Energy storage assemblies

Abstract

Techniques for accommodating various energy storage configurations within a uniform enclosure are disclosed. An energy storage assembly includes an enclosure (102) having a cavity with a plurality of cells (110) retained by removable holders. A bottom cell holder (106) with slots positions cells in predetermined configurations based on energy storage capacities, while a top cell holder (112) secures the cells. The common enclosure (102) accommodates different cell types by interchanging holders based on physical attributes of cells (110). The energy storage assembly supports capacities including 7.44 kWh, 6 kWh, 4.5 kWh, 3.5 kWh, and 2.5 kWh with corresponding series-parallel configurations. Further, the common enclosure (102) achieves different energies by depopulating cells. The approach enables standardized manufacturing while supporting various battery capacities. By utilizing removable holders, the energy storage assembly allows adaptation to different cell sizes without making any modifications in the enclosure (102).

Description

TECHNICAL FIELD

[0001] The subject matter described herein, in general, relates to energy storage assemblies, and more particularly, to an energy storage assembly having a uniform enclosure.BACKGROUND

[0002] Vehicles, such as Electric vehicles (EVs) and hybrid vehicles, rely on an energy storage device for various purposes. The energy storage device includes components such as a battery including a plurality of electrical or electrochemical cells, an accumulator, and the like. The energy storage device supplies energy for various systems and components of the vehicles. For instance, the battery powers various components of the vehicle and propels the vehicle. In particular, the battery stores energy received from an external source. The stored energy is then delivered to the vehicle for propelling the vehicle and / or powering various components of the vehicle. To maintain the integrity and performance of the energy storage device, the energy storage device may have to be protected from ingress of dirt, water, dust, and debris. A sturdy protective layer (an enclosure) provides structural strength and shields the energy storage device from external contaminants.BRIEF DESCRIPTION OF DRAWINGS

[0003] The detailed description is provided 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. The same numbers are used throughout the drawings to reference like features and components.

[0004] Figures 1A, 1 B, 1 C, 1 D, 1 E, and Figures 1 F, 1 G, 1 H illustrate an energy storage assembly depicting different cell packs of different energies, in accordance with various implementations of present subject matter.DETAILED DESCRIPTION

[0005] In vehicles, such as electric vehicles (EVs) and hybrid vehicles, an energy storage device provides energy for various systems and components of the vehicles. The energy storage device is housed in an enclosure. The enclosure includes components such as a battery including a plurality of electrical or electrochemical cells, an accumulator, and the like. The enclosure is positioned within the vehicle. The enclosure shields the energy storage device from external elements that can potentially damage or impair the vehicle performance. The enclosure is designed to prevent exposure to contaminants such as dirt, water, dust, and debris. By protecting against contaminants, the enclosure helps in ensuring that the energy storage device remains functional and reliable. The enclosure also facilitates the recharging process through secure electrical connections while maintaining protection.

[0006] In the vehicle the capacity of the energy storage device, such as the battery, varies across different segments. The segment may include but are not limited to 7.44 Kilowatt hour (kWh), 6 kWh, 4.5 kWh, 3.5 kWh, or 2.5 kWh. Each segment represents a specific energy storage capacity tailored to the needs of different user needs. Higher capacity segments require more cells and occupy more space, while lower capacity segments require fewer cells and occupy less space.

[0007] In conventional vehicles, the size of the enclosure varies depending on the segment of the vehicle. The variation is closely tied to the capacity of the energy storage device, such as the battery, which differs across various segments. As the battery capacity increases, the enclosure must be designed to accommodate a larger number of cells, resulting in a larger enclosure size. In an example, when the size of cells varies, whether for the same capacity or different capacities, the enclosure size may be adjusted accordingly. Further, changes in the enclosure lead to changes inthe overall vehicle layout and packaging of various components of the vehicle, thereby adding to tooling costs.

[0008] In conventional vehicles, the use of enclosures that are specifically designed for current battery types poses a limitation when future changes in cell technology occur. As new types of cells are developed, they may differ significantly in size and form compared to existing cells. This discrepancy means that the currently manufactured enclosures may not accommodate these new cell types. Consequently, a new enclosure must be designed and manufactured to fit the new cell type, which can involve significant modifications to the vehicle’s design. The conventional enclosures, which are tailored to specific cell types, may thus hinder the ability to future-proof vehicles against advancements in cell technology.

[0009] In conventional vehicle design, the need to manufacture different enclosures for various types of cells leads to increased inventory requirements. Each type of cell, depending on its size and specifications, necessitates a uniquely designed enclosure. As a result, manufacturers must produce multiple enclosures to match the different cell types available. The variety in enclosures requires a substantial inventory to accommodate each specific design. The need to stock multiple enclosures for different cell types increases the complexity of inventory management and demands more storage space. Manufacturers must keep a range of enclosures to meet various requirements, leading to higher costs associated with warehousing and managing these parts. The increased operational costs associated with producing and managing a range of enclosures can impact the overall efficiency and profitability of vehicle manufacturing.

[0010] In addition, multiple assembly lines are required to handle different enclosure designs, necessitating a larger manufacturing facility to house the expanded production setup. Each assembly line must be equipped with specialized tools and machinery tailored to the specific requirements of different enclosures. The expansion of the plant may thus result in higher capital expenditure. The costs associated with building andmaintaining a larger facility, as well as investing in the diverse equipment needed for various enclosures, may contribute to increased financial outlays.

[0011] In conventional systems, switching from one type of cell to another or using different types of cells within the enclosure presents significant challenges. Each type of cell typically requires a uniquely designed enclosure and associated components, leading to difficulties in maintaining inventory flexibility. The conventional techniques demand a redesign of the entire enclosure to accommodate the new cells. This lack of adaptability increases costs and complexity, as manufacturers must maintain separate inventories for each type of cell and its corresponding components, leading to inefficiencies in production and supply chain management.

[0012] The present subject matter relates to an energy storage assembly. In one example implementation, the energy storage assembly may correspond to a battery assembly, particularly for electric and hybrid vehicles. The energy storage assembly will be explained with reference to a battery assembly. The battery assembly includes a plurality of cells. The plurality of cells represents energy storage elements that can vary significantly in number, size, type, and arrangement depending on the specific application requirements. The cells may include various battery technologies such as lithium-ion, nickel-metal hydride, or other battery chemistries, each with different physical dimensions and electrical characteristics. For example, a high-performance electric vehicle may utilize cylindrical lithium-ion cells with high energy density, while a hybrid vehicle may employ prismatic cells optimized for power delivery. The cells may be arranged in different series and parallel configurations to achieve specific voltage and capacity requirements, such as 14 series and 30 parallel configurations for higher capacity applications, or 14 series and 10 parallel configurations for lower capacity needs.

[0013] The cells are accommodated in a holding assembly. In an example, the holding assembly may be a modular holding assembly. The holding assembly may include a top cell holder (TCH) and a bottom cell holder (BCH) to hold the plurality of cells. The battery assembly includes an enclosure. In an example implementation, the enclosure may be a uniform enclosure accommodating various battery configurations through modular components rather than requiring entirely different enclosure designs for different applications. The enclosure includes a cavity with distinct inner and outer surfaces. The inner surface defines the boundaries of the interior volume where the battery cells and supporting components, such as the BCH and TCH, are housed, while the outer surface forms the external periphery that interfaces with the vehicle structure. The cavity may incorporate features such as mounting points, thermal management channels, and electrical routing pathways that remain consistent regardless of the specific battery configuration being implemented.

[0014] In an example implementation, the bottom cell holder (BCH) is removably attached to a first end of the inner surface of the cavity, which may correspond to the bottom portion of the enclosure when installed in a vehicle. The removable attachment mechanism of the BCH allows for easy replacement or reconfiguration of the holder to accommodate different cell types or arrangements. The attachment may be achieved through various means such as snap-fit connections, threaded fasteners, or specialized docking mechanisms that ensure secure positioning while allowing for service access. The bottom cell holder includes a plurality of slots, each specifically designed to receive and position one of the plurality of cells. The slots may vary in size, shape, and configuration depending on the specific cell type being accommodated. For cylindrical cells, the slots may include circular openings with retention features to prevent rotation, while for prismatic cells, the slots may include rectangular openings with compression features to accommodate thermal expansion. In one example, the slot design may also incorporate electrical connection points, thermalinterface materials, and vibration dampening features to ensure optimal cell performance and longevity.

[0015] In an example, each slot may receive and position one of the plurality of cells in a predetermined order. For example, the predetermined order may indicate the arrangement of each cell amongst the plurality of cells in a configuration selected from a group of configurations. The configuration may be selected based on a predefined energy storage capacity. The BCH corresponds to the size of the cells placed on the BCH. If the dimensions of the cells increase, the BCH is changed accordingly, while the enclosure remains the same.

[0016] The top cell holder (TCH) provides the complementary retention function by securing the cells from above and completing the structural assembly. The TCH is removably attached to the second end of the inner surface of the cavity, typically corresponding to the top portion of the enclosure. The top cell holder works in conjunction with the bottom cell holder to create a complete retention system that prevents cell movement during vehicle operation while allowing for thermal expansion and contraction. In an example, the top cell holder may mechanically engage with the bottom cell holder to form a support structure around the plurality of cells. The enclosure accommodates different types of cell sizes by just changing the removably attached bottom cell holder (BCH) and the top cell holder (TCH) to correspond to the dimensions of the cells.

[0017] For instance, the enclosure may correspond to a larger enclosure that is designed to accommodate the highest battery capacity. For instance, the highest battery capacity may be 7.44 kWh. The cells in the battery with a capacity of 7.44 kWh are connected in series and parallel configurations. Specifically, the cells in the 7.44 kWh battery capacity are connected in a 14 series and 30 parallel configurations. Similarly, for a 6 kWh battery capacity, the cells may be connected in a 14 series and 24 (14s24p) parallel configuration. For a 4.5 kWh battery capacity, the cells may be configured in a 14 series and 18 parallel (14s18p) configurations.For a 3.5 kWh battery capacity, the cells may be configured in a 14 series and 14 parallel (14s14p) configurations. Finally, for a battery capacity of 2.5 kWh, the cells may be configured in a 14 series and 10 parallel (14s10p) configurations. These configurations (e.g., 14 series and 30 parallel, denoted as 14s30p) refer to how the cells are configured within the battery, with 's' indicating cells connected in series and 'p' indicating cells connected in parallel.

[0018] The cells in the battery are configured based on the required capacity. The plurality of cells is positioned in a stacked arrangement within the interior volume of the enclosure, and cells are depopulated from a higher energy storage capacity configuration to a lower energy storage capacity configuration by selectively removing the number of cells from an uppermost layer of a stack in the stacked arrangement of the plurality of cells. During the depopulation of cells, such as reducing the number of cells in the enclosure to reduce the battery capacity, the battery is configured considering the center of gravity of the vehicle. The cells in the battery are arranged in series and parallel within the cavity of the enclosure as explained above. Depopulating cells to get less energy leads to lower center of gravity of the vehicle, which enhances the vehicles dynamics and stability. Depopulating the cells in an optimized manner provides flexibility in tuning the vehicle dynamics by varying the mass distribution of the battery.

[0019] The bottom and top cell holders are of reconfigurable nature. Thus, rather than designing unique enclosures for each battery configuration, the present subject matter allows the same enclosure to accommodate different cell arrangements through the use of interchangeable holders. The reconfiguration capability is based on physical parameters and configuration requirements of the plurality of cells. Physical parameters may include cell dimensions, weight, thermal characteristics, and electrical specifications, while configuration parameters may include the number of cells, series and parallel arrangements, and spatialorganization requirements. For example, when transitioning from a 7.44 kWh battery configuration using 420 cells in a 14s30p arrangement to a 4.5 kWh configuration using 252 cells in a 14s18p arrangement, the holding assembly may be modified while the enclosure itself would remain unchanged.

[0020] The correspondence between the cell holders and the plurality of cells ensures optimal fit and performance for each specific configuration. This correspondence may involve precise dimensional matching, electrical interface compatibility, thermal management optimization, and structural load distribution. The holders may be manufactured using various materials and processes depending on the specific requirements, such as injection- molded plastics for cost-effective applications, machined aluminum for high- performance thermal management, or composite materials for weightsensitive applications.

[0021] In the present subject matter, the size of the cells does not impact the size of the enclosure. Regardless of whether the cells are larger or smaller, or whether they have the same or different capacities, the enclosure remains the same. The design of the enclosure is adaptable to accommodate various cell sizes without requiring any changes to the enclosure . This design approach ensures that changes in cell size do not necessitate alterations to the enclosure. Whether the cells are larger or smaller, or whether they differ in capacity, the enclosure provides a uniform fit for all configurations. By maintaining a common enclosure, the present subject matter eliminates the need for designing multiple enclosure variations based on cell dimensions. This approach simplifies the integration of cells into the vehicle, reduces manufacturing complexity, and streamlines the overall vehicle design process.

[0022] In the present subject matter, the design of the enclosure addresses the limitations associated with accommodating future changes in cell technology. The enclosure is engineered to support a range of cell types and sizes, ensuring that it remains compatible with new cell technologies asthey are developed. The consistent enclosure and adaptable internal configuration allow it to accommodate various cell types, regardless of their future developments in size and form. This flexibility means that as new types of cells are introduced, they can be integrated into the existing enclosure without requiring a redesign or the manufacture of a new enclosure. The uniform enclosure that can adapt to different cell configurations, the design future-proofs the vehicle against changes in cell technology. The enclosure's ability to support various cell types without modification ensures that vehicles remain compatible with advancements in cell technology by changing the detachable bottom cell holder corresponding to the sizes of the cells adapted. This approach eliminates the need for extensive redesigns or new enclosures when cell technology evolves, enhancing the long-term adaptability and flexibility of vehicle designs.

[0023] In the present subject matter, the design of the enclosure addresses the challenges of inventory management associated with different cell types. A single, adaptable enclosure is used to accommodate a variety of cell sizes and configurations. This approach eliminates the need to manufacture and store multiple enclosures for different cell types. The use of a uniform enclosure design simplifies inventory management by reducing the number of different enclosures required. Manufacturers do not need to produce separate enclosures for each cell type, which decreases the complexity of managing inventory and reduces the amount of storage space needed. By standardizing the enclosure and incorporating adaptable features, the design minimizes warehousing costs and simplifies logistics. The approach ensures that a single enclosure type can support various cells, streamlining production and inventory processes. This results in cost savings and improved efficiency in managing enclosure inventory.

[0024] In the present subject matter, the production of a uniform enclosure simplifies manufacturing processes and reduces logistical challenges. This design eliminates the need for diverse enclosure types,which typically require specific materials, tooling, and production techniques for each variant. The uniform enclosure design standardizes the manufacturing process, removing the complexity associated with producing multiple enclosure types. There is no need for specialized equipment or techniques for different enclosures, which streamline production and reduces setup times. This approach minimizes the resources required for manufacturing and simplifies supply chain management. By consolidating to a single enclosure type, the present subject matter lowers production costs and improves efficiency. The design reduces the need for multiple tools and materials, cutting down on setup time and operational expenses. It also enhances inventory management, quality control, and distribution by maintaining a streamlined production process. Overall, this design minimizes the complexities and costs associated with producing and managing various enclosures, leading to more efficient vehicle manufacturing and improved profitability.

[0025] In the present subject matter, the enclosure remains consistent across different vehicle segments. By maintaining a uniform enclosure, there is no need for adjustments to the vehicle’s frame or structural design based on varying enclosure sizes. The use of a standard-sized enclosure eliminates the requirement to modify the frame’s dimensions or shape, simplifying the vehicle design process. Additionally, with a common enclosure, repositioning other vehicle components is unnecessary. Since the enclosure does not change, the placement of components within the vehicle remains stable and does not need reconfiguration to avoid interference with the enclosure. This reduces complexity in integrating various parts for vehicle functionality.

[0026] In the present subject matter, the design of a single, adaptable enclosure streamlines the assembly process by eliminating the need for multiple specialized assembly lines. With one enclosure type accommodating various cell sizes and configurations, there is no requirement for separate assembly lines for different enclosure designs.The use of a uniform enclosure reduces the complexity associated with assembly processes. Workers do not need specialized training for handling different enclosure types, as the same assembly procedures apply to all configurations. This standardization minimizes the risk of mismatches and errors during installation, as the placement and alignment of components remain consistent. The common enclosure design simplifies the coordination of vehicle components, as there is no variability introduced by different enclosure sizes or designs. By avoiding the need for multiple assembly lines, the present subject matter decreases production costs and enhances the efficiency of maintaining high-quality standards across vehicle configurations.

[0027] In the present subject matter, the use of a single, adaptable enclosure significantly reduces the need for an expanded plant size and lowers capital expenditures. With one enclosure design accommodating various cell sizes and configurations, a plurality of one type of assembly line is required. This eliminates the need for multiple assembly lines dedicated to different enclosure designs. The uniform enclosure design simplifies the manufacturing facility requirements. There is no need for specialized tools and machinery for different enclosures, which reduces the need for extensive plant expansion. The capital expenditure associated with building and maintaining a larger facility is minimized, as only standard equipment and infrastructure are necessary. By avoiding the need for diverse enclosures, the present subject matter reduces the need for extensive inventory space. This decreases the financial outlays associated with storing different enclosure types. The approach also lowers operational costs by streamlining labor, maintenance, and quality control processes. