Battery pack housing having overmoulded bus bar

Abstract

Present invention relates to a battery pack (200) for electric vehicle. The battery pack comprises: a battery module and a housing (202) having a contoured shape defining an opening (204) to face a battery management system (BMS) module 5 (212), wherein a first and a second bus bar (206, 208) having a predetermined length and a predetermined thickness are over-moulded within the housing, wherein each of the bus bars comprises a respective first terminal portion (206a, 208a) emanating at the opening and a second terminal portion (206b, 208b) emanating outside the housing. The terminal portions of the bus bars enable the 10 establishment of electrical connections between the battery pack and various external electrical components, ensuring reliable and secure connections while simplifying the assembly process.

Description

BATTERY PACK HOUSING HAVING OVER-MOULDED BUS BARTECHNICAL FIELD

[0001] The present subject matter pertains, in general, to a battery pack, and more specifically, to a battery pack housing having over-moulded bus bars facilitating electrical connections.BACKGROUND

[0002] Electric vehicle (EV) battery packs are crucial components that provide the necessary power for electric vehicles. The battery packs consist of multiple individual battery modules. Each module consists of multiple battery cells connected in series and / or parallel retained in a mechanical structure. A battery pack is assembled by connecting multiple modules together in series and / or parallel configurations to achieve the required voltage and capacity along with other components such as sensors and controllers including battery management systems and thermal management systems. These battery packs are often housed within a protecting housing made up of rigid and electrically non-conductive material such as resin or reinforced plastic composites, which serves to safeguard the battery cells and other internal components of the battery pack from potential impacts, vibrations and external forces that can jeopardize its performance and structural integrity.

[0003] The housing typically incorporates holes or ports provided for accommodating the high voltage terminals (positive and negative) of the battery pack. These terminals are responsible for transmitting power between the battery pack and various external electrical components of the vehicle. The external electrical components of the vehicle include, but may not be limited to, a charger port and a motor control unit (MCU).

[0004] In the conventional approaches, to enable electrical connections between the battery pack and the external electrical components, connector components are commonly used as the interface for the positive and negative terminals. The connector components particularly consist of male and female counterparts designed to fit together securely when connected, enabling secure electricalconnections between the battery pack and the external electrical components of the vehicle. In a few other approaches, cables secured within the glands typically sealed using rubber grommet or compression nuts are used for providing positive and negative electrical connections.BRIEF DESCRIPTION OF DRAWINGS

[0005] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears.

[0006] Figure 1 illustrates a conventional battery pack housing incorporating cable glands for establishing electrical connections between the battery pack and the external electrical components.

[0007] Figure 2 illustrates a battery pack, particularly, a battery pack housing, in accordance with an example of the present subject matter.

[0008] Figure 3 illustrates a perspective inside-view of the battery pack illustrated in figure 2, in accordance with an example of the present subject matter.

[0009] Figure 4 illustrates a perspective top inclined view of a battery management system (BMS) module provided in the battery pack illustrated in figures 2-3, in accordance with an example of the present subject matter.

[0010] Figure 5 illustrates a perspective view of one side electrical coupling of the BMS module illustrated in figure 4 provided in the battery pack illustrated in figures 2-3, in accordance with an example of the present subject matter.

[0011] Figure 6 illustrates a perspective top inclined and comprehensive view of the battery pack illustrate in figures 2-3, particularly, the other side electrical coupling of the BMS module illustrated in figure 4, in accordance with an example of the present subject matter.

[0012] The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Moreover, the drawings provide examples and / or implementations consistent with the description; however, the description is not limited to the examples and / or implementations provided in the drawings.DETAILED DESCRIPTION

[0013] As previously mentioned, in the conventional approach, connectors or fasteners are provided as interfaces for positive and negative terminals of the battery pack. Typically, these terminals are provided as male connector interfaces, characterized by the presence of pins or prongs. To establish electrical connections, cables terminated with female connecter interfaces are used. These female connectors are equipped with receptacles that align precisely with the pins or prongs of the male connectors when connected. It is to be noted here that the specific assignment of male and female connectors to the terminals of the battery pack and the cable ends may vary depending on the implementation. In other words, in a few of the systems, the terminals may be provided as female connectors and the cable ends may be designed as male connectors. However, the fundamental principle of using connectors (male and female counterparts) for establishing an electrical connection between the terminals of the battery pack and the cables ends connecting the said terminals to the external electrical components remains the same.

[0014] While the connectors are predominantly exploited for establishing electrical connections, they possess several inherent limitations. Firstly, over a period of time, a poor contact may occur between the male and female connectors due to various factors including connector design flaws, surface irregularities, temperature extremes, chemical exposure, moisture or contaminants such as dirt, debris or corrosion on the connecter surfaces. This can result in intermittent connections, voltage drops, increased resistance, compromised sealing, resulting in an unreliable electrical connection adversely impacting the performance of the various electrical components that rely on the power sourced from the battery pack for their functioning. Secondly, the connectors may experience mechanical instability, such as loose connections or accidental disconnections / dislodging due to vibrations, movement or external forces for which they are easily susceptible to, disrupting the flow of power on an intended path.

[0015] In addition to the above, when establishing electrical connections between the battery pack and multiple electrical components, the numerous wirescan result in cable clutter, cable entanglement, difficulty in identification and routing, increased time of installation and increased chances of misconnection.

[0016] Although, a few of these limitations are addressed by using various other fastening means such as cable glands and wire retaining clips. These solutions result in various other limitations such as improper installation and inferior quality of cable glands may compromise with the sealing or securing the cable in its place readily subjecting them to dust, moisture or other environmental factors. In a few of the cases, the improper torque applied to the cable gland may cause damage to the wires or create points of weakness in the harness leading to short circuits. While IP67 cable glands offer significant advantages in terms of protection and durability, they have a higher upfront cost. Further, the wire retaining clips may fail to properly accommodate the cables if they are of different sizes, resulting in multiple retaining clips being used, adding additional bulk to the wire harness.

[0017] To this end, the present subject matter discloses a battery pack, particularly, a battery pack housing having over-moulded bus bars facilitating electrical connections between the battery pack and various electrical components, ensuring reliable and secure connections while simplifying the assembly process.

[0018] As is commonly known, the battery pack may include a battery module comprising a plurality of battery cells. The battery cells may be electrically connected in series and / or parallel configurations for achieving the required voltage and capacity. In the event that there are more than one battery modules, the modules may be meticulously stacked or connected in series or parallel arrangements to constitute a battery pack. The battery module may be connected to a BMS module alternatively referred as battery management unit, a battery management device, and the like. As is known, the main functions of BMS module include monitoring battery voltage, current, temperature, etc., estimating battery SOC (State of Charge), SOH ( State of Health, SOE (State of Energy), SOP (State of Power), RM (Remaining Mileage), battery balancing management, battery thermal management, protection and diagnostics based on the real-time data provided by various sensors such as, but may not be limited to, temperature, current and / or voltage deployed in the battery pack.

[0019] The batery module connected to the BMS module along with the other components / modules such as thermal management system consisting of cooling elements (active or passive) deployed for managing heat generated while charging or discharging of battery cells and sensors are securely housed within a protective housing. The housing is generally made up of a resin or reinforced plastic composites. To optimize space utilization, thermal cooling and weight distribution, the shape of the battery pack housing may vary. A few of the possible shapes may include, but may not be limited to rectangular, T-shaped, L-shaped, curved, trapezoidal.

[0020] In an example, the present subject matter discloses a battery pack. The battery pack may include a housing having a contoured shape to accommodate a battery module. As mentioned earlier, the battery module may include a plurality of individual batery cells electrically connected in series and / or parallel configurations. In an example, the batery pack housing may include a first subhousing component and a second sub-housing component. These components when combined through coupling means may constitute the batery pack housing and may further define an opening to face a battery management system (BMS module) allowing access to the BMS module. It may be noted that the battery pack illustrated herein is curve shaped. However, as mentioned previously, other shapes are also possible without deviating from the scope of the present subject mater.

