DESC:The solutions of the present disclosure are to be clearly described in the following with reference to the accompanying drawings. It is obvious that the embodiments to be described are only a part rather than all the embodiments of the present disclosure. All other embodiments obtained by persons skilled in the art based on the embodiments of the present disclosure without creative efforts shall fall within the protection scope of the present disclosure.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

The prior art generally fails to provide a power supply system and method of operation which provides or results in thermal management which is either or both as effective and efficient as may be desired. Further, the prior art generally fails to provide power supply system thermal management and operation such as may more conveniently or effectively permit the use of larger-sized battery power supplies such as contemplated or envisioned for certain applications, such as to power electric vehicles, for example.

According to one non-limiting embodiment of the present invention, the present disclosure relate to an improved battery pack. The battery pack includes a plurality of cells connected in series and parallel. The battery pack can utilizes copper clad for heat distribution and maintains uniform pressure. The battery pack further includes compression support for structural support. The battery pack further includes a temperature sensor that can be attached either to cell surface or impregnated in PCM.

The present invention relate to an improved battery pack. The battery pack can include a plurality of battery stack, stack consisting plurality of battery modules containing plurality of cells connected in parallel surrounded by phase change material (PCM) by means of close fit maintaining surface contact.

According to the embodiments of the present invention provides the battery pack having each of the plurality of battery cells in contact with copper clad through copper connection, which act as heat distribution plate, wherein each of the plurality of battery cells is in contact with copper clad act as heat distribution plate exhibits a substantially uniform pressure distribution across the area of the contact and wherein each of the plurality of battery cells is in contact with copper clad act as heat distribution plate having etched track for electrical connection, wherein the clad is developed by a combination of copper plate and aluminum plate separated by insulation layer.

In an aspect, the present disclosure relate to the battery pack having the battery cell spot welded connection copper are sandwiched between two copper clad acting as a heat distribution plate as well an electrical conductor. The first copper clad plate can be in contact with plurality of the connection copper of battery module and the second copper clad plate can be in contact with plurality of the connection copper of same battery module from another side forming electrical connection.

In one aspect, the copper clad can have in plane thermal conductivity not less than 200 W/mk.

In one aspect, the PCM can have a thermal conductivity not less than 0.8 W/mk.

In one aspect, the present disclosure provides the battery pack having a plurality of compression supports which is then arranged in PCM block for structural support.

In one aspect, the present disclosure provides the battery pack having at least one support member termed which can have a positioning slot for cell holding plate and guide for position in battery box.

In one aspect, the present disclosure provides the battery pack having at least one temperature sensor attached to surface of cell or impregnated in PCM.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

As used in this specification, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure.

The prior art generally fails to provide a power supply system and method of operation which provides or results in thermal management which is either or both as effective and efficient as may be desired. Further, the prior art generally fails to provide power supply system with effective thermal management and operation such as may more conveniently or effectively permit the use of larger-sized battery power supplies such as contemplated or envisioned for certain applications, such as to power electric vehicles, for example.

In view of the limitations of the prior-art, there is a prospect to improve previously available battery packs of lithium batteries to increase the ambient temperature range at which the lithium battery pack can operates and also to provide novel battery pack with improved packaging characteristics. Similarly, there is a prospect to maintain the battery pack at the optimal operating temperature to ensure the increased life cycle, available capacity at a state, and nominal charge and discharge rates.

The most innovative, passive, cost effective and robust solution is PCM (phase change material), which is well known but not so popular in EV industry but widely used for thermal management in the pharmaceutical, food and low energy running refrigerator industries. Because of limitation in amount of energy absorption and additional weight as well as low thermal conductivity of PCM, it is not a desirable solution in high demanding application like electric vehicles. But phase change material with effective use of structural and electrical elements together can maintain uniform temperature across the battery pack preventing thermal runaway of cell by avoiding formation of hotspot and also keeping the temperature stagnant in PCM operational range for keeping battery pack in desirable temperature range.

