Description:FIELD OF INVENTION
The embodiments of a present disclosure relate generally to battery packs, and particularly to a Waterproofing Structure for Battery cells of a Battery pack.
BACKGROUND
With modern technological improvements, there is a need for environmentally friendly automobiles that are capable of catering to the needs of consumers. In case of such demands, there is always a possibility to use either hybrid or electric vehicles for less pollution and more convenience. In electrical vehicles battery systems are often installed to run the vehicles and efficient power distribution. The electrical battery packs are often getting disturbed by water entering the battery cells thereby causing serious damage to the battery cells as well as the entire unit.
In the conventional battery pack, an outer case of the battery pack would usually be configured with a box body, an upper cover, a battery pack, and a battery management system (BMS) These battery packs pose challenges as water might enter into the inner parts. With the aforementioned technical scheme in conventional battery packs, the structure form of the box body and the upper cover of the conventional battery box was said to be rationally arranged and reinforced but when the vehicle is ridden during heavy rainfall or in the waterlogged region, there are high chances that water enters into the battery pack and damages the electrical products. This damage leads to malfunctioning of the battery pack and may eventually result in short-circuiting of the battery cells. Moreover, it is difficult for the manufacturing company to completely seal the battery pack as there are power cables associated with the battery pack that is harnessed and connected to the other electrical components of the electric vehicle. Further, if the battery pack is completely sealed then cooling down the temperature of the battery pack becomes challenging for the manufacturing unit.
In such conventional battery packs, there is water resistant structure that offers very limited protection and poor performance is reported.
PROBLEM TO BE SOLVED BY INVENTION
In the conventional battery packs the waterproofing structure is susceptible to damping effects and water might enter into the battery packs. The vehicle’s all-weather performance is reduced and there is a risk of short circuits that blast off the sensitive electrical components when the water enters into them. There is a risk of thermal shocks when water enters into the structural component leading to the ultimate failure of the battery packs. Considering the above-mentioned failure modes, it is a primary objective of the current invention to prevent the entry of water inside the battery pack even when the vehicle passes through a waterlogged area.
It is yet another objective of the current invention to provide a battery pack that provides complete waterproofing even with the power cables harnessing out of the battery pack.
It is yet another objective of the current invention to provide a battery pack that possesses a complete waterproofing structure and can also regulate thermal transmission in order to maintain the temperature of the battery cells of the battery pack.
BRIEF DESCRIPTION OF THE INVENTION:
As per the current invention, the present invention is related to the waterproofing structure of battery cells for battery packs. In the present invention a waterproof packaging structure for a plurality of battery cells of a battery pack, the waterproof packaging structure comprises a middle plate assembly, a vertical plate, a first pair of modules, a front case assembly, a pair of centre plate assemblies, a second pair of modules, a rear case assembly, a pair of outer case assemblies, a top case assembly, and an electrical component module. The middle plate assembly comprising of at least a first pair of plates positioned at a top of the middle plate assembly and at least a second pair of plates configured as a base for the middle plate assembly. The vertical plate is configured to be sealed by a sealant at intermediary junctions of the first pair of plates and the second pair of plates wherein the vertical plates are rigidly configured to provide support to the first and the second pair of plates displaced in a perpendicular direction. The first pairs of modules are configured to hold a first plurality of battery cells, and the first pair of modules are rigidly disposed to the vertical plate of the middle plate assembly with the sealant. Moreover, the front case assembly is configured to be sealed with the sealant to the middle plate assembly and the first pair of modules, and the front case assembly is fastened with the middle plate assembly and the first pair of modules. Said pair of centre plate assemblies are configured to cover the plurality of battery cells of the first pair of modules, the pair of centre plate assemblies is further configured to be sealed at an outer portion of the first pair of modules, and the front case assembly. Also, the second pair of modules is configured to hold a second plurality of battery cells, and the second pair of modules are attached to the outer end of the pair of centre plate assemblies. The rear case assembly is configured to be sealed with the sealant to the middle plate assembly and the second pair of modules, the rear case assembly is fastened with the middle plate assembly and the second pair of modules. Further, the pair of outer case assemblies is configured to cover the second pair of modules, and the pair of outer case assemblies are sealed with the front case assembly and the rear case assembly. The top case assembly is configured to be sealed with the front case assembly, the rear case assembly, and the pair of outer case assemblies. Furthermore, the electrical component module is configured to provide a plurality of connectors for controlling a transmission of power from the battery cells of the battery pack, the electrical component module is secured by the top case assembly with a gasket. Lastly, the front case assembly, the rear case assembly, the pair of outer case assemblies, first pair of plates, the second pair of plates, the top case assembly, the sealant, and the gasket combinedly provides a rigid and waterproof covering to the plurality of battery cells of the battery pack.
As per the first embodiment of the present disclosure, the vertical plate of the waterproof packaging structure includes a plurality of holes for receiving a plurality of rods.
As per the second embodiment of the present disclosure, the waterproof packaging structure comprises a plurality of metal enclosures at the front, the bottom, and the rear end of the waterproof packaging structure connected through the fasteners to provide stiffness to the battery pack.
As per the third embodiment of the present disclosure, the sealant of the waterproof packaging structure acts as a bonding agent with a dispensing liquid, the dispensing liquid changes the phase from liquid to solid in a predetermined period.
As per the fourth embodiment of the present disclosure, the vertical plate of the waterproof packaging structure is configured to be tightly connected with the first and the second pair of plates by a first plurality of fasteners.
As per the fifth embodiment of the present disclosure. the first pair of modules of the waterproof packaging structure is tightly connected with the vertical plate by a second plurality of fasteners.
As per the sixth embodiment of the present disclosure, the front case assembly, the top case assembly, and the second pair of plates of the waterproof packaging structure comprise a predefined sealing dispensing profile on the intermediary junction of the vertical plate of the middle assembly.
As per the seventh embodiment of the present disclosure, the Front case assembly of the waterproof packaging structure is fastened with the middle plate assembly using a third plurality of fasteners.
As per the eighth embodiment of the present disclosure, the electrical component module of the waterproof packaging structure comprises one or more metal connectors disposed on one or more holes positioned on the electrical component module, the one or more metal connectors comprises an IP 67-rated Rubber Ring that gets compressed when the one or more metal connectors are configured with the electrical component module.
As per the ninth embodiment of the present disclosure, the gasket of the waterproof packaging structure is composed of a non-destructible material that can be detached to enable servicing.
As per the tenth embodiment of the present disclosure, the gasket of the waterproof packaging structure is made up of IP 67-rated PU Silicon Resin material that acts like a foam structure having a high compression ratio.
As per the eleventh embodiment of the present disclosure, the gasket of the waterproof packaging structure has an adhesive portion which is disposed on a lower part of the top case assembly.
As per the twelfth embodiment of the present disclosure, the electrical component module of the waterproof packaging structure comprises one or more IP67-rated Grommets that tightly fit with a cable assembly, the grommets are configured to seal an entrance portion of the cable assembly to the electrical component module.
As per the thirteenth embodiment of the present invention, the waterproof packaging structure complies with IP67 Standard.
As per the fourteenth embodiment of the present invention, the sealant complies with the IP67 standard.
As per the fifteenth embodiment of the present disclosure, the front case assembly and the pair of outer case assemblies of the waterproof packaging structure comprise a plurality of pressure vents for the release of pressure, the plurality of pressure vents remains closed to restrict the entrance of water inside the battery pack and only opens up to exert pressure out when extreme pressure generates inside the battery pack.
LIST OF FIGURES
The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
FIGURE 1 is a perspective view of the waterproof packaging structure for a battery pack as per the current invention.
FIGURE 2 is a rear view of the waterproof packaging structure for the battery pack as per the current invention.
FIGURE 3 is a schematic representation of the waterproof packaging structure for the battery pack in accordance with an embodiment of the current invention.
FIGURE 4 is a schematic representation of a centre plate assembly of the waterproofing packaging structure for the battery pack.
FIGURE 5 is a schematic representation of a middle plate assembly of the waterproofing structure for the battery packs.
FIGURE 6 is a schematic representation of a top case assembly of the waterproofing structure for the battery packs.
FIGURE 7 is a schematic representation of one of the second pair of plates of the waterproofing structure for the battery packs.
FIGURE 8 is a schematic representation of a front case assembly of the waterproofing structure for the battery packs.
FIGURE 9 is a schematic representation of a rear case assembly of the waterproofing structure for the battery pack.
FIGURE 10 is a schematic representation of an outer case assembly of the waterproofing structure for the battery pack.
FIGURE 11 is a top-view representation of an electrical component module for the waterproofing structure of the battery pack.
FIGURE 12 is a bottom-view representation of the electrical component module for the waterproofing structure of the battery pack.
FIGURE 13 is a schematic representation of a First pair of modules of the waterproof packaging structure of the battery pack.
FIGURE 14 is a schematic representation of one or more metal connectors of the waterproof packaging structure of the battery pack.
Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION OF THE INVENTION
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
The terms “comprises”, "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a'' does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
Embodiments of the present invention will be described below in detail with reference to the accompanying figures.
FIGURE 1 shows a perspective view of a waterproof packaging structure (10) for a battery pack as per the current invention. The figure illustrates the assembled battery pack connected with a cable assembly (112). The figure also illustrates a pair of outer case assemblies (106), a front case assembly (103) and a top case assembly (108) are interconnected with each other with a plurality of fasteners.
FIGURE 2 illustrates a rear view of the waterproof packaging structure (10) for the battery pack as per the current invention. The figure illustrates a rear case assembly (105), the top case assembly (108), and a pair of outer case assemblies (106) are interconnected with each other with a plurality of fasteners.
FIGURE 3 illustrates a schematic representation of the waterproof packaging structure (10) for the battery pack in accordance with an embodiment of the current invention. The figure illustrates an exploded view of the waterproof battery pack. The figure represents a vertical plate (1013) of a middle plate assembly (101) covered by a first pair of plates (1011) and a second pair of plates (1012) coupled on the opposite ends of the vertical plate (1013). The first pair of plates (1011) and the second pair of plates (1012) includes a plurality of fasteners that keep the pair of plates intact. Moreover, the figure represents a first pair of modules (1021) connected to the middle plate assembly (101) with a plurality of fasteners wherein the first pair of modules (1021) is covered on the front side by the front case assembly (103) and a pair of centre plate assemblies (104) on the sideways of the first pair of modules (1021). Thereafter, a second pair of modules (1022) are coupled to the pair of centre plate assemblies (104). The second pair of modules (1022) are covered by a pair of outer case assemblies (106). Moreover, the top and bottom portion of the battery pack is sealed with the top case assembly (108) and the second pair of plates (1012). Over the top case assembly (108) comprises an electrical component module (109) that includes a plurality of connectors for controlling and monitoring the transmission of power and the health of the battery cells. The electrical component module (109) also comprises connectors (1091) coupled with the cable assembly (112) that are confgured to be connected to a load. Further, the figure illustrates a gasket (1092) provided in between the top case assembly (108) and the electrical component module (109) that provides a waterproofing layer and prevents the entrance of water inside the battery pack. Furthermore, the figure also represents the rear case assembly (105) coupled to the pair of outer case assemblies (106), the top case assembly (108), and the second pair of plates (1012) by a plurality of fasteners.
FIGURE 4 illustrates the vertical plate (1013) of the middle plate assembly (101) for the waterproof packaging structure (10) of the battery cells of the battery pack. The vertical plate (1013) comprises a plurality of holes (110) through which a plurality of rods (1101) passes for fastening the first and second pair of modules (1022) with the pair of the centre plate assemblies (104) and the middle plate assembly (101). Moreover, the vertical plate (1013) also comprises a plurality of openings for coupling the vertical plate (1013) with the first pair of plates (1011) and second pair of plates (1012). Also, the vertical plate (1013) includes a plurality of apertures that connects the vertical plate (1013) with the front case assembly (103) and the rear case assembly (105).
FIGURE 5 illustrates the middle plate assembly (101) of the waterproof packaging structure (10) of battery cells of battery packs. The figure illustrates the first pair of plates (1011), and the second pair of plates (1012) are coupled to the vertical plate (1013) of the middle assembly with a plurality of fasteners. Moreover, the top and bottom portion of the vertical plate (1013) acts as a sandwich between the plurality of plates of the first pair and the second pair.
FIGURE 6 illustrates the top case assembly (108) of the waterproof packaging structure (10) of battery cells of battery packs. The figure illustrates that the top case assembly (108) includes a plurality of openings for the passing of the cable assembly (112) that provides an electrical connection between the battery modules and the electrical component module (109).
FIGURE 7 illustrates the second pair of plates (1012) of the waterproof packaging structure (10) of battery cells of battery packs. The second pair of plate (1012) acts as a supporting structure for the battery pack. Moreover, the plates of the second pair of plates (1012) are interconnected with each other through a plurality of fasteners.
FIGURE 8 illustrates the front case assembly (103) of the waterproof packaging structure (10) of battery cells of battery packs. The front case assembly (103) includes one or more pressure vents (113) that release the pressure generated inside the battery pack. Moreover, the front case assembly (103) comprises a plurality of fins that assist in the transmission of heat generated inside the battery pack. Further, the front case assembly (103) is coupled with the middle plate assembly (101), the pair of outer case assemblies (106) with a plurality of fasteners, and sealed with an IP67-rated sealant.
FIGURE 9 illustrates the rear case assembly (105) of the waterproof packaging structure (10) of the battery cells of the battery pack. The rear case assembly (105) may comprise one or more plates that are coupled and sealed with each other through sealant and fasteners. Moreover, the rear case assembly (105) is coupled to the top case assembly (108), the middle plate assembly (101), and the pair of outer case assemblies (106) by a plurality of fasteners and are sealed with the sealant.
FIGURE 10 illustrates the pair of outer case assemblies (106) from the pair of outer case assemblies (106) as a part of the waterproof packaging structure (10) of the battery cells of the battery pack. Similar to the front case assembly (103), the pair of the outer case assemblies (106) may also include one or more pressure vents (113). The pair of outer case assemblies (106) may also include a plurality of fins for transmitting the heat out of the battery pack. Moreover, the pair of the outer case assemblies (106) is coupled to the top case assembly (108), the first pair of plates (1011), the second pair of plates (1012), the front case assembly (103), and the rear case assembly (105) through a plurality of fixtures and are sealed with each other through an IP67-rated sealant.
FIGURE 11 illustrates a top view of the electrical component module (109) of the waterproof packaging structure (10) of battery cells of the battery pack. The electrical component module (109) includes the cable assembly (112) connected to the electrical component module (109) through one or more grommets (111). Moreover, the electrical component module (109) includes one or more metal connectors (1095) that are detachable and can be removed for repairing or servicing the different components of the module. The electrical component module (109) also includes a plurality of fins for the transmission of heat out of the module.
FIGURE 12 illustrates a bottom view of the electrical component module (109) of the waterproof packaging structure (10) of the battery cells of the battery pack. The bottom view of the electrical component module (109) illustrates the gasket (1092) present on the border area of the electrical component module (109) that gets compressed when pressed and fills the gap between the electrical component module (109) and the top case assembly (108) to prevent the entrance of water inside the battery pack.
FIGURE 13 illustrates the first pair of modules (1021) of the waterproof packaging structure (10) of the battery cells of the battery pack. The first pair of modules (1021) includes one or more cell holders wherein each holder accommodates a plurality of battery cells. The first payer of the module may also include a Metal Clad Printed Circuit Board (MCPCB) with interconnected tabs that assist in the connection of the plurality of battery cells and final output power is obtained from a predetermined point of the MCPCB. Moreover, the second pair of modules (1022) may be similar in configuration to the first pair of modules (1021). The number of battery cells present in the second pair of modules (1022) may differ from the number of battery cells present in the first pair of modules (1021).
FIGURE 14 illustrates a metal connector (1095) of the electrical component module (109) of the battery pack. The bottom portion of the metal connector (1095) may include a threaded portion that assists the metal connector (1095) in easily connecting it with the opening located on the electrical component module (109). The metal connector (1095) further includes a rubber ring (1094) encircled around the tapered portion of the metal connector (1095).
