0001] The present invention relates to energy storage systems and, more
particularly, to a battery unit and manufacturing method thereof.
BACKGROUND
5 [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
effective, and efficient. Right from electric vehicles, to household applications,
rechargeable batteries are found all around us. When used in an automotive
10 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
members, e.g., the wheels.
[0003] The rechargeable batteries are formed using a plurality of
15 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
individual cell may be unable to provide substantial charge, the plurality of cells
arranged together electrically combine to provide an output usable in various
20 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
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.
25 Therefore, it is desired that maximum number of cell are stacked within the battery
casing.
~ 3 ~
[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
while also being potentially hazardous. Therefore, if it required that the heat generated
during the operation of the battery is properly dissipated.
5 [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
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
10 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
considerably expensive, difficult to repair and manufacture.
BRIEF DESCRIPTION OF DRAWINGS
15 [0008] 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
embodiments of the present invention are now described, by way of example only
wherein like reference numerals represent like elements and in which:
20 [0009] Figure 1 illustrates a perspective view of an energy storage system,
according to an embodiment of the present invention;
[00010] Figure 1A illustrates a perspective view of a base bracket of an energy
storage system, according to an embodiment of the present invention;
[00011] Figure 1B illustrates a perspective view of a base bracket of an energy
25 storage system, according to another embodiment of the present invention
~ 4 ~
[00012] 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;
[00013] Figure 2A illustrates a perspective view of an intermediate bracket of the
5 energy storage system of Figure 1A, according to an embodiment of the present
invention;
[00014] Figure 2B illustrates a perspective view of an intermediate bracket of the
energy storage system of Figure 1B, according to another embodiment of the present
invention;
10 [00015] 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;
[00016] Figure 3B illustrates a perspective view of two intermediate brackets of
the energy storage system of Figure 1B, according to another embodiment of the
15 present invention;
[00017] 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;
[00018] Figure 4B 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;
[00019] Figure 5A illustrates a perspective view of multiple intermediate brackets
of the energy storage system of Figure 1A, according to an embodiment of the present
invention;
~ 5 ~
[00020] 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
[00021] Figure 6 illustrates a perspective view of the energy storage system,
5 according to an embodiment of the present invention;
[00022] Figure 7 illustrates a perspective view of the energy storage system,
according to an embodiment of the present invention;
[00023] Figure 8 illustrates top view of a bus bar of the energy storage system,
according to an embodiment of the present invention;
10 [00024] Figure 9 illustrates perspective view of the bus bar of the energy storage
system, according to an embodiment of the present invention;
[00025] Figure 10 illustrates a perspective view of a portion of the bus bar of the
energy storage system, according to an embodiment of the present invention;
[00026] Figure 11 illustrates a side view of a portion of the bus bar of the energy
15 storage system, according to an embodiment of the present invention;
[00027] Figure 12A illustrates a perspective view the energy storage system of,
according to an embodiment of the present invention. and
[00028] Figure 12B illustrates a perspective view the energy storage system of,
according to another embodiment of the present invention.
20 [00029] 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.
~ 6 ~
SUMMARY OF INVENTION
[00030] A busbar of an energy storage system is disclosed. The energy storage
system comprises a layered battery structure having one or more individual cells. The
busbar comprising a first busbar strip comprises an elongated strip, and a plurality of
5 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, at least one second busbar strips comprises an elongated
10 strip, a plurality of profile arms and a plurality of second 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 second 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 the at least one second busbar strips configures
15 the one or more coupled individual cells in series configuration and a third busbar strip
comprises an elongated strip, and a plurality second profile arms, wherein the second
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 placed in the last row in parallel
20 configuration, and wherein the elongated strip acts as an negative terminal for the
energy storage system. The present invention has advantage while manufacturing the
energy storage system. The busbar is easily assemble onto the individual cells placed
in the layered structure.
[00031] In an embodiment, the plurality of tabs comprise at least one shorter tab,
25 and at least one longer tab.
[00032] In an embodiment, the plurality profile arms comprise at least one longer
profile arm and at least one shorter profile arm.
~ 7 ~
[00033] In an embodiment, the e plurality of tabs protrude traversably from the
elongated strip.
[00034] In an embodiment, the plurality of profile arms protrude from one side
of the elongated strip while plurality of tabs protrude from another side of the
5 elongated strip.
[00035] In an embodiment, the plurality of tabs lie in different plane than a plane
(XX’) of the elongated strip.