[0021] Further, the battery pack may include a first and a second bus bar having a predetermined length and a predetermined thickness. The bus bars may be overmoulded within the housing. In an example, the bus bars may be over-moulded in a manner that each of the sub-housing components of the housing may include one bus bar. Each of the bus bars may comprise a respective first terminal portion emanating at the opening and a second terminal portion emanating outside the housing. The first terminal portions of the bus bars may be electrically and mechanically coupled to a first side of the BMS module. A second side of the BMS module may be electrically and mechanically coupled to the battery module. The BMS module may be held thereby in a suspended position. The second side of the BMS module may be present opposite to the first side. Further, the second terminalportions of the bus bars may be electrically and mechanically coupled to one or more external electrical components such as but may not be limited to, a charger port and a motor control unit (MCU). In this way, the bus bars over-moulded in the battery pack housing facilitate electrical connection between the battery pack and the external electrical components of the electric vehicle.

[0022] It may be noted that, to obtain the over-moulded bus bars, any of the known process technologies such as but may not limited to injection-moulding or resin transfer moulding may be used. These over-moulding processes allow material to flow over and around the metal bus bars, while leaving ends of the bus bars accessible (i.e., uncovered) at the terminal portions.

[0023] Typically, the bus bars may be high voltage bus bars over-moulded such that each of the bus bars has the thickness oriented in direction of thickness of the housing and the length oriented perpendicular to the thickness of the housing. Each of the bus bars is bent inward at multiple regions to align with the contoured shape of said housing. The bus bars are spaced apart at a predetermined distance, where one of the bus bars is of a first polarity configured for conducting electric current and the other is of a second polarity configured for conducting electric current. In an example, the terminal portions of the bus bars are flat surfaces devoid of the electrically non-conductive material such as but may not be limited to, resin or reinforced plastic composites, the housing is made from, providing an electrically conductive surface. The terminal portions may feature at least one aperture for facilitating the electrical coupling.

[0024] The battery pack in an example may include visual indicators for identifying the polarities (positive and negative) of the bus bars.

[0025] In another example, the present subject matter discloses a stacked BMS module. The stacked BMS module may include split BMS units vertically stacked together to monitor and manage the battery modules thereby the battery cells within the battery pack when deployed therein. Further, the stacked BMS module may include a first side and a second side formed on a top surface of an upper stack of the stacked BMS module, The second side is present opposite to the first side. Each side may include two mounting lugs extending upwardly from the top surface. Themounting lugs may be oppositely arranged near comers of the top surface. Each of these mounting lugs may be provided with a metal threaded hole. Particularly, the mounting lugs formed on the first side of the BMS module that may be placed proximal to the first terminal portions of the bus bars may be formed such that the aperture formed on the first terminal portions of each of the bus bars precisely aligns with the corresponding metal threaded hole of the mounting lugs. In other words, the predetermined distance between the bus bars may be equal to or corresponds to the separation between the mounting lugs proximal to the bus bars. The separation between the remaining mounting lugs formed on the second side of the BMS module near the comers may or may not be same.

[0026] In another example, mounting of the BMS module, resulting in a suspended position of the BMS module is illustrated. The BMS module may be detachably fastened to the first terminal portions of the bus bars through fastening means, where the fastening means includes complementary mounting metal screws and metal washers, where the mounting metal screw passing through the metal washer and the aperture on the first terminal portion may be screwed into the corresponding metal threaded hole of the mounting lugs formed on the first side of the BMS module placed proximal to the terminal portions of the bus bars for securing the BMS module. This fastening results in mechanical and electrical coupling of the BMS module to the first terminal portions of the bus bars.

[0027] The second side of the BMS module may be electrically and mechanically coupled to the battery module using the two mounting lugs formed on the second side of the BMS module using any of the known fastening means. The known fastening means may include additional bus bars symmetrical or asymmetrical in shape mounted on said mounting lugs, such that the aperture provided on one end of these bus bars aligns with the corresponding metal threaded holes provided on said mounting lugs, and a metal screw passing through a metal washer is screwed into the metal threaded hole, securing the mounting lugs thereby the other side of the BMS module. The other end of the bus bars provided with apertures may be electrically and mechanically fastened to the battery module usingany of the known fastening mechanisms, for example, metal press nuts and bolts may be used to secure the bus bars in their place.

