[0001] The present invention relates to energy storage systems and, more
particularly, to a battery unit and manufacturing method thereof.
5
BACKGROUND
[0002] Rechargeable batteries are of growing significance in various fields and
application where electrical power is required. Over the years, the rechargeable
batteries have undergone various developments and evolutions, to make them more
10 effective, and efficient. Right from electric vehicles, to household applications,
rechargeable batteries are found all around us. When used in an automotive
application, the rechargeable batteries are typically carried by the frame of the vehicle.
Further, the rechargeable batteries are electrically coupled to a rotating electrical
machine, e.g., a motor that provides requisite traction power to the ground engaging
15 members, e.g., the wheels.
[0003] The rechargeable batteries are formed using a plurality of
electrochemical cells, hereinafter interchangeably referred to as cells, arranged in a
predetermined manner with respect to one another. Each cell has the capacity of
getting charged, and provide power output, as and when desired. While single
20 individual cell may be unable to provide substantial charge, the plurality of cells
arranged together electrically combine to provide an output usable in various
applications, such as in powering the rotating electrical machine of an electric vehicle.
[0004] The cells are contained within a casing composed of a sturdy, often a
sturdy non-conducting material. The casing includes provisions to facilitate electrical
25 connections of the electrical output of the battery. It is known that the electrical output
of the battery depends largely on the number of individual cells contained therein.
~ 3 ~
Therefore, it is desired that maximum number of cell are stacked within the battery
casing.
[0005] Moreover, the individual cells, and thus the battery, tends to produce heat
during operation thereof. This heat may adversely affect the performance of the battery
5 while also being potentially hazardous. Therefore, if it required that the heat generated
during the operation of the battery is properly dissipated.
[0006] Each cell of the plurality of cells includes a positive terminal and a
negative terminal. The positive terminals and the negative terminals are connected to
the bus bars, through connecting points, in series or parallel, in such a manner that the
10 electrical output of the battery is obtained through the bus bars. However, in case of a
malfunction in one or more of the plurality of cells, the bus bar remains prone to
damages, which threatens electrical output of the battery.
[0007] There have been various attempts to overcome the disadvantages
associated with the rechargeable batteries. However, all the existing systems remain
15 considerably expensive, difficult to repair and manufacture.
SUMMARY OF INVENTION
[0008] In one aspect of the present invention, a method of manufacturing an
energy storage unit is provided. The method of manufacturing the energy storage unit
20 comprising; providing a first bracket having a plurality of troughs forming a
continuous corrugated structure, the first bracket is adapted to hold a plurality of cells;
applying a glue to the plurality of cells of the first bracket, wherein the glue having
adhesive properties; providing at least one intermediate bracket comprising a first
portion, a second portion, a plurality of intermediate arms; disposing plurality of
25 individual cells on the at least one intermediate bracket; disposing the at least one
intermediate bracket having the plurality of individual cells on to the plurality of cells
of the first bracket; applying a glue to the plurality of cells of the at least one
~ 4 ~
intermediate bracket; sequentially stacking plurality of similar intermediate brackets
having the plurality of individual cells one above another; providing a second bracket
having a plurality of inverted troughs forming a continuous corrugated structure; and
disposing the second bracket on the last intermediate bracket of the stacking of the
5 plurality of similar intermediate brackets.
[0009] The method of manufacturing the energy storage unit comprises
obtaining a first bracket having a series of parallel ridges and groves, forming a
corrugated structure; applying a glue layer to at least a portion of the first bracket ,
wherein the glue layer is composed of a material having adhesive and fastening
10 properties; obtaining an intermediate bracket having a first portion , a second portion
, a plurality of intermediate arms , a first side wall , and a second side wall; applying
a glue layer on at least a portion of the intermediate bracket; and, providing a row of
individual cells on the intermediate bracket.
[00010] This manufacturing process results in increased speed of production of
15 the layered battery structure. Further, this manufacturing process allows the
manufacturing of different components of the layered battery structure to be separate,
and independent, allowing the manufacturing and assembly of the layered battery
structure to be flexible.
[00011] In another embodiment, the method of manufacturing the energy storage
20 unit further comprising: applying Phase Change Material over plurality of individual
cells of each of the at least one intermediate bracket after each of the at least one
intermediate bracket is stacked. Pouring Phase Change Material over the plurality of
individual cells of the last intermediate bracket.
[00012] In another embodiment, the glue is applied on boundary portions of the
25 plurality of individual cells. The Phase Change Material is applied on portion of the
plurality of individual cells confined by the glue. The Phase Change Material is poured
down through the at least one intermediate bracket to the plurality of individual cells
of each of the at least one intermediate bracket.
~ 5 ~
[00013] In another embodiment, glue is applied to the at least a portion of the at
least one intermediate bracket before disposing the plurality of individual cells. The
glue is applied to the at least a portion of the at least one intermediate bracket and to
the plurality of cells at one workstation of the assembly line.
5 [00014] In another embodiment, plurality of cells are disposed on first bracket,
the at least one intermediate bracket at one workstation of the assembly line.
[00015] In another aspect of the present invention, an energy storage unit is
provided. The energy storage unit comprising: a first bracket having a plurality of
troughs forming a continuous corrugated structure, the first bracket is adapted to hold
10 a plurality of cells; a glue applied to the plurality of cells, wherein the glue having
adhesive properties; at least one intermediate bracket having a first portion, a second
portion, a plurality of intermediate arms; a plurality of individual cells disposed on the
at least one intermediate bracket; the at least one intermediate bracket having the
plurality of individual cells, disposed on to the plurality of cells of the first bracket; a
15 layer applied to the plurality of cells of the at least one intermediate bracket; plurality
of similar intermediate brackets sequentially stacking one above another; a second
bracket having a plurality of inverted troughs forming a continuous corrugated
structure disposed on the last intermediate bracket of the stacking plurality of similar
intermediate brackets.
20 [00016] In another aspect of the present invention, an energy storage unit is
provided. The energy storage unit comprising: an upper bracket member adapted to
accommodate plurality of individual cell comprising: a first portion, a second portion,
and a plurality of intermediate arms, the plurality of intermediate arms are disposed
spaced apart and connect the first portion with the second portion, wherein each of the
25 first portion and the second portion has plurality of trough portions, the plurality of
trough portions of the first portion are joined with each other, and the plurality of
trough portions of the second portion are joined with each other, such that the trough
portions of the first portion and the second portion are aligned with each other, wherein
the plurality of trough portions of each of the first portion and the second portion have
~ 6 ~
a downwardly extending support tab; a lower bracket member adapted to
accommodate plurality of individual cell comprising: a first portion, a second portion,
and a plurality of intermediate arms, the plurality of intermediate arms are disposed
spaced apart and connect the first portion with the second portion, wherein each of the
5 first portion and the second portion has plurality of trough portions, the plurality of
trough portions of the first portion are joined with each other, and the plurality of
trough portions of the second portion are joined with each other, such that the trough
portions of the first portion and the second portion are aligned with each other, wherein
the plurality of trough portions of each of the first portion and the second portion have
10 a downwardly extending support tab. The upper bracket member is positioned over
the lower bracket member.
[00017] In another aspect of the present invention, a busbar of an energy storage
system, wherein the energy storage system comprises a layered battery structure
composed of one or more individual cells, is provided. The busbar comprising: a first
15 busbar strip comprises an elongated strip, and a plurality of tabs, wherein the plurality
of tabs coupled to a positive electrode of one or more individual cells placed in an
initial row of the layered battery structure, wherein the first busbar strip configures the
one or more individual cells placed in the initial rows in parallel configuration, and
wherein the elongated strip acts as an positive terminal for the energy storage system;
20 at least one second busbar strips comprises an elongated strip, a plurality of profile
arms and a plurality of tabs, wherein the plurality of profile arms electrically coupled
to a negative electrode of the one or more individual cells placed in the rows and the
plurality of tabs electrically coupled to the positive electrode of the one or more
individual cells placed in the adjacent row of the layered battery structure, and wherein
25 the at least one second busbar strips configures the one or more coupled individual
cells in series configuration; and a third busbar strip comprises an elongated strip, and
a plurality profile arms, wherein the plurality profile arms coupled to the negative
electrode of the one or more individual cells placed in a last row of the layered battery
structure, wherein the third busbar strip configures the one or more individual cells
~ 7 ~
placed in the last row in parallel configuration, and wherein the elongated strip acts as
an negative terminal for the energy storage system.
[00018] In another embodiment, the plurality of tabs comprise at least one shorter
tab, and at least one longer tab. The plurality profile arms comprise at least one longer
5 profile arm and at least one shorter profile arm. The plurality of tabs protrudes
traversably from the elongated strip.
[00019] In another embodiment, the plurality of profile arms protrude from one
side of the elongated strip while plurality of tabs protrude from another side of the
elongated strip.
10 [00020] In another embodiment, the plurality of tabs lie in different plane than a
plane of the elongated strip. The plurality profile arms lie in different plane than a
plane of the elongated strip. The plurality of profile arms and the plurality of tabs lie
in a plane different than a plane of the elongated strip.
[00021] In another embodiment, the plurality of tabs and the plurality of tabs are
15 extended via a bend portion, wherein the bend portion formed with a lesser width or
thickness with respect to the width of other portion of the plurality of tabs, and wherein
the bend portion to act as a fuse element.
