing 305 is preferably made of
materials capable of providing thermal and electrical insulation and thereby ensuring
safety to users and surroundings of the battery pack 105.
[0044] The battery pack 105 further includes a plurality of intermediate plates 315,
as illustrated in FIG. 3B. In the preferred embodiment, the plurality of intermediate
plates 315 include a first plate 315a, a second plate 315b, and a third plate 315c. A
first end 320 of the first plate 315a is coupled to a first end 322 of the second plate
310b. Likewise, a first end 325 of the third plate 310c is coupled to a second end
330 of the second plate 310b. Each of the plurality of intermediate plates 315 are
made of thermally conductive materials to aid in maintaining an ambient temperature
within the housing 205, and thereby within the battery pack 105. Owing to which,
the battery pack 105 is adapted to, advantageously, one of charge and discharge
efficiently. In one embodiment, the each of the plurality of intermediate plates 315
are made of thermal insulating materials, to prevent flame propagation during an
event of thermal runaway, and electrically insulating materials. As mentioned
earlier, the housing 205 is made of thermally insulating materials. In this regard, in
one embodiment the casing 305 and each of the plurality of intermediate plates 315
are optional and need not be mandatorily disposed within the housing 205 of the
battery pack 105.
[0045] The battery pack 105 further includes at least one cell holder tray 405, as
illustrated in FIG. 4A, according to one or more embodiments of the present
invention. The cell holder tray 405 includes a plurality of annular cavities 410 for
receiving and positioning a plurality of cells 415 therein. Shape and dimensions of
the plurality of annular cavities 410 are adapted to conform with a shape of the
plurality of cells 415. Number of plurality of cells 415 to be positioned within the
cell holder tray 405 is dependent on application and voltage requirements of the
12
battery pack 105. Further, the plurality of cells 415 is adapted to be positioned in
various configurations as per the voltage requirements.
[0046] Further, each of the plurality of annular cavities 410 is provided with a
stopper 420. The stopper 420 aids in constraining movement of each of the plurality
of cells 415. Each of the plurality of annular cavities 410 along with the stopper 420
aid in securely holding each of the plurality of cells 415 within the respective annular
cavity 410 of the cell holder tray 405.
[0047] In one embodiment, each of the plurality of cells 415 is one of, but not
limited to, a Lithium ion (Li-ion), a Lead acid gel, and Nickel metal hydride. In an
alternate embodiment, composition of each of the plurality of cells 415 is lithium or
lithium polymer cells (referred to as “lithium”) combined with nickel hydrate battery
cells. In alternate embodiments, any suitable battery cell composition may be used,
including, but not necessarily limited to, lithium ion, zinc air, zinc oxide, super
charged zinc oxide, and fuel cells.
[0048] Each of the plurality of cells 415 is electrically coupled to the each other in
one of a series connection, a parallel connection and a combination thereof. In this
regard, each of the plurality of cells 415 are interconnected to each other via a first
bus bar 430. A surface of the first bus bar 430, as illustrated in FIG. 4B, includes
multiple apertures 435 defined thereon. The first bus bar 430 is placed over the
plurality of cells 415 so that each of the multiple apertures 435 of the first bus bar
430 is in line with each of the plurality of cells 415. Each of the plurality of cells
415 include a cathode and an anode. Accordingly, the cathode of each of the
plurality of cells are interconnected via the first bus bar 430. Similarly, the anode of
each of the plurality of cells 415 are interconnected via the first bus bar 430.
[0049] Further, a first end 432 and a second end 434 of the first bus bar 430 is
positioned on a first surface 425 and a second surface 427 of the cell holder tray 405.
In this regard, the cell holder tray 405 includes multiple projections 429 defined
along the first and the second surface 425, 427. The multiple projections 429 aid in
constraining the movement of the at least one first bus bar 430. In one embodiment,
the first end 432 of the first bus bar 430 is adapted to be coupled to the BMS 705.
13
As a result, the BMS 705 receives the data pertaining to the multiple operating
parameters of the plurality of cells 415. In addition, the cell holder tray 405 includes
a plurality of cavities 428 defined on a third surface 431 of the cell tray holder 405.
[0050] Further, although the first bus bar 430, as illustrated in FIG. 4B, is of a
specific shape and includes a certain number of apertures 435, it is to be understood
that the first bus bar 430 may of any shape and may include any number of apertures
435 with respect to the number of the plurality of cells 415, without deviating from
the scope of the present disclosure. The first bus bar 430 is further coupled to the
plurality of cells 415 via one of, but not limited to, welding, fasteners, and adhesives.
The first bus bar 430 is adapted to one of couple each of the plurality of cells 415,
and isolate at least one of plurality of cells 415 during an event of thermal runaway
and short circuit. Further, the first bus bar 430 is adapted to connect each of the
plurality of cells 415 as per the voltage requirement. The first bus bar 430 is
preferably made of materials having high corrosion resistance and thermal
properties.
[0051] As mentioned earlier, the battery pack 105 includes at least four cell holder
trays 405. For the purpose of description and explanation, the cell holder tray 405 is
here forth explained with respect to a first cell holder tray 405a, a second cell holder
tray 405b, a third cell holder tray 405c, and a fourth cell holder tray 405d, and
should nowhere be construed as limiting the scope of the present disclosure. The
plurality of cells 415 is positioned within the first cell holder tray 405a and the
second cell holder tray 405b, as explained above, to form a first cell core pack 445.
Likewise, a plurality of cells 447 is positioned within the third cell holder tray 405c
and the fourth cell holder tray 405d to form a second cell core pack 450 (as shown in
FIG. 5).
[0052] In one embodiment, the battery pack 105 includes the first and the second
core pack 445, 450. In another embodiment, the battery pack 105 includes multiple
cell core packs, as per requirement of the application. In one embodiment, each of
the first, the second, the third, and fourth cell holder tray 405a-d are adapted to
position 90 cells therein. In the preferred embodiment, a gap between each of the
14
plurality of cells 415, 446 is 0.8mm. As such, the plurality of cells 415 are adapted
to be arranged in a compact manner within the housing 205 of the battery pack 105,
without compensating for efficiency and safety of the battery pack 105.
[0053] Referring to FIG. 5, FIG. 5 illustrates a plurality of cell core packs 505 and
interconnection there between, according to one or more embodiments of the
invention. For the purpose of the description and explanation, the plurality of cell
core packs 505 is explained with reference to the first cell core pack 445 and the
second cell core pack 450. It is to be however understood that the plurality of cell
core packs 505 includes multiple cell core packs coupled to each other without
deviating from the scope of the present disclosure.
[0054] Each of the first and second core pack 445, 450 is stacked parallel to one
another. Subsequently, each of the first and the second cell core pack 445, 450 are
interconnected to each other via at least a second bus bar 510.
[0055] As per the illustrated embodiment, the second bus bar 510 is provided with
multiple apertures 515 defined on a surface thereof. Also, as mentioned earlier, the
cell holder tray 405 includes the plurality of cavities 428 defined on the third surface
431 of the cell holder tray 405. As such, each of the first, the second, the third, and
the fourth cell holder tray 405a-d includes the plurality of cavities 428 defined
thereon. In order to interconnect the first cell core pack 445 and the second cell core
pack 450, the second bus bar 510 is positioned on the second and the third cell holder
tray 405c, 405d of the first cell core pack 445 and the second cell core pack 450,
respectively. More specifically, the second bus bar 510 is positioned such that each
of the plurality of cavities 428 and the multiple apertures 515 are aligned in line with
each other. Subsequently, the second bus bar 510 is coupled on to the second and
the third cell holder 405c, 405d via fasteners. In one embodiment, the second bus
bar 510 is coupled on to the second and the third cell holder 405c, 405d via one of,
but not limited to, welding and adhesives.
[0056] The second bus bar 510 is adapted to one of couple the first cell core pack
445 and the second cell core pack 450, and isolate at least one of the first and the
second cell core pack 445, 450 during an event of thermal runaway and short circuit.
15
The second bus bar 510 is preferably made of materials having high corrosion
resistance and thermal properties.
[0057] Each of the first and second core pack 445, 450 further includes a first set
of barrier sheets 520 and a second set of barrier sheets 525. The first set of barrier
sheets 520 includes a plurality of first barrier sheets 520a-h extending along a
horizontal direction within each of the first and the second cell core pack 445, 450.
The plurality of barrier sheets 520a-h is positioned in between adjacent cells of the
plurality of cells 415. Similarly, the second set of barrier sheets 525 includes a
plurality of second barrier sheets 525a-i extending along a vertical direction within
each of the first and the second cell core pack 445, 450. The plurality of second
barrier sheets 525a-i are positioned in between adjacent cells of the plurality of cells
415. As a result, the plurality of the first barrier sheets 520a-h and the plurality of
second barrier sheets 525a-i intersect with each other to form a plurality of cell
isolation slots 530. Each of the plurality of cells 415 is positioned within each of the
plurality of cell isolation slots 530 formed in the first cell core pack 445. Likewise,
each of the plurality of cells 447 is positioned within each of the plurality of cell
isolation slots 530 formed in the second cell core pack 450.
[0058] Further, the cell of the plurality of cells 415, 447 positioned along corner of
each of the first and the second cell core pack 445, 450, respectively, are shielded
from two sides, and the cell positioned on sides are shielded from three sides, and
remaining cells of the plurality of cells 415 are shielded from four sides by each of
the plurality of the first barrier sheets 520a-h and the plurality of second barrier
sheets 525a-i.
[0059] The plurality of cell isolation slots 530 prevents propagation of fire from
one cell to the adjacent cell of the plurality of cells 415, 447. As a result, during
event of one of thermal runaway and short circuit, only a damaged cell of the
plurality of cells 415, 446 needs to be replaced. Each of the plurality of the first
barrier sheets 520a-h and the plurality of second barrier sheets 525a-i are preferably
made of mica and other flame resistant materials.
16
[0060] The battery pack 105 includes at least one insulation sheet 605, as
illustrated in FIG. 6. The at least one insulation sheet 605 is adapted to be disposed
between each of the first and second core pack 445, 450. The at least one insulation
sheet 605, hereinafter referred to as “the insulation sheet 605” aids to isolate each of
the first and second core pack 445, 450 from each other. The insulation sheet 605
further include plurality of through holes 610 defined thereon. The plurality of
through holes 610 aid in routing of connectors between the plurality of cell core
packs 505. In one embodiment, plurality of sensors (not shown), such as, but not
limited to, temperature sensors, are positioned within the plurality of through holes
610. The plurality of sensors is thereafter communicably coupled to the BMS 705.
[0061] The battery pack 105 further includes the BMS 705, as illustrated in the
FIG. 7A. The BMS 705 may include at least one processor 706, an input/output
(I/O) interface unit 707, and a memory 709. The at least one processor 706 may be
implemented as one or more microprocessors, microcomputers, microcontrollers,
digital signal processors, central processing units, state machines, logic circuitries,
and/or any devices that manipulate signals based on operational instructions. Among
other capabilities, the at least one processor 706 is configured to fetch and execute
computer-readable instructions stored in the memory 709.
[0062] The I/O interface unit 707 may include a variety of software and hardware
interfaces, for example, a web interface, a graphical user interface, Light Emitting
Diode (LED) and the like. The I/O interface unit 707 may allow the user to interact
with the BMS 705 directly or through the user device 145. Further, the I/O interface
unit 707 may enable the BMS 705 to communicate with other computing devices,
such as the server 135 and external data servers (not shown). The I/O interface 707
may facilitate multiple communications within a wide variety of networks and
protocol types, including wired networks, for example, LAN, cable, etc., and
wireless networks, such as WLAN, cellular, or satellite. In one embodiment, The
I/O interface unit 707 may include one or more ports for connecting a number of
devices to one another or to another server.
17
[0063] The memory 709 may include any computer-readable medium known in
the art including, for example, volatile memory, such as static random access
memory (SRAM) and dynamic random access memory (DRAM), and/or nonvolatile memory, such as read only memory (ROM), erasable programmable ROM,
flash memories, hard disks, optical disks, and magnetic tapes.
[0064] In one embodiment, the BMS 705 is positioned within the battery pack 105.
In alternate embodiments, the BMS 705 is located at a location remotely accessible
by the user. The BMS 705 receives data pertaining to multiple operational
parameters of each of the plurality of cells 415 within each of the first and second
core pack 445, 450 via the first bus bar 430. The multiple operational parameters are
one of, but not limited to, current, voltage, and temperature of each of the plurality of
cells.
[0065] The BMS 705 is further electrically and communicably coupled to each of
the first and second core pack 445, 450 and is communicably coupled to a plurality
of sensors (not shown) to measure the multiple operational parameters of the
plurality of cells 415, 447 of the battery pack 105. The BMS 705 further transmits
the data pertaining to the multiple operational parameters of the battery pack 105 to
the server 135 via the network 140. In one embodiment, subsequent to transmission
of the data related to the multiple parameters from the BMS 705 to the server 135,
copy of the relevant data is automatically from the BMS 705. By doing so, ensures
that the BMS 705 is not accumulated with previously stored data which is already
transmitted to the server 135. Advantageously, the BMS 705 is not burdened with
large volume of data beyond the capacity of the BMS 705, thereby ensuring that
effective monitoring service is provided and improving the operational efficiency of
the BMS 705. In one embodiment, the BMS 705 is communicably coupled to the
telematics unit 215 of the battery pack 105.
[0066] The BMS 705 is further mounted and coupled on to a mounting plate 710,
as illustrated in FIG 7B. The mounting plate 710 is preferably made of one of
thermal conductive, thermally isolating, and electrically insulating materials. The
mounting plate 710 includes multiple fasteners on order to couple the BMS 705
18
thereon. In the illustrated embodiment, the mounting plate 710 includes clinch
standoffs 715 that are push fitted to the BMS 705 for the purpose of coupling. In
other embodiments, the BMS 705 is coupled to the mounting plate 710 via fasteners,
such as screws, nuts, and rivet, welding, and adhesives.
[0067] The battery pack 105 further includes a rear plate 805, as illustrated in FIG.
8. The rear plate 805 is adapted to be coupled to the rear end 209 (as shown in FIG.
2A) of the housing 205 via one of, but not limited to, fasteners, adhesives, clinching
and welding. The rear plate 805 is preferably made of a material having high
structural strength capable of managing weight load of the battery pack 105. In one
embodiment, the rear plate 805 and the housing 205 of the battery pack 105 is a
single component.
[0068] FIG. 9 is an exploded view of the battery pack 105, according to one or
more embodiments of the present invention. The battery pack 105 includes the
housing 205 having the at least one open end 207 and the rear end 209 opposite and
distal to the at least one open end 207.
[0069] The battery pack 105 further includes the casing 305 disposed within the
housing 205 via the open end 207 of the housing 205. The casing 305 is disposed
along a longitudinal axis 905 of the housing 205 and is one of in contact and adjacent
to the housing 205 to define the hollow space within the casing 305. Thereafter, the
plurality of intermediate plates 315 is disposed along the longitudinal axis 905 and
within the housing 205. The plurality of intermediate plates 315 is positioned in
close proximity to the casing 305 of the housing 205. In one embodiment, the casing
305 and the plurality of intermediate plates 315 are coupled to the housing 205 via
fasteners.