[0028] This way, the first and second side of the BMS module may be electrically and mechanically coupled to the first terminal portions of the bus bars and the battery module, respectively, retaining the BMS module in a suspended position.

[0029] Mounting or suspending the BMS module in the manner described above affords a several advantages such as enhanced thermal management and improved performance i.e., the BMS module is less likely to obstruct airflow, allowing for better ventilation and heat dissipation. Further, the compact arrangement of the BMS module provides some free space within the battery pack and this free space may be utilized for accommodating other components or additional battery cells. Furthermore, as the bus bars provide low resistance pathways for power flow, this minimizes power losses, resulting in an accurate monitoring and control of the battery cells by the BMS module.

[0030] Typically, in an example, the bus bars, metal screws, metal washers and the metal threaded holes may be made up of a conducting material such as but may not be limited to copper, aluminium, and their alloys.

[0031] In another example, an electric vehicle (EV) is illustrated. The battery pack and other arrangements described above may be used as an energy storage and supply source for the vehicle, where the battery pack is deployed in the vehicle. In an example, the electric vehicle may be a two-wheel EV. However, it should be noted that the scope of the present disclosure is not limited to energy storage and supply source for the two-wheel EV. A person of ordinary skill in the art will appreciate that the battery pack of the present disclosure may be used in a variety of other applications where any such battery pack may be used.

[0032] Overall, the approaches described herein may simplify the assembly process and may eliminate the need for holes to be drilled in the housing for accommodating connectors (positive and negative terminal interfaces). This may reduce the risk of environmental ingress and voltage drops. In addition to this, high voltage bus bars may offer low resistance pathways for electric current, minimizingthe power losses and heat generation. Further, over-moulding the bus bars in the housing may provide an inherent insulation and durability. Furthermore, the approaches described herein may offer robust electrical and mechanical connections, significantly mitigating the potential for loose connections, intermittent contact, or mechanical instability. Even further, as bus bars are cost effective compared to traditional cable glands, the approaches described herein may be more economical.

[0033] The above and other features, aspects, and advantages of the subject matter will be better explained with regard to the following description and accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter along with examples described herein and should not be construed as a limitation to the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and examples thereof, are intended to encompass equivalents thereof. Further, for the sake of simplicity, and without limitation, the same numbers are used throughout the drawings to reference like features and components.

[0034] Figure 1 illustrates a conventional battery housing incorporating cable glands and a wire harness for establishing electrical connections between the battery pack and the external electrical components. Referring to figure 1, a curve shaped battery pack 100 includes a housing 102. The housing 102 is drilled with holes 104a, 104b for accommodating the cable glands (106a, 106b) of different polarities (negative and positive) used for establishing the electrical connections between the battery pack and the external electrical components using high voltage wire harness 108. Typically, the wires or cables are provided with eyelet terminals 110 for end connections.

[0035] Figure 2 illustrates a battery pack, particularly, a battery pack housing, in accordance with an example of the present subject matter. Referring to figure 2, the battery pack 200 may include a battery module (not shown) comprising a plurality of battery cells (not shown). The battery pack 200 may further include a housing202 made from electrically non-conductive material such as but may not be limited to, resin or reinforced plastic composites causing the housing 202 to be electrically non-conductive in nature. The housing 202 may have a contoured shape defining an opening 204 and may have over-moulded bus bars 206, 208. The housing 202 may include a first sub-housing component 202a and a second sub-housing component 202b. The sub-housing components 202a and 202b when combined through coupling means may constitute the battery pack housing and may collectively define the opening 204. The bus bars 206 and 208 may be overmoulded within the housing such that each of the sub-housing components 202a and 202b may include one bus bar. For instance, the first sub-housing component 202a may include bus bar 206 and the second sub-housing component 202b may include bus bar 208. The opening 204 may be facing a battery management system (BMS) module 212 allowing access to the BMS module 212. The bus bars 206, 208 may have a predetermined length, predetermined thickness and may be spaced apart at a predetermined distance. Between the bus bars 206 and 208, a first bus bar 206 may be of a first polarity configured for conducting electric current and the second bus bar may be of a second polarity configured for conducting electric current. The battery pack 100 may further include visual indicators 210a, 210b for identifying the polarities (positive and negative) of the bus bars.

[0036] The bus bars 206, 208 are high voltage bus bars over moulded such that each of the bus bars 206, 208 has the thickness oriented in direction of thickness of the housing 202 and the length oriented perpendicular to the thickness of the housing 202, where each of the bus bars is bent inward at multiple regions to align with the contoured shape of said housing 202 which will become apparent from figure 3 and description provided in subsequent paragraphs.

[0037] Each of these bus bars may include a first terminal portion and a second terminal portion. For example, the bus bar 206 over-moulded within the housing 202 may include a first terminal portion 206a and a second terminal portion 206b. Similarly, the bus bar 208 over-moulded within the housing 202 may include a first terminal portion 208a and a second terminal portion 208b. The second terminal portion (206b, 208b) of each of these bus bars (206, 208) is at a distal end of thecorresponding first terminal portion (206a, 208a). Each of these terminal portions 206a, 206b, 208a and 208b may feature at least one aperture for facilitating the electrical and mechanical coupling which will become apparent from Figure 6 and description provided in subsequent paragraphs. The bus bars 206, 208 may be overmoulded within the housing such that the first terminal portions 206a and 208a may be emanating at the opening 204 and the second terminal portions 206b and 208b may be emanating outside the housing. The first terminal portions 206a, 208a and the second terminal portions 206b 208b of each of the bus bars 206, 208 may be flat surfaces devoid of the electrically non-conductive material the housing is made from, enabling the terminal portions to be electrically conductive in nature.

[0038] Figure 3 illustrates a perspective inside-view of the battery pack illustrated in figure 2, in accordance with an example of the present subject matter. Referring to figure 3, the battery pack 300 may include a battery housing 302. The housing 302 may be defining an opening 304 facing a BMS module 310. The battery pack housing 302 may have bus bars 306, 308 over-moulded in it. The bus bars 306, 308 may be bent inward at multiple regions to align with the contoured shape of the housing 302. The figure shows the bus bar 306 bent inward at multiple regions 306c, 306d to align with the contoured shape of the housing 302.

[0039] The bus bar 306 may include a first terminal portion 306a and a second terminal portion 306b. The first terminal portion 306a may be electrically and mechanically coupled to the BMS module 310 and the second terminal portion 308 may be used to establish electrical and mechanical coupling between the battery pack 300 and the external electrical components. Similar electrical and mechanical coupling may be established using terminal portions (partially shown) of the bus bar 308 (partially shown).

[0040] Figure 4 illustrates a perspective top inclined view of a battery management system (BMS) module provided in the battery pack illustrated in figures 2-3, in accordance with an example of the present subject matter. Referring to figure 4, the BMS module 400 may be a stacked BMS module. The stacked BMS module may include a first side 401a and a second side 401b formed on a top surface 401 of an upper stack 400a of the stacked BMS module. The second side may bepresent opposite to the first side. The stacked BMS module may further include a lower stack 400b. Each side 401a, 401b formed on the top surface 401 of the upper stack 400a of the BMS module 400 may include two mounting lugs 402a-402d extending upwardly from the top surface 401 near corners of the top surface 401. The mounting lugs 402a-402d may be oppositely arranged near corners of the top surface 401. For instance, the first side 401a may include two mounting lugs 402a and 402b oppositely arranged near the corners and the second side 401b may include two mounting lugs 402c and 402d arranged oppositely near the comers. Each of these mounting lugs 402a-402d may be provided with corresponding metal threaded holes 404a-404d.

[0041] The separation between the mounting lugs 402a and 402b that may be placed proximal to the first terminal portions 206a and 206b of the bus bars 206, 208 as shown in figure 2 may be corresponding to or equal to the predetermined distance between the bus bars 206 and 208 such that the aperture provided on the first terminal portions 206a, 208a aligns with the corresponding metal threaded holes 404a and 404b of the mounting lugs 402a and 402b. The separation between the remaining mounting lugs 402c and 402d formed on the second side of the BMS module near the other comers of the top surface 401 of the upper stack 400a may or may not be same.