[00036] In an embodiment, the plurality of tabs are extended via a bend portion,
wherein the bend portion formed with a lesser width or thickness with respect to the
10 width of other portion of the plurality of tabs to act as a fuse element. Additionally,
the bend portion in the tabs acts as a fuse which is integral part of the busbar itself and
this reduces complexity in the energy storage system to incorporate the fuse externally.
[00037] In an embodiment, the one or more individual have a cylindrical
geometry.
15 [00038] In an embodiment, the one or more individual cells comprises a positive
electrode and a negative electrode.
[00039] In an embodiment, the positive electrode formed on an inner portion and
the negative electrode formed on an outer circular peripheral portion.
[00040] In an embodiment, a method of coupling a busbar to one or more
20 individual cells of an energy storage system is disclosed.
[00041] In an embodiment, the method comprising placing the busbar onto the
one or more individual cells, wherein the busbar assembly including a first busbar
strip, a second busbar strip and a third busbar strip, wherein the first busbar strip
comprises an elongated strip, and a plurality of tabs, wherein the second busbar strip
25 comprises an elongated strip, a plurality of profile arms and a plurality of second tabs,
and wherein the third busbar strip comprises an elongated strip, and a plurality second
~ 8 ~
profile arms, and coupling electrically the busbar onto the one or more individual cells,
wherein coupling electrically the plurality of tabs and the plurality of tabs to a positive
electrode of the one or more individual cells, and coupling electrically the plurality of
profile arms and the plurality profile arms to a negative electrode of the one or more
5 individual cells.
[00042] In an embodiment, the method of coupling electrically includes heating,
soldering, fusing and their any combination thereof.
[00043] In an embodiment, the method of coupling electrically is performed
using an automated or manual hammering technique.
10 [00044] The present invention also has an advantage to assemble the energy
storage system is significantly reduced time. Moreover, the cost of manufacturing the
busbar via the present method is also significantly reduced.
[00045] Also, the busbar coupled with the individual cells makes the energy
storage system compact.
15 DETAILED DESCRIPTION
[00046] 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
is not intended to limit the invention to the particular forms disclosed, but on the
20 contrary, the invention is to cover all modifications, equivalents, and alternative
falling within the spirit and the scope of the invention.
[00047] 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
comprises a list of components or steps does not include only those components or
25 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,
~ 9 ~
preclude the existence of other elements or additional elements in the system or
apparatus.
[00048] For better understanding of this invention, reference would now be made
to the embodiment illustrated in the accompanying Figures and description here
5 below, further, in the following Figures, the same reference numerals are used to
identify the same components in various views.
[00049] 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
10 astride and these directions are referred by arrows Fr, Rr, U, Lr, L, R in the drawing
Figures.
[00050] 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
15 energy storage system (100) may embody any other energy storage system that may
be used in vehicles such as scooters, three-wheeled vehicles, All-Terrain Vehicles
(ATV) etc. without limiting the scope of the invention.
[00051] The energy storage system (100) comprises a plurality of energy storage
units (200). In the present embodiment, the plurality of energy storage units (200)
20 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
25 energy storage unit may be the second battery pack.
[00052] Referring now to Figure 2, the battery pack further includes at least one
intermediate bracket (306). The intermediate bracket (306) includes a first portion
(308), a second portion (310), and plurality of intermediate arms (312). The plurality
~ 10 ~
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
plurality of semicircular portion (310A) of the first portion (308) are joined with each
5 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
aligned with each other. In an embodiment, the intermediate arms (312) at one end is
10 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).
[00053] The intermediate bracket (306) further includes a first side wall (316),
and a second side wall (318). In an embodiment, the first side wall (316), and the
15 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
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).
20 [00054] 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
illustrated) is provided on the intermediate bracket layer (306A) before placing the
25 cells thereon. Subsequently, a layer of glue (320) is applied on first row of individual
cells (400).
[00055] 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
~ 11 ~
the cell (400A). In an example, a layer of glue (not 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). Further, an
additional layer (304) is provided on the first row of individual cells (400). In an
5 embodiment, the additional layer (304) is composed of a Phase Change Material (PCM
material).
[00056] 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
10 downwardly extending support tab (314) of the intermediate bracket layer (306A) abut
with the semicircular portion (310A) on the intermediate bracket layer (306A).
Subsequently, another intermediate bracket layer (306A) is positioned on above the
intermediate bracket layer (306A), as shown in Figure 4A.
[00057] A predetermined number of layers, similar to the intermediate bracket
15 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
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
20 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).
[00058] 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
25 the downwardly extending support tab (314) of the intermediate bracket layer (306B)
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.
