[0001] The present invention relates to energy storage systems and, more
particularly, to a battery unit of the energy storage system.
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
effective, and efficient. Right from electric vehicles, to household applications,
10 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
members, e.g., the wheels.
15 [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
individual cell may be unable to provide substantial charge, the plurality of cells
20 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
connections of the electrical output of the battery. It is known that the electrical output
25 of the battery depends largely on the number of individual cells contained therein.
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.
15 SUMMARY OF INVENTION
[0008] In one aspect of the present invention, a bracket member of an energy
storage unit is provided. The bracket member 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. Each of
20 the first portion and the second portion has plurality of crests and troughs portion, the
plurality of crests and troughs portion of the first portion are joined with each other,
and the plurality of crests and troughs portion of the second portion are joined with
each other, such that the crests and troughs portion of the first portion and the second
portion are aligned with each other.
25 [0009] In an embodiment, owing to connections of the front portion, and the
second portion with the intermediate arms, a plurality of slots are formed between the
~ 4 ~
front portion, and the second portion. The crests and troughs portions of each of the
front portion and the rear portion have a downwardly extending support tab.
[00010] In an embodiment, the downwardly extending support tabs are
positioned at an inclination from the crests and troughs portions. Further, the
5 downwardly extending support tabs rest on upper open portions formed on the crests
and troughs portions.
[00011] In an embodiment, the bracket member is adapted to hold a first row of
plurality of individual cells.
[00012] In an embodiment, a diameter of the crests and troughs portion,
10 corresponds to diameter of individual cell, and a length of the intermediate arms
corresponds to the length of the individual cells, to be housed in the bracket member,
such that the cell at one end rests on the first portion and at the other end on the second
portion.
[00013] In an embodiment, the bracket member of the energy storage unit further
15 comprises, a first side wall, and a second side wall, the first side wall, and the second
side wall being positioned at opposite ends of the front portion, the rear portion. The
distance between the first side wall, and the second side wall corresponds to the length
of the front portion, or the rear portion. Further, the length each of the first side wall,
and the second side wall corresponds to the length of the intermediate arms.
20 [00014] 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
~ 5 ~
the plurality of trough portions of each of the first portion and the second portion have
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
5 spaced apart and connect the first portion with the second portion, wherein each of the
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
10 the plurality of trough portions of each of the first portion and the second portion have
a downwardly extending support tab. The upper bracket member is positioned over
the lower bracket member.
[00015] In an embodiment, an individual cell placed on the lower bracket member
rests between two adjacent individual cells placed on the upper bracket member.
15 [00016] In an embodiment, the bottom tab on the upper bracket member rests
between the two arms of the trough portion of the plurality of trough portions on lower
bracket member.
[00017] In an embodiment, the last leg of the upper bracket member rests on the
first side wall of the lower bracket member.
20
BRIEF DESCRIPTION OF DRAWINGS
[00018] The invention itself, together with further features and attended
advantages, will become apparent from consideration of the following detailed
25 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:
~ 6 ~
[00019] Figure 1 illustrates a perspective view of an energy storage system,
according to an embodiment of the present invention;
[00020] 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
5 invention;
[00021] Figure 2A illustrates a perspective view of an intermediate bracket of the
energy storage system of Figure 1, according to an embodiment of the present
invention;
[00022] Figure 2B illustrates a perspective view of an intermediate bracket of the
10 energy storage system of Figure 1, according to another embodiment of the present
invention;
[00023] Figure 3A illustrates a perspective view of two intermediate brackets of
the energy storage system of Figure 1, according to an embodiment of the present
invention; and
15 [00024] Figure 3B illustrates a perspective view of two intermediate brackets of
the energy storage system of Figure 1, according to another embodiment of the present
invention.
[00025] 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
20 exemplary in nature.
DETAILED DESCRIPTION
[00026] While the invention is susceptible to various modifications and
alternative forms, an embodiment thereof has been shown by way of example in the
25 drawings and will be described here below. It should be understood, however that it
~ 7 ~
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.