[0042] Figure 5 illustrates a perspective view of one side electrical coupling of the BMS module illustrated in figure 4 provided in the battery pack illustrated in figures 2-3, in accordance with an example of the present subject matter. Referring to figure 5, a mounting lug 506 provided on the BMS module 504 may be provided with a metal threaded hole 506a. The first terminal portion 502a of the bus bar 502 of first polarity may be provided an aperture that aligns with the metal threaded hole 506a. A metal screw 508 passing through a metal washer 510 and the aperture provided on the first terminal portion 502a of the bus bar 502 is screwed into the metal threaded hole 506a securing the mounting lug 506 thereby the BMS module to the bus bar 502. The fastening mechanism provided herein results in electrical and mechanically coupling between the bus bar 502 and the BMS module 504, retaining the BMS module 504 in a suspended position. Similar fasteningarrangement is repeated for securing the other bus bar (not shown) of second polarity to another mounting lug (not shown) provided opposite to the mounting lug 506 and provided near other comer of the BMS module 504.

[0043] Figure 6 illustrates a perspective top inclined and comprehensive view of the battery pack illustrate in figures 2-3, particularly, the other side electrical coupling of the BMS module illustrated in figure 4, in accordance with an example of the present subject matter. Referring to figure 6, the battery pack 600 may include a housing 602 and the housing 602 may define an opening 604 facing a BMS module 606. The opening 604 may allow access to the BMS module 606. The housing 602 may be over-moulded with two bus bars, a first bus 608 and a second bus bar 610 of different polarities (positive and negative) configured to conduct electric current. The first bus bar 608 may be provided with a first terminal portion 608a provided with at least one aperture 608c and a second terminal portion 608b at a distal end from the first terminal portion 608a. The second terminal portion 608b may be provided with at least one aperture 608d. Similarly, the second bus bar 610 may be provided with a first terminal portion 610a provided with at least one aperture 610c and a second terminal portion 610b at a distal end from the first terminal portion 610a. The second terminal portion 610b may be provided with at least one aperture 610d.

[0044] The bus bars 608 and 610 may be spaced apart at a predetermined distance which corresponds to the separation between the mounting lugs 606a and 606b formed on the first side of the BMS module 606 proximal to the first terminal portions 608a, 610a of the bus bars 608 and 610. The aperture 608c formed on the first terminal portion 606a of the first bus bar 606 aligns with a metal threaded hole (not shown) provided on the mounting lug 606a. Similarly, the aperture 610c formed on the first terminal portion 610a of the second bus bar 610 aligns with a metal threaded hole (not shown) provided on the mounting lug 606b.

[0045] As mentioned previously, complementary metal screws and metal washers may be used for coupling the BMS module 606 to the first and second bus bars 608 and 610 thereby establishing an electrical and mechanical connectionbetween the BMS module 606, retaining the BMS module 606 in a suspended position.

[0046] The second terminal portions 608b and 610b of the bus bars 608 and 610 provided with corresponding apertures 608d and 610d are utilized for coupling the battery pack electrically and mechanically to an external electrical component (not shown) such as but may not be limited to, a charger port (not shown) and a motor control unit (MCU) (not shown).

[0047] Further, the mounting lugs (not shown) formed on the second side of the BMS module and oppositely arranged near other corners of the BMS module 606 may be electrically and mechanically coupled to a battery module (not shown) provided within the battery pack 600. As illustrated herein, bus bars 612 and 614 provided with corresponding apertures 612a and 614a may be screwed into corresponding metal threaded holes of the mounting lugs on the second side of the BMS module 606 resulting in an electrical and mechanical connection. The other end of the bus bars 612 and 614 may be electrically and mechanically coupled to the battery module. To achieve the said coupling, complementary press nuts and bolts may be used. This way, the BMS module 606 is secured, establishing an electrical connection and mechanical connection retaining the BMS module in a suspended position.

[0048] The present subject matter has been disclosed in connection with certain examples but is not limited to the particular constructions herein disclosed and shown in the drawings, but also comprises any modifications or equivalents within the scope of the present subject matter.