~ 12 ~
[00059] A predetermined number of layers, similar to the intermediate bracket
layer (306B) are positioned, one after the other, above the intermediate bracket layer
(306B), as shown in Figure 5B. Further, between each layer, the phase change material
is provided. Once all of the predetermined number of layers are joined together a
5 layered battery structure (500) is formed.
[00060] 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
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
10 layered battery structure (500).
[00061] 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
(500) according to an availability of space. In an embodiment, the busbar (600)
15 comprises at least one strip that is longer than its width of an interface with a single
row of individual cells (400A).
[00062] 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 (804) and a negative electrode (802). Both the
20 electrodes are provided at a same end of the individual cell (400A). For example, as
depicted in Figure 10, when the individual cell (400A) is constructed in a cylindrical
shape, the positive electrode (804) may be provided at an inner portion at one end
while the negative electrode (802) may be provided at an outer portion (802) at the
same end or vice versa. In embodiment, circumference of the negative electrode (802)
25 part is lesser than the circumference of the positive electrode (804). 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
~ 13 ~
other features of the individual cells (400A) may also differ from those shown
according to other exemplary embodiments.
[00063] The busbar (600) of an energy storage system (100), wherein the energy
storage system (100) comprises a layered battery structure composed of one or more
5 individual cells (400A). The busbar (600) comprising 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 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
10 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 from any conductive material, such as copper, according to known methods
and techniques, including but not limited to a die casting operation.
15 [00064] The first busbar strip (600A) comprises an elongated strip (602), and a
plurality of tabs (604, 606). 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)
of the layered battery structure (500). The first busbar strip (600A) configures the one
or more individual cells (400A) placed in the initial row (502) in parallel
20 configuration, and the elongated strip (602) acts as a positive terminal (650) for the
energy storage system (100). The plurality of tabs (604, 606) comprise at least one
shorter tab (604), and at least one longer tab (606). The plurality of tabs (604, 606)
protrude traversably from the elongated strip (602). In an embodiment, the shorter tab
(604) and the longer tab (606) protrudes traversable from the elongated strip (602). In
25 another embodiment, the shorter tab (604) and the 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 (804) of the individual cells (400A) placed in
the initial row (502) of the layered battery structure (500). The person skilled in the
art may appreciate that the coupling of the first busbar strip (600A) to the individual
~ 14 ~
cells (400A) or the initial row (502) depends on an output voltage requirement from
the battery pack and also depends on the individual cells (400A) capacity therein. As
these tabs (604 and 606) are connected to the positive electrodes (804), the first busbar
strip (600A) or in specific, the elongated strip (602) forms the positive terminal (650)
5 of the energy storage system (100), also shown in Figure 9.
[00065] The at least one second busbar strips (600B) comprises an elongated strip
(614), a plurality of profile arms (618) and a plurality of second tabs (616). 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
10 second tabs (616) electrically 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). The at least one second busbar strips (600B) configures the
one or more coupled individual cells (40A) in series configuration. The plurality of
profile arms (618) protrude from one side of the elongated strip (614) while the
15 plurality of second tabs (616) protrude from an opposite side of the elongated strip
(614). The elongated strip (614) comprises continuous crests and trough portions. The
plurality of second 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 tabs (604, 606)
20 to act as a fuse element. The bend portion (680) is formed with a lesser width or
thickness to act as a fuse element for the cell (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).
[00066] In an embodiment, the plurality of arms (618) and the plurality of second
25 tabs (616) are provided at trough and crest portions in an either directions of the
elongated strip (614). The plurality of profile arms (618) couple with the negative
electrodes (802) of the individual cells (400A) while the plurality of second tabs (616)
couple with the positive electrodes (804) of the individual cells (400A). The at least
one second busbar strip (600B) is positioned over the adjacent rows (506, 508) and
~ 15 ~
the rows (502, 504) 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. At least one second busbar strips (600B) comprises an
5 elongated strip (614), a plurality of profile arms (618) and a plurality of second 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 a row (504,
506,508) and the plurality of second tabs (616) electrically coupled to the positive
electrode (804) of the one or more individual cells (400A) placed in the adjacent row
10 (504, 506, 508,510) of the layered battery structure (500), and wherein the at least one
second busbar strips (600B) configures the adjacent rows, having one or more coupled
individual cells (40A), in series configuration.