[00027] The term “comprises”, comprising, or any other variations thereof, are
5 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
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,
10 preclude the existence of other elements or additional elements in the system or
apparatus.
[00028] 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
15 identify the same components in various views.
[00029] 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
20 Figures.
[00030] 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
25 be used in vehicles such as scooters, three-wheeled vehicles, All-Terrain Vehicles
(ATV) etc. without limiting the scope of the invention.
[00031] The energy storage system (100) comprises a plurality of energy storage
units (200). In the present embodiment, the plurality of energy storage units (200)
~ 8 ~
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
5 battery cells. The first energy storage unit may be the first battery pack, and the second
energy storage unit may be the second battery pack.
[00032] As illustrated in Figure 1A, the battery pack includes a bottom bracket
(300A). The bottom bracket (300A) has a series of parallel ridges and groves, forming
a corrugated structure. In an example, the diameter of the groves corresponds to an
10 outer diameter of individual cells.
[00033] The bottom bracket (300A) is also interchangeably referred to as a
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
15 an inner surface (not illustrated) and an outer surface (298). A glue 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).
[00034] Referring now to Figure 2, the battery pack includes at least one
20 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 trough
portions such as trough portions (310A) extending upwards. The terms “trough
25 portions (310A” and “trough portions (310A)” have been used interchangeably
hereinafter. The plurality of trough portions (310A) of the first portion (308) are joined
with each other. Similarly the second portion (310) has plurality of semicircular
portions, such as trough portions (310A) extending upwards. The plurality of trough
portions (310A) of the second portion (310) are joined with each other. The trough
~ 9 ~
portions (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
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
5 portions on the second arm (310).
[00035] Owing to such connections of the front portion (308), and the rear portion
(310) with the intermediate arms (312), a plurality of slots (312A) are formed between
the front portion (308), and the rear portion (310). Each of the plurality of slots (312A)
of the bracket member (306) is adapted to hold an individual cell (400’). In an
10 embodiment, slots defined between the intermediate arms (312) have a width smaller
that the width of the individual cells (400). The semicircular portions of each of the
front portion (308) and the rear portion (310) have a downwardly extending support
tab (314). In an embodiment, the downwardly extending support tabs (314) are
positioned at an inclination from the semicircular portions. The diameter of the
15 semicircular portions, such as the trough portions (310A), corresponds to diameter of
individual cell, also referred to as cell, contained therein. Further, the length of the
intermediate arms (312) corresponds to the length of the cells, such that the cell at one
end rests on the first portion (308) and at the other end on the second portion (310).
[00036] In an embodiment, the width of the trough portions (310a) is less than
20 diameter of individual cell (400’), and a length of the intermediate arms (312) is less
than the length of the individual cells, to be housed in the bracket member (306).
[00037] The downwardly extending support tab (314) rests on the individual cell
(400’) of the immediate lower bracket (306’)
[00038] 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
~ 10 ~
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).
[00039] 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).
[00040] 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’).
[00041]
[00042] 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
25 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
cells thereon. Subsequently, a layer of glue (320) is applied on first row of individual
cells (400).
~ 11 ~
[00043] 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 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 [00044] 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 trough portions (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.
[00045] A predetermined number of layers, similar to the intermediate bracket
layer (306A) are positioned, one after the other, above the intermediate bracket layer
(306A). Once all of the predetermined number of layers are joined together a layered
20 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 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).
25 [00046] In an embodiment, the individual cell (400’) placed on the lower bracket
member (306’) rests between two adjacent individual cells (400’) placed on the upper
bracket member (306). The bottom tab on the upper bracket member (306) rests
between the two arms (330) of the trough portion (310A’) of the plurality of trough
portions (310A) on lower bracket member (306’). Further, the last leg (306) of the
~ 12 ~
upper bracket member (306) rests on the first side wall (316) of the lower bracket
member (306’).