[0070] Subsequently, the plurality of cell core packs 505, including the first and
the second core pack 445, 450, is arranged within the casing 305. Further, the
plurality of cell core packs 505 is arranged such that the plurality of intermediate
plates 315 encompasses the plurality of cell core packs 505. In addition, the
insulation sheet 605 is disposed between the plurality of cell core packs 505. In one
19
embodiment, each of the plurality of cell core packs 505 further includes a primary
bus bar and a secondary bus bar. Construction of the primary bus bar and the
secondary bus bar is similar to the first bus bar 430 and the second bus bar 510, and
as such for the sake of brevity will not be repeated. The primary bus bar is adapted
to be coupled to each of the first and the second core pack 445, 450 and is adapted to
operate as a positive terminal of each of the first and the second core pack 445, 450.
Similarly, the secondary bus bar is adapted to be coupled to each of the first and the
second core pack 445, 450 and is adapted to operate as a negative terminal of each of
the first and the second core pack 445, 450.
[0071] The battery pack 105 further includes the BMS 705. The BMS 705 is
disposed within the casing 305 of the housing 205. More specifically, the BMS 705
is disposed adjacent to the plurality of cell core packs 505 via the open end 207 of
the housing 205. In one embodiment, prior to disposing the BMS 705 within the
casing 305, a first insulation sheet is coupled to the plurality of cell core packs 505.
The first insulation sheet electrically insulates the BMS 705 from the plurality of cell
core packs 505. Thereafter, the mounting plate 710 is coupled to the first insulation
sheet via fasteners and the BMS 705 is mounted on to the mounting plate 710. A
second insulation sheet is subsequently coupled to the BMS 705. In short, the BMS
705 is sandwiched by the first and the second insulation sheets.
[0072] The battery pack 105 further includes the top cover 210. The top cover 210
is detachably coupled to the periphery 915 of the at least one open end 207 of the
housing and along the longitudinal axis 905 of the housing 205. Similarly, the rear
plate 805 is coupled to the periphery (not shown) of the rear end 209 of the housing
205. The top cover 210 further includes the telematics unit 215 and the handle bar
220 coupled to the outer surface 225 thereof. The top cover 210 further includes the
opening 235 defined thereon. In one embodiment, connectors adapted to couple
each of the first and the second core pack 445, 450 of the battery pack 105 with the
vehicle 110 passes via the opening 235. In other embodiment, the battery pack 105
is provided with connectors coupled onto the housing 205.
20
[0073] Various embodiments disclosed herein are to be taken in the illustrative and
explanatory sense and should in no way be construed as limiting of the present
disclosure.
Industrial Applicability
[0074] The present disclosure provides the battery pack 105 and a method for the
providing the battery pack 105. The battery pack 105 includes the casing 305, the
plurality of intermediate plates 315, the plurality of cell core packs 505, the BMS
705, and the top cover 210 arranged in a compact manner within the housing 205.
Accordingly, the battery pack 105 efficiently utilizes space within the housing to
provide a portable, compact, and light weight battery pack 105 without
compromising on the efficiency and safety of the battery pack 105. Further, as the
plurality of cell core packs 505 are stacked parallel to each other, the battery pack
105 is able to provide more power while being lightweight.
[0075] FIG. 10 is a flow chart of a method 1000 for providing the battery pack
105, according to one or more embodiments of the present invention. For the
purpose of description and explanation, the method 1000 is described with respect to
the embodiment as illustrated in FIG. 9.