[00067] The third busbar strip (600C) comprises an elongated strip (608), and a
plurality second profile arms (610, 612). The plurality second profile arms (610, 612)
15 coupled to the negative electrode (802) of the one or more individual cells (400A)
placed in a last row (512) of the layered battery structure (500). The third busbar strip
(600C) configures the one or more individual cells (400A) placed in the last row (510)
in parallel configuration. The elongated strip (608) acts as a negative terminal (660)
for the energy storage system (100). The plurality second profile arms (610, 612)
20 comprise at least one longer profile arm (612) and at least one 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 coupled to the negative electrodes (802)
25 of the individual cells (400A) placed in the last row (512) of the layered battery
structure (500). As these profile arms (610 and 612) are connected to the negative
electrodes (802), the third busbar strip (600C) forms the negative terminal (660) of the
energy storage system (100), also shown in Figure 9.
~ 16 ~
[00068] During an assembling process, the first busbar strip (600A) is placed over
the energy storage system (100) 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
5 (600A) is oppositely positioned to the longer profile arm (612). The at least one second
busbar strip (600B) is placed on the energy storage system (100) 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 second tab (616) is coupled to the negative electrode (802) and the positive
10 electrode (804) respectively.
[00069] Figure 10 illustrates a coupling scheme between the at least one second
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 second tab (616) couples with the positive electrode
15 (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 (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) due to failure of one or more cells. In a
20 normal operation, power drawn from the energy storage system (100) flows through
the busbar (600) and through the fuse element (680) to the external electronic systems
or 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
25 electric motor.
[00070] Figure 11 illustrates a method of coupling a busbar (600) to one or more
individual cells (400A) of an energy storage system (100). The method comprising
placing the busbar (600) onto the one or more individual cells (400A). The busbar
(600) including a first busbar strip (600A), a second busbar strip (600B) and a third
~ 17 ~
busbar strip (600C). The method involves coupling electrically the busbar (600) onto
the one or more individual cells, wherein coupling electrically the plurality of tabs
(604, 606) and the plurality of second tabs (616) to a positive electrode (804) of the
one or more individual cells (400A), and coupling electrically the plurality of profile
5 arms (618) and the plurality second profile arms (610, 612) to a negative electrode
(802) of the one or more individual cells (400A). In an embodiment, coupling
electrically includes heating, soldering, fusing and their any combination thereof. In
another embodiment, coupling electrically is performed using an automated or manual
hammering technique.
10 [00071] The method configures the plurality of tabs (604, 606) to lie in different
plane than a plane (XX’) of the elongated strip (602). Additionally, the plurality
second profile arms (610, 612) lie in different plane than a plane (XX’) of the
elongated strip (608). Similarly, the plurality of profile arms (618) and the plurality of
second tabs (616) lie in a plane different than a plane (XX’) of the elongated strip
15 (614). For example, the profile arms (610, 612 618) and the tabs (604, 606, 616) are
adapted to be placed in an XX’ plane which is substantially planer and when the strips
(600A, 600B, 600C) are placed over the energy storage system (100) during the
assembling process. An automated or manual hammering technique may be used to
press the profile arms (610, 612, 618) and the tabs (604, 606, 616) along the XX’ plane
20 to couple the profile arms (610, 612, 618) with the negative electrode (802) of the
individual cells (400A) and the tabs (604, 606, 616) to couple with the positive
electrode (804). In an embodiment, the first busbar strip (600A), the second busbar
strip (600B) and the third busbar strip (600C) are placed over the energy storage
system (100) and coupling electrically at once by using the automated or manual
25 hammering technique. In another embodiment, the busbar strips (600A, 600B, 600C)
are individual placed over the rows of the energy storage system (100) and these strips
are automatically or manually hammered.
[00072] Figure 12A and 12B, illustrates different view the battery pack (700)
formed by assembling the bottom bracket (300A) or the bottom bracket (300B), with
~ 18 ~
multiple intermediate bracket layer (306), and multiple rows of individual cells (400),
such as a cell (400A). Thereafter, the busbar (600) is electrically coupled to the cell
terminals of the different individual cells (400A). In an example, the bottom bracket,
the multiple intermediate bracket layers (306), and multiple rows of individual cells
5 (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).
[00073] The present invention has advantage while manufacturing the energy
10 storage system (100). The busbar (600) is easily assemble onto the individual cells
(400A) placed in the layered structure. The time to assemble the energy storage system
(100) is significantly reduced. Moreover, the cost of manufacturing the busbar (600)
via the present method is also significantly reduced. The busbar coupled with the
individual cells (400A) makes the energy storage system (100) compact. Additionally,
15 the bend portion (680) in the tabs (606) acts as a fuse which is integral part of the
busbar (600) itself and this reduces complexity in the energy storage system (100) to
incorporate the fuse externally.
[00074] 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
20 and modifications may be appropriately made thereto within the spirit and scope of
the invention.
[00075] 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
25 moveable (e.g., removable or releasable). Such joining may be achieved with the two
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.
~ 19 ~
[00076] While considerable emphasis has been placed herein on the particular
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
5 nature of the invention or the preferred embodiments will be apparent to those skilled
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:

1. A busbar (600) of an energy storage system (100), wherein the energy storage
system (100) comprises a layered battery structure having one or more individual
cells (400A) in each of the layer, the busbar (600) of the energy storage system
5 (100) comprising:
a first busbar strip (600A) comprises an elongated strip (602) and a
plurality of tabs (604, 606), wherein the plurality of tabs (604, 606) electrically
coupled to a positive electrode (804) of one or more individual cells (400A)
placed in an initial row (502) of the layered battery structure (500), wherein the
10 first busbar strip (600A) configures the one or more individual cells (400A)
placed in the initial row (502) in parallel configuration, and wherein the
elongated strip (602) acts as an positive terminal (650) for the energy storage
system (100);
at least one second busbar strips (600B) comprises an elongated strip
15 (614), a plurality of profile arms (618) and a plurality of second 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 a row (504,
506,508) and the plurality of second tabs (616) electrically coupled to the
positive electrode (804) of the one or more individual cells (400A) placed in the
20 adjacent row (, 504, 506, 508,510) of the layered battery structure (500), and
wherein the at least one second busbar strips (600B) configures the adjacent
rows, having one or more coupled individual cells (40A), in series configuration;
and
a third busbar strip (600C) comprises an elongated strip (608) and a
25 plurality second profile arms (610, 612), wherein the second plurality profile
arms (610, 612) coupled to the negative electrode (802) of the one or more
individual cells (400A) placed in a last row (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 (512) in parallel configuration, and
~ 21 ~
wherein the elongated strip (608) acts as an negative terminal (650) for the
energy storage system (100).
2. The busbar (600) as claimed in claim 1, wherein the plurality of tabs (604, 606)
5 comprise at least one shorter tab (604) and at least one longer tab (606).
3. The busbar (600) as claimed in claim 1, wherein the plurality second profile arms
(610, 612) comprise at least one longer profile arm (612) and at least one shorter
profile arm (610).
10
4. The busbar (600) as claimed in claim 1, wherein the plurality of tabs (604, 606)
protrude traversably from the elongated strip (602).
5. The busbar (600) as claimed in claim 1, wherein the plurality of profile arms
15 (618) protrude from one side of the elongated strip (614) while plurality of
second tabs (616) protrude from another side of the elongated strip (614).
6. The busbar (600) as claimed in claim 1, wherein the plurality of tabs (604, 606)
lie in different plane than a plane (XX’) of the elongated strip (602), wherein the
20 plurality second profile arms (610, 612) lie in different plane than a plane (XX’)
of the elongated strip (608), and wherein the plurality of profile arms (618) and
the plurality of second tabs (616) lie in a plane different than a plane (XX’) of
the elongated strip (614).
25 7. The busbar (600) as claimed in claim 1, wherein the plurality of second 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 tabs (604, 606, 616) to
act as a fuse element.
30
8. A method of coupling of a busbar (600) with one or more individual cells (400A)
of an energy storage system (100), the method comprising:
~ 22 ~
placing the busbar (600) onto the one or more individual cells (400A),
wherein the busbar assembly (600) including a first busbar strip (600A), a
second busbar strip (600B) and a third busbar strip (600C),
wherein the first busbar strip (600A) comprises an elongated strip
5 (602), and a plurality of tabs (604, 606),
wherein the second busbar strip (600B) comprises an elongated
strip (614), a plurality of profile arms (618) and a plurality of second tabs
(616), and
wherein the third busbar strip (600C) comprises an elongated
10 strip (608), and a plurality second profile arms (610, 612); and
coupling, electrically, the busbar (600) onto the one or more individual
cells (400A), wherein coupling electrically the plurality of tabs (604,
606) to a positive electrode (804) of the one or more individual cells
(400A) and the plurality of second tabs (616) to a positive electrode (804)
15 of the one or more individual cells (400A), and coupling electrically the
plurality of profile arms (618) and the plurality second profile arms (610,
612) to a negative electrode (802) of the one or more individual cells
(400A).
20 9. The method as claimed in claim 8, wherein coupling electrically includes
heating, soldering, fusing and their any combination thereof.
10. The method as claimed in claim 8, wherein coupling electrically is performed
using an automated or manual hammering technique.