[00047] In accordance with another embodiment Figure 3B, two intermediate
bracket layers (306) stacked one above other. In particular, one intermediate bracket
5 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)
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.
10 [00048] 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 poured. Once all of the predetermined number of layers are joined together a layered
battery structure (500) is formed.
15 [00049] 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
the invention.
[00050] The terms “coupled,” “connected,” and a like as used herein mean the
20 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
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
25 or the two members and any additional intermediate members being attached to one
another.
[00051] While considerable emphasis has been placed herein on the particular
features of this invention, it will be appreciated that various modifications can be
~ 13 ~
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
in the art from the disclosure herein, whereby it is to be distinctly understood that the
5 foregoing descriptive matter is to be interpreted merely as illustrative of the invention
and not as a limitation.

We claim:

1. A bracket member (306) of an energy storage unit (200), the bracket
member (306) 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 each of the first
10 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 portions (310A) of the first portion (308) and the
15 second portion (310) are aligned with each other.
2. The bracket member (306) of the energy storage unit (200) as claimed in
claim 1, wherein owing to connections of the front portion (308), and the
second portion (310) with the intermediate arms (312), a plurality of slots
20 (312A) are formed between the front portion (308), and the second
portion (310).
3. The bracket member (306) of the energy storage unit (200) as claimed in
claim 1, wherein the plurality of trough portions (310A) of each of the
25 first portion (308) and the second portion (310) have a downwardly
extending support tab (314).
4. The bracket member (306) of the energy storage unit (200) as claimed in
claim 3, wherein at least one downwardly extending support tab (314)
30 positioned at an inclination from the trough portions (310A).
~ 15 ~
5. The bracket member (306) of the energy storage unit (200) as claimed in
claim 2, wherein each of the plurality of slots (312A) of the bracket
member (306) is adapted to hold an individual cell (400’).
5
6. The bracket member (306) of the energy storage unit (200) as claimed in
claims 3 and 5, wherein the downwardly extending support tab (314)
rests on the individual cell (400’) of the immediate lower bracket (306’).
10
7. The bracket member (306) of the energy storage unit (200) as claimed in
claim 5, wherein slots defined between the intermediate arms (312) have
a width smaller that the width of the individual cells (400).
15 8. The bracket member (306) of the energy storage unit (200) as claimed in
claim 1, wherein the width of the trough portions (310A), corresponds to
diameter of individual cell (400’), and a length of the intermediate arms
(312) correspond to the length of the individual cells(400’) to be housed
in the bracket member (306), such that the cell (400’) at one end rests on
20 the first portion (308) and at the other end on the second portion (310).
9. The bracket member (306) of the energy storage unit (200) as claimed in
claim 8, wherein the width of the trough portions (310a) is less than
diameter of individual cell (400’), and a length of the intermediate arms
25 (312) is less than the length of the individual cells, to be housed in the
bracket member (306).
10. The bracket member (306) of the energy storage unit (200) as claimed in
claim 1 further comprises a first side wall (316), and a second side wall
30 (318), wherein the first side wall (316), and the second side wall (318)
being positioned at opposite ends of the first portion (308), the second
portion (310).
~ 16 ~
11. An energy storage unit (200) comprising:
an upper bracket member (306) adapted to accommodate
plurality of individual cells (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 cells (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
~ 17 ~
(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. The energy storage unit (200), as claimed in claim 11, wherein an
individual cell (400’) placed on the lower bracket member (306’) rests
between two adjacent individual cells (400’) placed on the upper bracket
10 member (306).
13. The energy storage unit (200), as claimed in claim 12, wherein the
bottom tab on the upper bracket member (306) rests between the two
arms (330) of the trough portion (310A’) of the plurality of trough
15 portions (310A) on lower bracket member (306’).
14. The energy storage unit (200), as claimed in claim 14, wherein the last
leg (306) of the upper bracket member (306) rests on the first side wall
20 (316) of the lower bracket member (306’)