[0076] At step 1005, the method 1000 includes the step of disposing the casing 305
within the housing 205. The casing 305 is disposed along the longitudinal axis 905
via the at least one open end 207 of the housing 205. The casing 305 includes
multiple sheets 310 coupled to each other to define the hollow space within the
casing 305. The multiple sheets 310 of the casing 305 are one of in close proximity
and in contact with the housing 205. Thereafter, the plurality of intermediate plates
315 is disposed within the casing 305. The plurality of intermediate plates 315 is
positioned in close proximity to the multiple sheets 310 of the casing 305.
[0077] The housing 205 of the battery pack 105 further includes the rear plate 805.
The rear plate 805 is adapted to be coupled to the periphery (not shown) of the rear
end 209 of the housing 205 via one of, but not limited to, fasteners, adhesives,
21
clinching and welding. The rear plate 805 is preferably made of a material having
high structural strength capable of managing weight load of the battery pack 105.
[0078] At step 1010, the method 1000 includes the step of interconnecting each of
the plurality of cells 415 via at least the first bus bar 430. The plurality of cells 415
is received and positioned within the plurality of annular cavities 410 of the cell
holder tray 405. The first bus bar 430 is placed over the plurality of cells 415 so that
each of the multiple apertures 435 of the first bus bar 430 is aligned in line with each
of the plurality of cells 415. Each of the plurality of cells 415 include a cathode and
an anode. Accordingly, the cathode of each of the plurality of cells are
interconnected via the first bus bar 430. Similarly, the anode of each of the plurality
of cells 415 are interconnected via the first bus bar 430. Further, the first bus bar 430
is adapted to one of couple the plurality of cells 415, and isolate at least one of the
plurality of cells 415 during an event of thermal runaway and short circuit.
[0079] As per the illustrated embodiment shown in FIG. 5, the plurality of cells
415 is positioned within the first cell holder tray 405a and the second cell holder tray
405b, as explained above, to form a first cell core pack 445. Likewise, a plurality of
cells 447 is positioned within the third cell holder tray 405c and the fourth cell holder
tray 405d to form a second cell core pack 450.
[0080] At step 1015, the method 1000 includes the step of arranging the plurality
of cell core packs 505 within the casing 305 and adjacent to the rear end 209 of the
housing 205. The plurality of cell core packs 505 is disposed via the open end 207
of the housing 205. On arranging the plurality of cell core packs 505 within the
casing 305, the plurality of intermediate plates 315 encompasses the plurality of cell
core packs 505. The plurality of intermediate plates 315 aids in providing thermal
protection to the plurality of cell core packs 505 and further aids in maintaining
ambient temperature within the housing 205. As per the illustrated embodiments, the
plurality of cell core packs 505 include the first core pack 445 and the second core
pack 450.
22
[0081] At step 1020, the method 1000 includes the step of interconnecting each of
the plurality of cell core packs 505 via at least the second bus bar 510. The second
bus bar 510 is provided with multiple apertures 515 defined on a surface thereof. As
mentioned earlier, each of the first, the second, the third, and the fourth cell holder
tray 405a-d includes the plurality of cavities 428 defined thereon. Accordingly, the
second bus bar 510 is positioned on the second and the third cell holder tray 405b,
405c. More specifically, the second bus bar 510 is positioned such that each of the
plurality of cavities 428 and the multiple apertures 515 are aligned in line with each
other. Subsequently, the second bus bar 510 is coupled on to the second and the
third cell holder 405c, 405d via fasteners. In one embodiment, the second bus bar
510 is coupled on to the second and the third cell holder 405b, 405c via one of, but
not limited to, welding and adhesives. The second bus bar 510 is adapted to one of
couple the first cell core pack 445 the second cell core pack 450, and isolate at least
one of the first and the second cell core pack 445, 450 during an event of thermal
runaway and short circuit.
[0082] At step 1030, the method 1000 includes the step of arranging the at least
one insulation sheet 605 between the plurality of cell core packs 505 to electrically
isolate the plurality of cell core packs 505 from each other.