The general object of the invention can be attained, at least in part and in accordance with one embodiment of the invention, through a lithium ion battery pack. The lithium ion battery pack includes plurality of cylindrical format cells. Each cell is surrounded by PCM material in two parts which is separated by high thermal conductive material (such as but not limited to polymer, plastic and/or metal) sheet. The cells are stacked and spot welded to copper connector plate, which is then sandwiched in between copper clad under initial compression force for effective current and heat conduction.

In one implementation, the present invention provides an improved battery pack. The battery pack includes a plurality of cells connected in parallel. The battery pack can utilizes copper clad for heat distribution and maintains uniform pressure. The battery pack further includes compression support for structural support. The battery pack further includes a temperature sensor that can be attached either to cell surface or impregnated in PCM.

In one implementation, the present invention provides an improved battery pack. The battery pack can include a plurality of battery stack, stack consisting plurality of battery modules containing plurality of cells connected in parallel surrounded by phase change material (PCM) by means of close fit maintaining surface contact.

In one implementation, the present invention provides a battery pack having the battery cell spot welded connection copper are sandwiched between two copper clad acting as a heat distribution plate. The first copper clad plate can be in contact with plurality of the connection copper of battery module and the second copper clad plate can be in contact with plurality of the connection copper of same battery module from another side forming electrical connection.

The present invention may be embodied in a variety of different structures. As representative, Figure 1 illustrates an isometric view of cell module in accordance with an embodiment of the present disclosure. Figure 1 shows a battery module having a plurality of cells 2 connected in parallel by means of spot welding to connection plate 7.

Figure 2 illustrates an isometric view of copper connection in accordance with an embodiment of the present disclosure. Figure 2 and 2(a) shows that a connection plate 7 that can be a high thermal and electrically conductive material not limited to copper or nickel or aluminum plate or various metal/nonmetal plated copper of a desired thickness preferably 0.1 to 3 mm with plurality of dimples drown on it at cell 2, 2a connection point. The connection plate 7, 7a can have one or more holes “A” for temperature sensor wiring connection.

Figure 3 illustrates an isometric view of spot-welded battery cells in accordance with an embodiment of the present disclosure. Figure 3 illustrates an array of battery module in accordance with an embodiment of the present disclosure. The cells 2 are connected with connection plate 7 in this array of battery module by means of spot welding. Referring figure 3 (a), The cells 2a are connected with connection plate 7a as shown in figure 2 (a), which doesn’t depend on the Clad for series and parallel connection of cells in this array of battery module by means of spot welding. Supporting plate 23 is supporting/holding the cells 2 a and accommodate connection plate 7 a as well as separate it from PCM 4 a in case of the conductive PCM.

Figure 4 and 4(a) explain a PCM 4 & 4a matrix having holes 41 that can accommodate cells 2 such that efficient heat transfer takes place. While assembling cells 2 in PCM 4 & 4a matrix 1, the thermal paste may or may not applied in between.

In an aspect, the PCM 4 & 4a is a form stable type which can retains its shape even after its phase change and may not leak out.

In an aspect, the PCM 4 & 4a absorb large amount of heat till melting point which is termed as latent heat.

In an aspect, the heat required to increase temperature of the PCM 4 & 4a is significantly higher at the time of melting, the temperature of the PCM 4 & 4 a remains stagnant at such high temperature till the melting occurs and hence it limits the temperature of the battery pack.

Further, relief 42 and 43 are provided in PCM 4 matrix for accommodating compression support and series and parallel connection of stacks respectively accordance with figure 4. However, referring figure 4 (a), which doesn’t require compression support relief 42.

In an aspect, the PCM matrix 4 can have slots 42 and 43 for structural clamping with compression support 5 and for connecting plurality of stacks as in Figure 5.

Figure 5 illustrates an isometric view of cell holding / supporting plate 8 showing electrical connection track for series/ parallel connection for cells and temperature sensor track in accordance with an embodiment of the present disclosure. Figure 5 shows a stack of module assembled in PCM matrix 4 having cell holding/ supporting plate 8.

In an aspect, the cell holding/ supporting plate 8 hold cells 2 together and maintain cell spacing. The cell holding plate can be connected to compression supports 5 (figure 6) in slots.

Figure 5(a) illustrates an isometric view of cell holding / supporting plate 3a is supporting/holding the cells 2 a and accommodate connection plate 7 a as well as separate it from PCM 4 a in case of the conductive PCM in accordance with an embodiment of the present disclosure. Further, a stack of module assembled in PCM matrix 4a having cell holding/ supporting plate 3a.

In an aspect, the cell holding/ supporting plate 3a hold cells 2a together and maintain cell spacing. The cell holding plate 3a sandwiches cell and PCM matrix 4 a together and provide structural support by binding the whole assembly using compression support 5a.

Figure 6 illustrates an isometric view of compression support in accordance with an embodiment of the present disclosure. Figure 6 shows a compression support having male 53 female 51 sockets on either side and mounting slot 52 to position cell supporting plate. In an aspect, a long stud runs through the compression support to hold the stacks together to form a pack. Whereas figure 6 (a) shows compression support 5a which directly fit in place of cell 2a and doesn’t require any sockets and slots. Through hole 51a is provided in compression support 5a for binding multiple stack together.

Figure 7 illustrates an isometric view of a complete stacked module in accordance with an embodiment of the present disclosure.

In an aspect, according to an experimental research work publication, due to inherent property of jellyroll type internal structure of cell, the cell can have different thermal conductivity in axial and radial direction, making axial thermal conductivity ten folds more than radial.

In an aspect, a copper clad 3 is provided in contact with cell 2 through connection plate. The heat is conducted through cell to clad through connection plate.

In an aspect, as all cells are in contact with clad 3, thereby achieving uniform temperature is achieved across the stack by making. Due to this efficient use of phase change material 4. All the heat generated from cells 2 is uniformly distributed and absorbed in phase change material 4 making battery pack operation in desired temperature zone. Whereas rreferring figure 7a shows the complete stack assembly without copper clad where connection plate 7a and cell holding / supporting plate 3a perform the functional aspect of copper clad because of bigger connection plate and thermal conductivity of cell holding/supporting plate 3a. Series connection jump 36 a is provided for series connection of multiple stacks together.

Figure 8 illustrates an isometric exploded view of complete stack in accordance with an embodiment of the present disclosure. Figure 8 shows copper clad 3 which sandwiches battery modules, having a plurality of cells 2, together to connect them again in parallel or series by means of etched track on clad.

As shown in Figure 8, a battery module includes a plurality of cells 2 connected in parallel by means of spot welding to connection plate 7.

Further, as shown in Figure 8, the battery module from top to bottom includes a top copper clad 3, the connection plate 7 is provide with plurality of dimples drown on it, a first layer of PCM 1, the cell holding/ supporting plate 8, the plurality of cells 2, a second layer of PCM 1, and a bottom copper clad 3. The stack of battery module can be assembled in PCM matrix 4 having the cell holding/ supporting plate 8.

Figure 9 shows a plurality of battery stack connected together to form a battery pack. Stack is rested over the other making male-female joint together of compression support. To maintain the uniform pressure across the copper clad compliance structure 35 is placed in between each stack. The components 36 and 37 connects stack in series and parallel. Whereas Figure 9(a) shows plurality of battery stack connected together electrically by means of series connection jump 36a and structurally by means of compression support 5a.

The present disclosure achieves best possible and reliable performance of the battery, while thermal management in such battery power supply systems.

The present disclosure provides an improved battery pack of lithium batteries to increase the ambient temperature range at which the lithium battery pack can operates.

The present disclosure provides new and improved battery packs of lithium batteries to increase the ambient temperature range at which the lithium battery pack which permit either or both more efficient and effective thermal management.