20
BRIEF DESCRIPTION OF DRAWINGS
[00022] The invention itself, together with further features and attended
advantages, will become apparent from consideration of the following detailed
description, taken in conjunction with the accompanying drawings. One or more
25 embodiments of the present invention are now described, by way of example only
wherein like reference numerals represent like elements and in which:
~ 8 ~
[00023] Figure 1 illustrates a perspective view of an energy storage system,
according to an embodiment of the present invention;
[00024] Figure 1A illustrates a perspective view of a base bracket of the energy
storage system, according to an embodiment of the present invention;
5 [00025] Figure 1B illustrates a perspective view of the base bracket of the energy
storage system, according to another embodiment of the present invention
[00026] Figure 2 illustrates a perspective view of an intermediate bracket of the
energy storage system of Figure 1, according to an embodiment of the present
invention;
10 [00027] Figure 2A illustrates a perspective view of the intermediate bracket of
the energy storage system of Figure 1A, according to an embodiment of the present
invention;
[00028] Figure 2B illustrates a perspective view of the intermediate bracket of
the energy storage system of Figure 1B, according to another embodiment of the
15 present invention;
[00029] Figure 3A illustrates a perspective view of two intermediate brackets of
the energy storage system of Figure 1A, according to an embodiment of the present
invention;
[00030] Figure 3B illustrates a perspective view of two intermediate brackets of
20 the energy storage system of Figure 1B, according to another embodiment of the
present invention;
[00031] Figure 4A illustrates a perspective view of three intermediate brackets of
the energy storage system of Figure 1A, according to an embodiment of the present
invention;
~ 9 ~
[00032] Figure 4B illustrates a perspective view of two intermediate brackets of
the energy storage system of Figure 1B, according to another embodiment of the
present invention;
[00033] Figure 5A illustrates a perspective view of multiple intermediate brackets
5 of the energy storage system of Figure 1A, according to an embodiment of the present
invention;
[00034] Figure 5B illustrates a perspective view of multiple intermediate brackets
of the energy storage system of Figure 1B, according to another embodiment of the
present invention
10 [00035] Figure 6 illustrates a perspective view of the energy storage system,
according to an embodiment of the present invention;
[00036] Figure 7 illustrates a perspective view of the energy storage system,
according to an embodiment of the present invention;
[00037] Figure 8 illustrates top view of a bus bar of the energy storage system,
15 according to an embodiment of the present invention;
[00038] Figure 9 illustrates top perspective view of a bus bar of the energy storage
system, according to an embodiment of the present invention;
[00039] Figure 10 illustrates top perspective view of the bus bar of the energy
storage system, according to an embodiment of the present invention; and
20 [00040] Figure 11 illustrates side view of a portion of the bus bar of the energy
storage system, according to an embodiment of the present invention.
[00041] The drawings referred to in this description are not to be understood as
being drawn to scale except if specifically noted, and such drawings are only
exemplary in nature.
25
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DETAILED DESCRIPTION
[00042] While the invention is susceptible to various modifications and
alternative forms, an embodiment thereof has been shown by way of example in the
drawings and will be described here below. It should be understood, however that it
5 is not intended to limit the invention to the particular forms disclosed, but on the
contrary, the invention is to cover all modifications, equivalents, and alternative
falling within the spirit and the scope of the invention.
[00043] The term “comprises”, comprising, or any other variations thereof, are
intended to cover a non-exclusive inclusion, such that a setup, structure or method that
10 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 structure or method. In other words, one or more elements in a system
or apparatus proceeded by “comprises… a” does not, without more constraints,
preclude the existence of other elements or additional elements in the system or
15 apparatus.
[00044] For better understanding of this invention, reference would now be made
to the embodiment illustrated in the accompanying Figures and description here
below, further, in the following Figures, the same reference numerals are used to
identify the same components in various views.
20 [00045] The terms “front / forward”, “rear / rearward / back / backward”, “up /
upper / top”, “down / lower / lower ward / downward, bottom”, “left / leftward”, “right
/ rightward” used therein represents the directions as seen from a vehicle driver sitting
astride and these directions are referred by arrows Fr, Rr, U, Lr, L, R in the drawing
Figures.
25 [00046] Referring to Figures 1, an energy storage system (100), according to an
embodiment of the present invention is illustrated. The energy storage system (100)
referred to herein, embodies a battery unit of a two wheeled vehicle. Alternatively, the
energy storage system (100) may embody any other energy storage system that may
~ 11 ~
be used in vehicles such as scooters, three-wheeled vehicles, All-Terrain Vehicles
(ATV) etc. without limiting the scope of the invention.
[00047] The energy storage system (100) comprises a plurality of energy storage
units (200). In the present embodiment, the plurality of energy storage units (200)
5 include a first energy storage unit and a second energy storage unit. In other
embodiments, the plurality of energy storage units (200) may include fewer or more
number of energy storage units, such as the first energy storage unit or the second
energy storage unit. The energy storage unit (200) may be embodied as plurality of
battery cells. The first energy storage unit may be the first battery pack, and the second
10 energy storage unit may be the second battery pack.
[00048] As illustrated in Figure 1A, the battery pack includes a bottom bracket
(300A). The bottom bracket (300A) has a plurality of troughs, forming a continuous
corrugated structure. In an example, the diameter of the groves corresponds to an outer
diameter of individual cells.
15 [00049] The bottom bracket (300A) is also interchangeably referred to as a first
bracket (300a), bottom plate or base plate. In other examples, the bottom bracket
(300A) may also act as a top bracket. As illustrated in Figure 1A, the bottom bracket
(300A) has peripheral edges extending along a rectangular profile. Further, the bottom
bracket (300A) has an inner surface (not illustrated) and an outer surface (298). A glue
20 layer (302A) is applied to the bottom structure (300A). In the illustrated example, the
glue layer (302A) is provided along the peripheral edge of the bottom bracket (300A)
on the outer surface (298).
[00050] In accordance to another embodiment, as illustrated in Figure 1B, the
battery pack includes a bottom bracket (300B), also referred to as second bracket
25 (300B). In shape and configuration, the bottom bracket (300B) may be similar to the
bottom bracket (300A). Therefore, the bottom bracket (300B) also has a plurality of
troughs, forming a corrugated structure. The diameter of the groves corresponds to an
outer diameter of individual cells.
~ 12 ~
[00051] As illustrated in Figure 1B, the bottom bracket (300B) includes
peripheral edges extending along a rectangular profile. A glue layer (302B) is applied
to the bottom bracket (300B). In the illustrated example, the glue layer (302B) is
applied along the peripheral edge of the bottom bracket (300B). In addition, the bottom
5 bracket (300B) further includes an additional layer (304). In an embodiment, the
additional layer (304) is composed of a Phase Change Material (PCM material).
[00052] Each of the glue layer (302A) and the glue layer (302B) is composed a
suitable material with adhesive properties.
[00053] Referring now to Figure 2, the battery pack further includes at least one
10 intermediate bracket (306). The intermediate bracket (306) includes a first portion
(308), a second portion (310), and plurality of intermediate arms (312). The plurality
of intermediate arms (312) are disposed spaced apart and connecting the first portion
(308) with the second portion (310). The first portion (308) has plurality of
semicircular portions such as semicircular portion (310A) extending upwards. The
15 plurality of semicircular portion (310A) of the first portion (308) are joined with each
other. Similarly the second portion (310) has plurality of semicircular portions, such
as semicircular portion (310A) extending upwards. The plurality of semicircular
portion (310A) of the second portion (310) are joined with each other. The
semicircular portion (310A) of the first portion (308) and the second portion (310) are
20 aligned with each other. In an embodiment, the intermediate arms (312) at one end is
connected to a joining point of two adjacent semi-circular portions on the front arm
(308) and at the other end is connected to a joining point of two adjacent semicircular
portions on the second arm (310).
[00054] The intermediate bracket (306) further includes a first side wall (316),
25 and a second side wall (318). In an embodiment, the first side wall (316), and the
second side wall (318) are positioned at opposite ends of the front portion (308), the
rear portion (310). Therefore, the first side wall (316), and the second side wall (318)
are separated from one another by the length of the front portion (308), or the rear
~ 13 ~
portion (310). Further, the length of the first side wall (316), and the second side wall
(318) corresponds to the length of the intermediate arms (312).
[00055] The middle bracket layer (306) is adapted to receive a first row or series
of individual cells. As such, the number of semicircular portions on the front portion
5 (308) and the rear portion (310) dictate the number of cells that can be received in the
intermediate bracket (306).
[00056] In an embodiment, the energy storage unit (200) includes an upper
bracket member (306), and a lower bracket member (306’). Each of the upper bracket
member (306), and a lower bracket member (306’) having the first portion (308), the
10 second portion (310), and the plurality of intermediate arms (312). The plurality of
intermediate arms (312) are disposed spaced apart and connect the first portion (308)
with the second portion (310). Each of the first portion (308) and the second portion
(310) has plurality of trough portions (310A).The plurality of trough portions (310A)
of the first portion (308) are joined with each other, and the plurality of trough portions
15 (310A) of the second portion (310) are joined with each other, such that the trough
portions (310A) of the first portion (308) and the second portion (310) are aligned
with each other, wherein the plurality of trough portions (310A) of each of the first
portion (308) and the second portion (310) have a downwardly extending support tab
(314). The upper bracket member (306) is positioned over the lower bracket member
20 (306’).
[00057] As shown in Figure 2A, an intermediate bracket layer (306A) in
accordance to an embodiment of the present disclosure is illustrated. The intermediate
bracket later (306A) includes the intermediate bracket layer (306), and a first row of
individual cells (400), such as a cell (400A). In an example, a layer of glue (not
25 illustrated) is provided on the intermediate bracket layer (306A) before placing the
cells thereon. Subsequently, a layer of glue (320) is applied on first row of individual
cells (400).
~ 14 ~
[00058] In accordance with another embodiment, an intermediate bracket layer
(306B) is illustrated in Figure 2B. The intermediate bracket layer (306B) includes the
intermediate bracket layer (306), and the first row of individual cells (400), such as
the cell (400A). In an example, a layer of glue (not illustrated) is provided on the
5 intermediate bracket layer (306A) before placing the cells thereon. Subsequently, a
layer of glue (320) is applied on the boundary portions (402) of first row of individual
cells (400). Further, an additional layer (304) is provided on the first row of individual
cells (400). In an embodiment, the additional layer (304) is composed of a Phase
Change Material (PCM material).
10 [00059] Figure 3A illustrates a view of two intermediate bracket layers (306)
stacked one above other. In particular, one intermediate bracket later (306A) is
positioned on top of another intermediate bracket layer (306A) such that the
downwardly extending support tab (314) of the intermediate bracket layer (306A) abut
with the semicircular portion (310A) on the intermediate bracket layer (306A).
15 Subsequently, another intermediate bracket layer (306A) is positioned on above the
intermediate bracket layer (306A), as shown in Figure 4A. In an embodiment, the
plurality of similar intermediate brackets (306) having the plurality of individual cells
(400) are sequentially stacked one above another. Subsequently, the second bracket
(300B) is disposed on the last intermediate bracket of the stacking of the plurality of
20 similar intermediate brackets (306).
[00060] A predetermined number of layers, similar to the intermediate bracket
layer (306A) are positioned, one after the other, above the intermediate bracket layer
(306A), as shown in Figure 5A. Once all of the predetermined number of layers are
joined together a layered battery structure (500) is formed on which the layered
25 material (304) is provided. Further, as the plurality of intermediate bracket layers
(306A) are joined, one over the other, the plurality of first side walls (316) are joined
to form the side wall of the layered battery structure (500), and the plurality of second
side walls (318) are joined to form the side wall of the layered battery structure (500).
~ 15 ~
[00061] In accordance with another embodiment Figure 3B, two intermediate
bracket layers (306) stacked one above other. In particular, one intermediate bracket
later (306B) is positioned on top of another intermediate bracket later (306B) such that
the downwardly extending support tab (314) of the intermediate bracket layer (306B)
5 abut with the semicircular portion (310B) on the intermediate bracket layer (306B).
Subsequently, another intermediate bracket layer (306B) is positioned on above the
intermediate bracket layer (306B), as shown in Figure 4B.
[00062] A predetermined number of layers, similar to the intermediate bracket
layer (306B) are positioned, one after the other, above the intermediate bracket layer
10 (306B), as shown in Figure 5B. Further, between each layer, the phase change material
is poured. Once all of the predetermined number of layers are joined together a layered
battery structure (500) is formed.
[00063] As illustrated in Figure 6 and Figure 7, the bottom bracket (300A) or
bottom bracket (300B) is positioned on top of the layered battery structure (500). In
15 an example, the bottom bracket (300A) or the bottom bracket (300B) may be applied
with glue, causing the bottom bracket (300A) or bottom bracket (300B) to stick to the
layered battery structure (500).
[00064] The glue is applied to the at least a portion of the at least one intermediate
bracket (306) and to the plurality of cells (400) at one workstation of the assembly
20 line. The plurality of cells are disposed on first bracket (300A), the at least one
intermediate bracket (306) at one workstation of the assembly line.
[00065] Referring now to Figure 8, a busbar (600) is illustrated. As such, the
busbar (600) provides electrical connection to the layered battery structure (500). The
busbar (600) is positioned on a top or a bottom side of the layered battery structure
25 (500) according to an availability of space. In an embodiment, the busbar (600)
comprises at least one strip that is longer than its width of an interface with a single
row of battery cells.
~ 16 ~
[00066] The individual cell (400A) may be in any geometrical shape, but in a
preferred embodiment, it is cylindrical in nature. In an embodiment, the individual cell
(400A) comprises a positive electrode and a negative electrode. Both the electrodes
are provided at a same end of the individual cell (400A). For example, as depicted in
5 Figure 10, when the individual cell (400A) is constructed in a cylindrical shape, the
positive electrode may be provided at an inner portion (804) at one end while the
negative electrode may be provided at an outer portion (802) at the same end which
encloses the inner circumfencial part (804) or vice versa is also a possibility. In
embodiment, circumference of the positive electrode part is lesser than the
10 circumference of the negative electrode portion. A person skilled in the art understands
that any type Lithium Ion Secondary cell may be formed in any geometrical shape
according to a specific requirement and both of the electrodes of the cell (400A),
positive or negative, may formed at the same end or side of the geometrical shape.
Moreover, the capacity, size, design, terminal configuration, and other features of the
15 individual cells (400A) may also differ from those shown according to other
exemplary embodiments.
[00067] The busbar (600) comprises a first busbar strip (600A), at least one
second busbar strips (600B) and a third busbar strip (600C). In an embodiment, the
busbar (600) refers to any metallic conductor that is connected to at least two cell
20 terminals of the different individual cells (400A) in order to deliver power from the
battery cells to the electrical motor or the electronic system. In addition to electrical
connection, the busbar (600) also communicates a state of health or a state of electric
charge stored in the individual cells (400A) to a battery management system (not
shown). In an embodiment, the busbar strips (600A, 600B, 600C) may be fabricated
25 from any conductive material, such as copper, according to known methods and
techniques, including but not limited to a die casting operation.
[00068] The first busbar strip (600A) comprises an elongated strip (602), a shorter
tab (604) and a longer tab (606). The shorter tab (604) and the longer tab (606)
protrudes traversable from the elongated strip (602). The shorter tab (604) and the
~ 17 ~
longer tab (606) are alternatively positioned along the length of the elongated strip
(602). Both the tabs (604 and 606) are coupled to the positive electrodes of the
individual cells (400A) placed in an initial row/s of the layered battery structure (500).
The person skilled in the art may appreciate that the coupling of the first busbar strip
5 (600A) to the individual cells (400A) or the initial row/s depends on an output voltage
requirement from the battery pack and also depends on the individual cells (400A)
capacity therein. The cells (400A) coupled by the first busbar strip (600A) are
configured in a series configuration. As these tabs (604 and 606) are connected to the
positive electrodes, the first busbar strip (600A) forms a positive terminal (650) of the
10 battery pack, also shown in Figure 9.