The waterproof packaging structure(10) is disclosed in the present invention for a plurality of battery cells of a battery pack, the waterproof packaging structure(10) comprises the middle plate assembly (101), the vertical plate (1013), the first pair of modules (1021), the front case assembly (103), the pair of centre plate assemblies (104), the second pair of modules (1022), the rear case assembly (105), the pair of outer case assemblies (106), the top case assembly (108), the electrical component module (109). A middle plate (101) assembly comprising of at least the first pair of plates (1011) positioned at a top of the middle plate assembly (101) and the middle plate assembly (101) also includes at least the second pair of plates (1012) configured as a base for the middle plate assembly (101). The vertical plate (1013) is configured to be sealed by a sealant at an intermediary junction of the first pair of plates (1011) and the second pair of plates (1012). The vertical plates (1013) are rigidly configured to provide support to the first pair of plates (1011) and the second pair of plates(1012) displaced in a perpendicular direction. The first pairs of modules (1021) are configured to hold a first plurality of battery cells (1023), and the first pair of modules (1021) are rigidly disposed to the vertical plate (1013)of the middle plate assembly (101) assembly with the sealant. The front case assembly (103) is configured to be sealed with the sealant to the middle plate assembly (101) and the first pair of modules (1021). Other than this, the front case assembly (103) is fastened with the middle plate assembly(101) and the first pair of modules(1021). Moreover, the pair of centre plate assemblies (104) covers the plurality of battery cells of the first pair of modules (1021) and is configured to be sealed with an outer portion of the first pair of modules(1021) and the front case assembly(103). The pair of centre plate assemblies (104) are sandwiched between the first pair of modules (1021) and the second pair of modules (1022). Said second Pair of modules (1022) is configured to hold a second plurality of battery cells (1024) wherein the second pair of modules (1022) is attached to an outer end of the pair of centre plate assemblies (104). Thereafter, the rear case assembly (105) is configured to be sealed with the sealant to the middle plate assembly (101) and the second pair of modules (1022), the rear case assembly (105) is fastened with the middle plate assembly and the second pair of modules (1022). The pair of outer case assemblies (106), as previously mentioned, is configured to cover the second pair of modules (1022), the pair of outer case assemblies (106) is sealed with the front case assembly (103) and the rear case assembly (105). Further, the second pair of plate (1012)s are configured to cover the base of the battery pack wherein the second pair of plates (1012) are sealed with the pair of outer case assemblies (106), the front case assembly (103), and the rear case assembly (105). The top case assembly (108) is configured to be sealed with the front case assembly (103), the rear case assembly (105), and the pair of outer case assemblies (106). Furthermore, the electrical component module (109) is configured to provide a plurality of connectors for controlling the transmission of power from the battery cells of the battery pack, and the electrical component module (109) is attached to the top case assembly (108) by a gasket (1092). The front case assembly (103), the rear case assembly (105), the pair of outer case assemblies (106), the first pair of plates (1011), the second pair of plates (1012), the top case assembly (108), the sealant, and the gasket (1092) combinedly provides a rigid and waterproof covering to the plurality of battery cells of the battery pack.
As per the first embodiment of the present invention, the vertical plate (1013) of the middle plate assembly (101) includes a plurality of holes (110). The plurality of holes (110) is provided to pass through the plurality of rods (1101) that are to be fastened on both ends of the rods (1101) to keep the battery pack intact. Moreover, the plurality of rods (1101) may be fastened with nuts and bolts. In another embodiment, the plurality of rods (1101) may have a threaded body that requires only nuts to tighten directly to the rods (1101) and makes the different modules of the battery pack hold close to each other.
As per the second embodiment of the present invention, the waterproof packaging structure (10) comprises a plurality of metal enclosures at the front, the bottom, and the rear end of the waterproof packaging structure (10) connected through the fasteners to provide stiffness to the battery pack.
As per the third embodiment of the present invention, except for the connection between the top case assembly (108) and the electrical component module (109), all the other modules as disclosed in the invention are sealed to each other by the sealant wherein the sealant is a bonding agent with a dispensing liquid. Initially, in the liquid phase of the dispensing liquid, it is applied to the modules, and the modules are suitably connected. The modules are tightly held and pressurized with one or a plurality of fasteners. After a predetermined period of time, the liquid changes its phase to solid and provides a waterproof bond between the different modules.
As per the fourth embodiment of the present invention, the vertical plate (1013) of the middle plate assembly (101) is connected to the first pair of plates (1011) and the second pair of plates (1012) of the same middle plate assembly (101) by the first plurality of fasteners (1014). In another embodiment, the pair of plates of the first pair and/or the pair of plates of the second pair are connected with another plurality of fasteners.
As per the fifth embodiment of the present invention, the first pair of modules (1021) are tightly held close to the vertical plate (1013) of the middle plate assembly (101) by a second plurality of fasteners (1015).
As per the sixth embodiment of the present invention, the front case assembly (103), the top case assembly (108), and the second pair of plates (1012) comprise a predefined sealing dispensing profile on the intermediary junctions of the vertical plate (1013) of the middle plate assembly (101). the sealing dispensing profile is filled with the sealant to seal the gap between the modules.
As per the seventh embodiment of the present invention, the front case assembly (103) is fastened with the middle plate assembly (101) by a third plurality of fasteners (1031).
As per the eighth embodiment of the present invention, the electrical component module (109) of the battery pack comprises one or more metal connectors (1095) disposed on the electrical component module (109). The one or more metal connectors (1095) include the rubber ring (1094) wherein the rubber ring (1094) complies with the IP 67 standard. When the one or more metal connectors (1095) is detachably threaded to one or more holes (1093) positioned on the electrical components, the rubber ring (1094) gets compressed and fills the gap between the metal connector (1095) and the hole (1093) to prevent any entry of water or any liquid material. Said one or more metal connectors (1095) are detached at the time of repairing or servicing of the electrical connections of the electrical component module (109).
As per the ninth embodiment of the present invention, the gasket (1092) provided between the electrical component module (109) and the top case assembly (108) is composed of a non-destructible material and is detachable at the time of servicing or repair.
As per the tenth embodiment of the present invention, the gasket (1092) is prepared from IP67-rated PU Silicon Resin material. Said gasket (1092) acts as a foam-like structure comprising a high compression ratio.
As per the eleventh embodiment of the present invention, at least one side of the gasket (1092) has an adhesive portion. The adhesive side of the gasket (1092) is disposed of on the lower part of the top case assembly (108). The gasket (1092) is adhesively attached to the boundary portion of the top case assembly (108) and while fixing the electrical component module (109) the gasket (1092) gets compressed and fills the gap between the top case assembly (108) and the electrical component module (109).
As per the twelfth embodiment of the present invention, the electrical component module (109) comprises one or more IP67-rated grommets (111) that tightly fit with the cable assembly (112). The grommets (111) are configured to seal an entrance portion of the cable assembly (112) to the electrical component module (109). Moreover, the grommets (111) may be composed of synthetic rubber material and possess a flexible conjunction point for the entrance of the cable assembly (112).
As per the thirteenth embodiment of the present invention, the waterproof packaging structure (10) as disclosed in the current invention complies with the IP 67 standard. The standard indicates that the packaging structure (10) is waterproof and provides ingress protection to the battery pack.
As per the fourteenth embodiment of the present invention, the sealant used for sealing the different modules of the battery pack also complies with the IP 67 standard. The sealant provides a waterproof layer that prevents the entry of moisture and water.
As per the fifteenth embodiment of the present invention, the front case assembly (103) and the pair of outer case assemblies (106) comprise one or more pressure vents (113) for the release of pressure generated inside the battery pack. One or more of pressure vents (113) normally remains closed to restrict the entrance of water inside the battery pack and when the amount of pressure generated inside the battery pack surpasses a predetermined threshold then the pressure vents (113) automatically open due to huge pressure exerted on the one or more pressure vents (113) and the pressure vents (113) releases the generated pressure. As soon as the pressure inside the waterproof packaging structure (10) is reduced to a predetermined level the one or more pressure vents (113) get closed.
The IP code, also known as the Ingress Protection code is defined by the International Electrotechnical Commission (IEC) under the International Standard IEC 60529 that classifies and provides a guideline to the degree of protection provided by mechanical casings and electrical enclosures against intrusion, dust, accidental contact, and water. The code IP67 is a rating of a product that indicates that the product is waterproof. The numerical digit 6 of IP67 indicates complete protection against dust over an extended time as well as it also indicates protection against contact with objects greater than 1mm in diameter. On the other hand, the numerical digit 7 indicates that the product is protected against short periods of immersion in water while under pressure between 15cm and 1 meter.