Claims

I / We Claim:

1. A battery pack (200), comprising: a battery module comprising a plurality of battery cells; a housing (202) having a contoured shape defining an opening (204) to face a battery management system (BMS) module (400), wherein the housing is to accommodate the battery module; and a first and a second bus bar (206, 208) having a predetermined length and a predetermined thickness and are over-moulded within the housing, wherein each of the bus bars comprises a respective first terminal portion (206a, 208a) emanating at the opening and a second terminal portion (206b, 208b) emanating outside the housing, wherein the first terminal portions of the bus bars are to be electrically and mechanically coupled to first side (401a) of the BMS module, wherein second side (401b) of the BMS module is to be electrically and mechanically coupled to the battery module, wherein the BMS module is held thereby in a suspended position, wherein the second terminal portions of the bus bars are electrically and mechanically coupled to one or more external electrical components.

2. The battery pack as claimed in claim 1, wherein the housing comprises a first sub-housing component 202a and a second sub-housing component 202b, wherein the first sub-housing component and the second sub-housing component when combined through coupling means collectively define the opening.

3. The battery pack as claimed in claim 1 , wherein the bus bars are high voltage bus bars over-moulded within the housing such that each of the bus bars has the thickness oriented in direction of thickness of the housing and the length oriented perpendicular to the thickness of the housing, wherein each of the bus bars is bent inward at multiple regions (306c, 306d) to align with the contoured shape of the housing.

4. The battery pack as claimed in claim 1, wherein the first bus bar is of a first polarity configured for conducting electric current and the second bus bar is of a second polarity configured for conducting electric current.

5. The battery pack as claimed in claim 1, wherein the housing is made up of an electrically non-conductive material and the terminal portions of the bus bars are flat surfaces devoid of the electrically non-conductive material providing an electrically conductive surface, wherein the terminal portions are featuring at least one aperture (608c, 608d, 610c, 610d).

6. The battery pack as claimed in claim 1, wherein the BMS module is a stacked BMS module having the first side and the second side formed on a top surface 401 of an upper stack (400a) of the stacked BMS module, wherein the second side is present opposite to the first side, wherein each side has two mounting lugs (402a-402d) extending upwardly from the top surface and oppositely arranged near corners of the top surface, wherein each of the mounting lugs is featuring a metal threaded hole (404a-404d).

7. The battery pack as claimed in claim 6, wherein the bus bars are spaced apart at a predetermined distance, wherein the predetermined distance corresponds to separation between the mounting lugs on the first side of the BMS module to be placed proximal to the bus bars such that the aperture on the first terminal portion of each of the bus bars aligns with the corresponding metal threaded hole of the mounting lugs.

8. The battery pack as claimed in claim 6, wherein the first terminal portions of the bus bars are to be electrically and mechanically coupled to the first side of the BMS module through detachable fastening means including complementary mounting metal screws (508) and metal washers (510), wherein the mounting metal screw passing through the metal washer and the aperture on the first terminal portion is screwed into the corresponding metal threaded hole of the mounting lugs on the first side of the BMS module, wherein the second side of the BMS module is to be electrically and mechanically coupled to the battery module via the mounting lugs on the second side of the BMS module using detachable coupling meansincluding additional bus bars (612, 614), complementary press nuts and bolts.

9. The battery pack as claimed in claim 1, wherein the one or more external electrical components comprises a charger port and / or a motor control unit (MCU).

10. An electric vehicle, comprising: a battery pack (200), wherein the battery pack comprises: a battery module comprising a plurality of battery cells; a housing (202) having a contoured shape defining an opening (204) to face a battery management system (BMS) module (400), wherein the housing is to accommodate the battery module; and a first and a second bus bar (206, 208) having a predetermined length and a predetermined thickness and are over-moulded within the housing, wherein each of the bus bars comprises a respective first terminal portion (206a, 208a) emanating at the opening and a second terminal portion (206b, 208b) emanating outside the housing, wherein the first terminal portions of the bus bars are to be electrically and mechanically coupled to first side (401a) of the BMS module, wherein second side (401b) of the BMS module is to be electrically and mechanically coupled to the battery module, wherein the BMS module is held thereby in a suspended position, wherein the second terminal portions of the bus bars are electrically and mechanically coupled to one or more external electrical components.

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