[00069] The at least one second busbar strip (600B) comprises an elongated strip
(614), a profile arm (618) and a tab (616). The profile arm (618) protrudes from one
side of the elongated strip (614) while the tab (616) protrudes from an opposite side
of the elongated strip (614). The elongated strip (614) comprises continuous crests and
15 trough portions. In an embodiment, the tab (616) is protruded or extended via a bend
portion (680, refer Figure 10). In an embodiment, the profile arm (618) and the tab
(616) is provided at trough and crest portions in an either directions of the elongated
strip (614). The profile arm (618) couples with the negative electrodes of the
individual cells (400A) and the tab (616) couples with the positive electrodes of the
20 individual cells (400A). The at least one second busbar strip (600B) is positioned over
an intermediate row/s of the individual cells (400A) and thus, configuring the cells
(400A) in a series configuration with the other rows of the individual cells (400A) and
in a parallel configuration within a same row on which the at least one second busbar
strip (600B) is positioned.
25 [00070] The third busbar strip (600C) comprises an elongated strip (608), a longer
profile arm (612) and a shorter profile arm (610). The longer profile arm (612) and the
shorter profile arm (610) protrude from traversable from the elongated strip (608). The
longer profile arm (612) and the shorter profile arm (610) are alternatively positioned
along the length of the elongated strip (608). Both the profile arms (610 and 612) are
~ 18 ~
coupled to the negative electrodes of the individual cells (400A) placed in a last row/s
of the layered battery structure (500). As these profile arms (610 and 612) are
connected to the negative electrodes, the third busbar strip (600C) forms a negative
terminal (650) of the battery pack, also shown in Figure 9.
5 [00071] During an assembling process, the first busbar strip (600A) is placed over
the battery pack in such as a way that the longer tab (606) of the first busbar strip
(600A) is oppositely positioned to the shorter profile arm (610) of the third busbar
strip (600C). Similarly, the shorter tab (604) of the first busbar strip (600A) is
oppositely positioned to the longer profile arm (612). The at least one second busbar
10 strip (600B) is placed on the battery pack in such as a way that the elongated strip
(614) is held relatively up than plane formed by a top or a bottom surface of the
individual cells (400A) and on another side, the profile arm (618) and the tab (616) is
coupled to the negative electrode (802) and the positive electrode (804) respectively.
[00072] Figure 10 illustrates a coupling scheme between the at least one second
15 busbar strip (600B) and the individual cell (400A). The profile arm (618) couples with
the negative electrode (802) of the cell (400A) placed in the intermediate row of the
individual cell (400A) while the tab (616) couples with the positive electrode (804) of
the cell (400A) placed in an adjacent row of the intermediate row. The bend portion
(680) is formed with a lesser width or thickness to act as a fuse element for the cell
20 (400A). Owing to the lesser width or thickness of the bend portion (680), this bend
portion (680) melts in case of more than a specified amount current is drawn towards
the coupled individual cell (400A) with the at least one second busbar strip (600B). In
a normal operation, power drawn from the battery pack flows through the
busbar (600) and through the fuse element (680) to the external electronic systems or
25 electric motor. However, when current flow through the fuse element (680)
approaches a predetermined level this fusible element (680) opens the electrical
circuit and prevents damaging current flow to the external electronic systems or
electric motor.
~ 19 ~
[00073] Figure 11 illustrates a coupling scheme or process used to couple the
profile arm (618) with the negative electrode (802) of the cell (400A) and the tab (616)
to couple with the positive electrode (804). In an embodiment, the profile arm (618)
and the tab (616) are formed in an XX’ plane which is substantially planer and when
5 the at least second busbar strips (600B) is placed over the battery pack during the
assembling process, a stamping process may be used to press the profile arm (618)
and the tab (616) along the XX’ plane to couple the profile arm (618) with the negative
electrode (802) of the cell (400A) and the tab (616) to couple with the positive
electrode (804). In an embodiment, the stamping process may include but not limited
10 to punching, blanking, bending, coining, embossing, and flanging. Similarly, for
coupling the first busbar strip (600A) and the third busbar strip (600C) to the
individual cells (400A) same coupling scheme is used. In an embodiment, the busbar
(600) including the first busbar strip (600A), the second busbar strip (600B) and the
third busbar strip (600C) is placed over the battery pack and stamped at once to
15 achieve the aforementioned stamping process. In another embodiment, the busbar
strips (600A, 600B, 600C) are individual placed over the rows of the battery pack and
these strips are stamped one by one using a stamping process.
[00074] The busbar (600) is electrically coupled to the cell terminals of the
different individual cells (400A). In an example, the bottom bracket, the multiple
20 intermediate bracket layers (306), and multiple rows of individual cells (400) along
with the busbar (600) may be placed in a compartment having various side walls,
namely wall (702), and wall (704). All or few of the side walls may also include vents
or opening to allow passage of air for cooling purposes. Further, the side wall may
also include provisions (not illustrated) for handling the battery pack (700).
25 [00075]
[00076] The layered battery structure (500), as disclosed above, may be
manufactured, in parts, in various separate manufacturing point such as workstations
or assembly lines, to improve the quick manufacturability thereof. In an example,
multitude of bottom brackets, such as the bottom bracket (300A) or the bottom bracket
~ 20 ~
(300B) may be manufactured in a work station. Simultaneously, at a separate
manufacturing point such as workstations or assembly lines, multiple identical
intermediate bracket layer, such as the intermediate bracket layer (306A) or the
intermediate bracket layer (306B) may be manufactured. Further, one by one, the
5 intermediate bracket layer (306A) may be applied with the glue and subsequently
other the intermediate bracket layer (306A) may be placed on the other.
[00077] This manufacturing process results in increased speed of production of
the layered battery structure (500). Further, this manufacturing process allows the
manufacturing of different components of the layered battery structure (500) to be
10 separate, and independent, allowing the manufacturing and assembly of the layered
battery structure (500) to be flexible.
[00078] While few embodiments of the present invention have been described
above, it is to be understood that the invention is not limited to the above embodiments
and modifications may be appropriately made thereto within the spirit and scope of
15 the invention.
[00079] The terms “coupled,” “connected,” and a like as used herein mean the
joining of two members directly or indirectly to one another. These terms may also
represents an electronic or any such joining may be stationary (e.g., permanent) or
moveable (e.g., removable or releasable). Such joining may be achieved with the two
20 members or the two members and any additional intermediate members being
integrally formed as a single unitary body with one another or with the two members
or the two members and any additional intermediate members being attached to one
another.
[00080] While considerable emphasis has been placed herein on the particular
25 features of this invention, it will be appreciated that various modifications can be
made, and that many changes can be made in the preferred embodiments without
departing from the principles of the invention. These and other modifications in the
nature of the invention or the preferred embodiments will be apparent to those skilled
~ 21 ~
in the art from the disclosure herein, whereby it is to be distinctly understood that the
foregoing descriptive matter is to be interpreted merely as illustrative of the invention
and not as a limitation.

We claim:

A method of manufacturing an energy storage unit (200), the method of
manufacturing the energy storage unit (200) comprising;
providing a first bracket (300A) having a plurality of troughs
forming a continuous corrugated structure, the first bracket (300A) is
adapted to hold a plurality of cells (400);
10 applying a glue (302A) to the plurality of cells (400) of the first
bracket (300), wherein the glue (302A) having adhesive properties;
providing at least one intermediate bracket (306) comprising a
first portion (308), a second portion (310), a plurality of intermediate
arms (312);
15 disposing plurality of individual cells (400) on the at least one
intermediate bracket (306);
disposing the at least one intermediate bracket (306) having the
plurality of individual cells (400) on to the plurality of cells (400) of the
first bracket (300A);
20 applying a glue (302A) to the plurality of cells (400) of the at
least one intermediate bracket (306);
sequentially stacking plurality of similar intermediate brackets
(306) having the plurality of individual cells (400) one above another;
providing a second bracket (300B) having a plurality of inverted
25 troughs forming a continuous corrugated structure; and
disposing the second bracket (300B) on the last intermediate
bracket of the stacking of the plurality of similar intermediate brackets
(306).
~ 23 ~
2. The method of manufacturing the energy storage unit (200) as claimed
in claim 1 further comprising:
applying Phase Change Material (PCM material) over plurality
of individual cells (400) of each of the at least one intermediate bracket
5 (306) after each of the at least one intermediate bracket (306) is stacked.
3. The method of manufacturing the energy storage unit (200) as claimed
in claim 1 further comprising:
pouring Phase Change Material (PCM material) over the plurality
10 of individual cells (400) of the last intermediate bracket (306).
4. The method of manufacturing the energy storage unit (200) as claimed
in claim 1, wherein the glue is applied on boundary portions (402) of the
plurality of individual cells (400).
15
5. The method of manufacturing the energy storage unit (200) as claimed
in claims 2, 3, and 4, the of Phase Change Material (PCM material) is
applied on portion of the plurality of individual cells (400) confined by
the glue.
20
6. The method of manufacturing the energy storage unit (200) as claimed
in claim 3, the Phase Change Material (PCM material) is poured down
through the at least one intermediate bracket (306) to the plurality of
individual cells (400) of each of the at least one intermediate bracket
25 (306).
7. The method of manufacturing the energy storage unit (200) as claimed
in claim 1, wherein a glue is applied to the at least a portion of the at least
one intermediate bracket (306) before disposing the plurality of
30 individual cells (400).
~ 24 ~
8. The method of manufacturing the energy storage unit (200) as claimed
in claim 1, wherein the glue is applied to the at least a portion of the at
least one intermediate bracket (306) and to the plurality of cells (400) at
one workstation of the assembly line.
5
9. The method of manufacturing the energy storage unit (200) as claimed
in claim 1, wherein the plurality of cells (400) are disposed on first
bracket (300A), the at least one intermediate bracket (306) at one
workstation of the assembly line.
10
10. An energy storage unit (200) comprising:
a first bracket (300A) having a plurality of troughs forming a
continuous corrugated structure, the first bracket (300A) is adapted to
hold a plurality of cells (400);
15 a glue (302A) applied to the plurality of cells (400), wherein the
glue (302A) having adhesive properties;
at least one intermediate bracket (306) having a first portion
(308), a second portion (310), a plurality of intermediate arms (312);
a plurality of individual cells (400) disposed on the at least one
20 intermediate bracket (306);
the at least one intermediate bracket (306) having the plurality of
individual cells (400), disposed on to the plurality of cells (400) of the
first bracket (300A);
a layer (302A) applied to the plurality of cells (400) of the at least
25 one intermediate bracket (306);
plurality of similar intermediate brackets (306) sequentially
stacking one above another;
a second bracket (300B) having a plurality of inverted troughs
forming a continuous corrugated structure disposed on the last
30 intermediate bracket of the stacking plurality of similar intermediate
brackets.
~ 25 ~
11. An energy storage unit (200) comprising:
an upper bracket member (306) adapted to accommodate
plurality of individual cell (400) comprising:
5 a first portion (308),
a second portion (310), and
a plurality of intermediate arms (312), the plurality of
intermediate arms (312) are disposed spaced apart and connect
the first portion (308) with the second portion (310), wherein
10 each of the first portion (308) and the second portion (310) has
plurality of trough portions (310A), the plurality of trough
portions (310A) of the first portion (308) are joined with each
other, and the plurality of trough portions (310A) of the second
portion (310) are joined with each other, such that the trough
15 portions (310A) of the first portion (308) and the second portion
(310) are aligned with each other, wherein the plurality of trough
portions (310A) of each of the first portion (308) and the second
portion (310) have a downwardly extending support tab (314);
a lower bracket member (306’) adapted to accommodate plurality
20 of individual cell (400) comprising:
a first portion (308),
a second portion (310), and
a plurality of intermediate arms (312), the plurality of
intermediate arms (312) are disposed spaced apart and connect
25 the first portion (308) with the second portion (310), wherein
each of the first portion (308) and the second portion (310) has
plurality of trough portions (310A), the plurality of trough
portions (310A) of the first portion (308) are joined with each
other, and the plurality of trough portions (310A) of the second
30 portion (310) are joined with each other, such that the trough
portions (310A) of the first portion (308) and the second portion
~ 26 ~
(310) are aligned with each other, wherein the plurality of trough
portions (310A) of each of the first portion (308) and the second
portion (310) have a downwardly extending support tab (314),
wherein the upper bracket member (306) is positioned over the lower
5 bracket member (306’).
12. A busbar (600) of an energy storage system (100), wherein the energy
storage system (100) comprises a layered battery structure composed of
one or more individual cells (400A), the busbar (600) comprising:
10 a first busbar strip (600A) comprises an elongated strip (602), and a
plurality of tabs (604, 606),
wherein the plurality of tabs (604, 606) coupled to a positive
electrode (804) of one or more individual cells (400A) placed in an initial
row (502, 504) of the layered battery structure (500),
15 wherein the first busbar strip (600A) configures the one or more
individual cells (400A) placed in the initial rows (502, 504) in parallel
configuration, and
wherein the elongated strip (602) acts as an positive terminal
(650) for the energy storage system (100);
20 at least one second busbar strips (600B) comprises an elongated strip
(614), a plurality of profile arms (618) and a plurality of tabs (616),
wherein the plurality of profile arms (618) electrically coupled to
a negative electrode (802) of the one or more individual cells (400A)
placed in the rows (502, 504) and the plurality of tabs (616) electrically
25 coupled to the positive electrode (804) of the one or more individual cells
(400A) placed in the adjacent row (506, 508) of the layered battery
structure (500), and
wherein the at least one second busbar strips (600B) configures
the one or more coupled individual cells (40A) in series configuration;
30 and
~ 27 ~
a third busbar strip (600C) comprises an elongated strip (608), and a
plurality profile arms (610, 612),
wherein the plurality profile arms (610, 612) coupled to the
negative electrode (802) of the one or more individual cells (400A)
5 placed in a last row (510, 512) of the layered battery structure (500),
wherein the third busbar strip (600C) configures the one or more
individual cells (400A) placed in the last row (510, 512) in parallel
configuration, and
wherein the elongated strip (608) acts as an negative terminal
10 (650) for the energy storage system (100).
13. The busbar (600) as claimed in claim 12, wherein the plurality of tabs
(604, 606) comprise at least one shorter tab (604), and at least one longer
15 tab (606).
14. The busbar (600) as claimed in claim 12, wherein the plurality profile
arms (610, 612) comprise at least one longer profile arm (612) and at
least one shorter profile arm (610).
20
15. The busbar assembly (600) as claimed in claim 12, wherein the plurality
of tabs (604, 606) protrudes traversably from the elongated strip (602).
16. The busbar assembly (600) as claimed in claim 12, wherein the plurality
25 of profile arms (618) protrude from one side of the elongated strip (614)
while plurality of tabs (616) protrude from another side of the elongated
strip (614).
17. The busbar assembly (600) as claimed in claim 12, wherein the plurality
30 of tabs (604, 606) lie in different plane than a plane (XX’) of the
elongated strip (602).
~ 28 ~
18. The busbar assembly (600) as claimed in claim 12, wherein the plurality
profile arms (610, 612) lie in different plane than a plane (XX’) of the
elongated strip (608).
5
19. The busbar assembly (600) as claimed in claim 12, wherein the plurality
of profile arms (618) and the plurality of tabs (616) lie in a plane different
than a plane (XX’) of the elongated strip (614).
10
20. The busbar assembly (600) as claimed in claim 12, wherein the plurality
of tabs (616) and the plurality of tabs (604, 606) are extended via a bend
portion (680), wherein the bend portion (680) formed with a lesser width
or thickness with respect to the width of other portion of the plurality of
15 tabs (616, 604, 606), and wherein the bend portion (680) to act as a fuse
element.