[0083] At the step 1035, the method 1000 includes the step of coupling the BMS
705 to each of the plurality of cell core packs 505. The BMS 705 is disposed within
the casing 305 and, more specifically, adjacent to the plurality of cell core packs 505
via the at least one open end 207 of the housing 205. The BMS 705 receives data
pertaining to multiple operational parameters of each of the plurality of cells 415
within each of the first and second core pack 445, 450. The multiple operational
parameters are one of, but not limited to, current, voltage, and temperature of each of
the plurality of cells. The BMS 705 is further mounted and coupled on to the
mounting plate 710. The mounting plate 710 is preferably positioned adjacent to the
plurality of cell core packs 505. The mounting plate 710 includes multiple fasteners
to couple the BMS 705 thereon. The mounting plate 710 includes clinch standoffs
715 that are push fitted onto the BMS 705 for the purpose of coupling. In other
23
embodiments, the BMS 705 is coupled to the mounting plate 710 via fasteners, such
as screws, nuts, and rivet, welding, and adhesives.
[0084] At step 1035, the method 1000 includes the step of detachably coupling the
top cover 210 to the periphery of the at least one open end 207 of the housing 205.
The top cover 210 includes the telematics unit 215 mounted and coupled onto the top
cover 210 of the battery pack 105 via fasteners. The telematics unit 215 is
configured to provide a display interface unit to a user of the battery pack 105. The
telematics unit 215 displays information pertaining to, but not limited to, a State of
Charge (SOC) of the battery pack 105, time remaining for battery pack to drain,
battery pack 105 SOC low alert, and emergency alerts. The top cover 210 further
includes a handle bar 220 coupled to thereon. More specifically, the handle bar 220
is coupled to an outer surface 225 of the top cover 210 via one of fasteners, press
joining, and clinching. The handle bar 220 is adapted to aid in lifting the battery
pack as per requirement of the user. The top cover 210 of the housing further
includes a venting apparatus 230 machined onto the battery pack 110. The venting
apparatus 230 includes a venting membrane. The venting membrane is adapted to
rupture to allow gases to escape from within the battery pack 110 to atmosphere
during instances of pressure build up within the battery pack 110. During instances
of thermal runaway, inflammable gases are generated within the battery pack 110,
and there is a pressure build up therein. Failure of timely release of the gases
generated therein leads to explosion of the battery pack 110. As the pressure builds
up within the battery pack 110, ruptures are formed on the venting membrane of the
venting apparatus 230. As such, the gases generated within the battery pack 110
escapes quickly to the atmosphere.
[0085] The top cover 210 further includes the opening 235 machined thereon in
which one or more battery connectors are positioned. The one or more battery
connectors aid in transferring power from the battery pack 105 to propel and power
the vehicle 110.
24
[0086] While aspects of the present invention have been particularly shown and
described with reference to the embodiments above, it will be understood by those
skilled in the art that various additional embodiments may be contemplated by the
modification of the disclosed machines, systems and methods without departing from
the scope of what is disclosed. Such embodiments should be understood to fall
within the scope of the present invention as determined based upon the claims and
any equivalents thereof.

We Claim:

1. An energy storage apparatus (105), the apparatus (105) comprising:
a housing (205) having at least one open end (207) and a rear end
(209) opposite to the at least one open end (207);
a casing (305), disposed within the housing (205) through the at
least one open end (207) along a longitudinal axis of the housing (205),
the casing (305) having multiple sheets (310) coupled to each other and
in contact with the housing (205) to define a hollow space within the
casing (305);
a plurality of cell core packs (505) arranged within the casing (305)
and adjacent to the rear end (209) of the housing (205), each of the
plurality of cell core packs (505) positioned parallel to each other and at
an offset from the longitudinal axis of the housing (205);
a battery management system (BMS) (705) coupled to each of the
plurality of cell core packs (505), the BMS (705) disposed within the
casing (305) and adjacent to the plurality of cell core packs (505) via the
at least one open end (207) of the housing (205); and
a top cover (210) detachably coupled to a periphery (915) of the at
least one open end (207) of the housing (205).
2. The apparatus (105) as claimed in claim 1, wherein a handle bar (220)
coupled to an outer surface (225) of the top cover (210) via one of fasteners,
press joining, and clinching, the handle bar adapted to aid in lifting the
apparatus (105) as per requirement of user.
3. The apparatus (105) as claimed in claim 1, wherein each of the plurality of
cell core packs (505) having a plurality of cells (447) coupled in one of a
series connection, a parallel connection, and a combination thereof.
26
4. The apparatus (105) as claimed in claim 3, wherein each of the plurality of
cells (415, 447) are interconnected via at least a first bus bar (430), each of
the at least first bus bar (430) adapted to one of couple the plurality of cells
(447) and isolate at least one of the plurality of cells (447) during one of an
event of thermal runaway and short circuit.
5. The apparatus (105) as claimed in claim 3, wherein each of the plurality of
cells (447) is adapted to be positioned within each of a plurality of cell
isolation slots (530).
6. The apparatus (105) as claimed in claim 5, wherein the plurality of cell
isolation slots (530) is formed based on an intersection of a first set of barrier
sheets (520) extending along a horizontal direction within the cell core pack
(505), and a second set of barrier sheets (525) extending along a vertical
direction of the cell core pack (505).
7. The apparatus (105) as claimed in claim 1, wherein each of the plurality of
cell core packs (505) are interconnected via at least a second bus bar (510),
each of the at least second bus bar (510) adapted to one of couple the
plurality of cell core packs (505) and isolate at least one of the plurality of
cell core packs (505) during one of an event of thermal runaway and short
circuit.
8. The apparatus (105) as claimed in claim 1, wherein at least one insulation
sheet (605) is positioned between the plurality of cell core packs (505) to one
of electrically and thermally isolate the plurality of cell core packs (505).
9. The apparatus (105) as claimed in claim 1, wherein the BMS (705) is
mounted and coupled to a mounting plate (710) positioned adjacent to the
plurality of cell core packs (505).
27
10. The apparatus (105) as claimed in claim 1, wherein a plurality of intermediate
plates (315) encompasses the plurality of cell core packs (505) to one of
thermally and electrically insulate the plurality of cell core packs (505).
11. A method (1000) for providing an energy storage apparatus (105), the
method (1000) comprising the steps of:
disposing a casing (305) within a housing (205) along a
longitudinal axis through at least one open end (207) of the housing
(205), the casing (305) having multiple sheets (310) coupled to each
other and in contact with the housing (205) to define a hollow space
therein;
interconnecting each of a plurality of cells (415, 447) via at least a
first bus bar (430) to one of couple the plurality of cells (415,447) and
isolate at least one of the plurality of cells (415,447) during one of an
event of thermal runaway and short circuit, wherein each of the plurality
of cells (415, 447) interconnected to each other in one of a series
connection, a parallel connection, and a combination thereof;
arranging a plurality of cell core packs (505) within the casing
(305) and adjacent to a rear end (209) of the housing (205), wherein the
plurality of cells (415, 447) are positioned within the plurality of cell
core packs (505);
interconnecting each of the plurality of cell core packs (505) via at
least a second bus bar (510) to one of couple the plurality of cell core
packs (505) and isolate at least one of the plurality of cell core packs
(505) during one of an event of thermal runaway and short circuit;
arranging at least one insulation sheet (605) between the plurality
of cell core packs (505) to isolate the plurality of cell core packs (505);
coupling a Battery Management System (BMS) (705) to each of
the plurality of cell core packs (505), the BMS (705) disposed within the
28
casing (305) and adjacent to the plurality of cell core packs (505) via the
at least one open end (207) of the housing (205); and
detachably coupling a top cover (210) to a periphery (915) of the at
least one open end (207) of the housing (205).