It will be appreciated by those skilled in the art that the foregoing description was in respect of preferred embodiments and that various alterations and modifications are possible within the broad scope of the appended claims without departing from the spirit of the invention with the necessary modifications.

Based on the description of disclosed embodiments, persons skilled in the art can implement or apply the present disclosure. Various modifications of the embodiments are apparent to persons skilled in the art, and general principles defined in the specification can be implemented in other embodiments without departing from the spirit or scope of the present disclosure. Therefore, the present disclosure is not limited to the embodiments in the specification but intends to cover the most extensive scope consistent with the principle and the novel features disclosed in the specification.
,CLAIMS:An improved battery pack for thermal management in battery power supply systems comprising:
a plurality of cells connected in parallel through copper connection plate to form a module;
Plurality of modules is connected in series through copper clad to form
a stack, wherein copper plate and copper clad are compressed to form series connection and allows heat transfer from said plate to clad which enable uniform temperature and contact pressure thorough out the stack;
Plurality of stack is connected to each other via a connector to form the battery pack.

2. The battery pack as claimed in claim 1, wherein the cells are of any shape /form and surrounded by phase change materials (PCM) in two parts which is separated by high thermal conductive material by means of close fit maintaining surface contact.

3. The battery pack as claimed in claim 1, wherein the phase change materials (PCM) are high thermal conductive material selected preferably from polymer, plastic and/or metal sheet.

4. The battery pack as claimed in claim 1, wherein the cells are stacked and connected to copper connector plate, which is then sandwiched in between copper clad under initial compression force for effective current and heat conduction.

5. The battery pack as claimed in claim 1, wherein the copper connection plate is plated to reduce the copper oxidation to enable reducing contact resistance between connection plate, copper clad and cell.

6. The battery pack as claimed in claim 1, wherein the stacks are connected vertically or horizontally by connecting the copper clad of one stack to copper clad of second or other stack.

7. The battery pack as claimed in claim 1, wherein plurality of stacks are structurally supported by having compression support to form the battery pack.

8. The battery pack as claimed in claim 1, wherein the clad is developed by a combination of copper plate and aluminum plate separated by insulation layer (pls confirm, if you would want this claim).

9. The battery pack as claimed in claim 8, wherein the clad has the specific shape where copper plate is etched out to form an electrical connection track.

10. The battery pack as claimed in claim 1, wherein the cells are sandwiched between the clad and said clad is providing electrical as well as mechanical support to the modules and transferring the weight to compression support.

11. The battery pack as claimed in claim 5, wherein the copper connection plate is having a protrusion which enable to maintain the distance between positive and negative terminal of cell and providing spring effect to maintain the uniform pressure between cell terminals.

12. An improved battery pack for thermal management in battery power supply systems comprising:
a plurality of cells connected through copper connection plate to form a stack, wherein copper plate is having large surface area adapted to provide series connection as well as parallel connection between the cells, wherein the cells are stacked and sandwiched in between high thermal conductive plastic tray for effective heat distribution;
plurality of stack are connected to each other via a connector to form the battery pack.

13. The battery pack as claimed in claim 12, wherein the phase change materials (PCM) may and may not electrically conductive material.

14. The battery pack as claimed in claim 12, wherein the plastic tray is providing a mechanical support to the cells and PCM and transferring the weight to dummy cells.

15. The battery pack as claimed in claim 15, wherein the plastic tray is adapted to separate electrically conductive PCM from any live connection part.

16. The battery pack as claimed in claim 12, wherein the copper connection plate is plated to reduce the copper oxidation to enable reducing contact resistance between connection plate and cell.
17. The battery pack as claimed in claim 12, wherein the stack are connected vertically or horizontally by connecting the copper connection of one stack with other stack.

18. The battery pack as claimed in claim 12, wherein the plurality of stacks are structurally supported by a dummy cell.

19. The battery pack as claimed in claim 12, wherein the copper connection plate is having a protrusion which enable to maintain the distance between positive and negative terminal of cell and providing spring effect to maintain the uniform pressure between cell terminals.