While specific language has been used to describe the invention, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
FURTHER ADVANTAGES OF THE INVENTION
So, the current invention provides a solution for the technical problem mentioned in the present invention. The solution provided by the present invention prevents the entry of water inside the battery pack even when the vehicle passes through a waterlogged area. Subsequently, the present invention also provides a complete waterproofing of the battery pack with power cables or cable assembly (112) harnessing out of the battery pack and sealing the entrance point of the cable assembly (112) that prevents the entrance of water. Except the connection between the electrical component module (109) and the top case assembly (108), the connections between all the modules are provided with IP67-rated sealant that provides the waterproof layer for the battery pack. Moreover, the waterproof packaging structure (10) as disclosed by the present invention comprises one or more pressure vents (113) that exert the generated pressure of the battery pack and helps in the regulation of thermal transmission and maintains the temperature of the battery cells of the battery pack. Additionally, the waterproof packaging structure (10) also provides an electrical component module (109) for the connection of battery cells with electrical connectors and electrical modules that controls and monitors the transmission of energy of the battery cells. The gap between the electrical component module (109) and the top case assembly (108) comprises an IP67-rated gasket (1092) that prevents entry of water inside, as a result, a complete waterproof packaging structure (10) is provided with provision for electrical transmission and cable assembly (112) for monitoring and control of power. Other than this, the rubber ring (1094) present on the one or more metal connectors (1095) present on the electrical component module (109) gets compressed when the one or more metal connector (1095) is threaded on the respective hole (1093) and fills the gap between the metal connector (1095) and the hole (1093) of the electrical component module, as a result, prevents the entry of water inside the waterproof packaging structure (10).
Moreover, the waterproof packaging structure (10) of the battery pack as disclosed in the present invention is easy to assemble and also to dismantle. In a situation of repairing or servicing wherein the waterproof packaging structure (10) has to be dismantled then the plurality of fasteners can be easily removed by unscrewing the fasteners and the sealed layer between the modules is be broken or tampered with by hammering the waterproof packaging structure (10). Once the sealed layer is broken or tampered then the multiple modules can be separated and servicing and repair are done. Thereafter, once the repairing or servicing has been completed then the designated modules can be consolidated and fixed with each other modules using the IP67 sealant and fasteners.

REFERENCE
S. No. Name Reference Numerals
1 Waterproof packaging structure 10
2 First plurality of battery cells 1023
3 Second plurality of battery cells 1024
4 Middle plate 101
5 First pair of plates 1011
6 Second pair of plates 1012
7 Vertical plate 1013
8 First pair of modules 1021
9 Second pair of modules 1022
10 Front case assembly 103
11 Centre plate assembly 104
12 Rear case assembly 105
13 Outer case assembly 106
14 Top case assembly 108
15 Electrical component module 109
16 Connector in electrical module 1091
17 Gasket 1092
18 Holes for rods 110
19 Rod 1101
20 First plurality of fasteners 1014
21 Second plurality of fasteners 1015
22 Metal Connectors 1095
23 Third plurality of fasteners 1031
24 Holes in electrical modules 1093
25 Rubber ring 1094
26 Grommets 111
27 Cable assembly 112
28 Pressure Vents 113
, Claims:CLAIMS
We claim:
1. A waterproof packaging structure (10) for a plurality of battery cells of a battery pack, the waterproof packaging structure (10) comprises:
a middle plate assembly (101) comprising of
at least a first pair of plates (1011) positioned at a top of the middle plate assembly (101),
at least a second pair of plates (1012) configured as a base for the middle plate assembly (101),
a vertical plate (1013) configured to be sealed by a sealant at intermediary junctions of the first and the second pair of plates (1012), wherein the vertical plate (1013) are rigidly configured to provide support to the first and the second pair of plates (1012) displaced in a perpendicular direction,
a first pair of modules (1021) configured to hold a first plurality of battery cells (1023), the first pair of modules (1021) are rigidly disposed to the vertical plate (1013) of the middle plate assembly (101) with the sealant,
a front case assembly (103) configured to be sealed with the sealant to the middle plate assembly (101) and the first pair of modules (1021), the front case assembly (103) is fastened with the middle plate assembly (101) and the first pair of modules (1021),
a pair of centre plate assemblies (104) to cover the plurality of battery cells of the first pair of modules (1021), the pair of centre plate assemblies (104) is configured to be sealed at an outer portion of the first pair of modules (1021) and the front case assembly (103),
a second Pair of modules (1022) configured to hold a second plurality of battery cells (1024), the second pair of modules (1022) are attached to the outer end of the pair of the centre plate assemblies (104),
a rear case assembly (105) configured to be sealed with the sealant to the middle plate assembly (101) and the second pair of modules (1022), the rear case assembly (105) is fastened with the middle plate assembly and the second pair of modules (1022),
a pair of outer case assemblies (106) configured to cover the second pair of modules (1022), the pair of outer case assemblies (106) are sealed with the front case assembly (103) and the rear case assembly (105),
a top case assembly (108) configured to be sealed with the front case assembly (103), the rear case assembly (105) and the pair of outer case assemblies (106),
an electrical component module (109) configured to provide a plurality of connectors for controlling a transmission of power from the battery cells of the battery pack, the electrical component module (109) is attached to the top case assembly (108) by a gasket (1092),
wherein
the front case assembly (103), the rear case assembly (105), the pair of outer case assemblies (106), the first pair of plates (1011), the second pair of plates (1012), the top case assembly (108), the sealant, and the gasket (1092) combinedly provides a rigid and waterproof covering to the plurality of battery cells of the battery pack.
2. The waterproof packaging structure (10) as claimed in claim 1, wherein the vertical plate (1013) includes a plurality of holes (110) for receiving a plurality of rods (1101).
3. The waterproof packaging structure (10) as claimed in claim 1, comprises a plurality of metal enclosures at a front, a bottom and a rear end of the waterproof packaging structure (10) connected through the fasteners to provide stiffness to the battery pack.
4. The waterproof packaging structure (10) as claimed in claim 1, wherein the sealant acts as a bonding agent with a dispensing liquid, the dispensing liquid changes the phase from liquid to solid in a predetermined period of time.
5. The waterproof packaging structure (10) as claimed in claim 1, wherein the vertical plate (1013) is configured to be tightly connected with the first pair of plates (1011) and the second pair of plates (1012) by a first plurality of fasteners (1014).
6. The waterproof packaging structure (10) as claimed in claim 1, wherein the first pair of modules (1021) are tightly connected with the vertical plate (1013) by a second plurality of fasteners (1015).
7. The waterproof packaging structure (10) as claimed in claim 1, wherein the front case assembly (103), the top case assembly (108) and the second pair of plates comprises a predefined sealing dispensing profile on the intermediary junction of the vertical plate (1013) of the middle plate assembly.
8. The waterproof packaging structure (10) as claimed in claim 1, the front case assembly (103) is fastened with the middle plate assembly (101) using a third plurality of fasteners (1031).
9. The waterproof packaging structure (10) as claimed in claim 1, the electrical component module (109) comprises one or more metal connectors (1095) disposed on one or more holes (1093) positioned on the electrical component module (109), the one or more metal connectors (1095) comprises an IP 67-rated rubber ring (1094) that gets compressed when the one or more metal connectors (1095) are configured with the electrical component module (109).
10. The waterproof packaging structure (10) as claimed in claim 1, wherein the gasket (1092) is composed of a non-destructible material that can be detached to enable servicing.
11. The waterproof packaging structure (10) as claimed in claim 1, wherein the gasket (1092) is made up of IP 67-rated PU Silicon Resin material that acts like a foam structure that has a high compression ratio.
12. The waterproof packaging structure (10) as claimed in claim 1, wherein the gasket (1092) has an adhesive portion which is disposed on an lower part of the top case assembly (108).
13. The waterproof packaging structure (10) as claimed in claim 1, wherein the electrical component module (109) comprises one or more IP67-rated grommets (111) that tightly fit with a cable assembly (112), the grommets (111) are configured to seal an entrance portion of the cable assembly (112) to the electrical component module (109).
14. The waterproof packaging structure (10) as claimed in claim 1, wherein the waterproof packaging structure (10) complies with IP67 standard.
15. The waterproof packaging structure (10) as claimed in claim 1, the sealant complies with the IP67 standard.
16. The waterproof packaging structure (10) as claimed in claim 1, wherein the front case assembly (103) and the pair of outer case assemblies (106) comprise a one or more of pressure vents (113) for release of a pressure, the one or more pressure vents (113) remains closed to restrict the entrance of water inside the battery pack and only opens up to exert pressure out when extreme pressure generates inside the battery pack.

Dated this the 10th day of September 2024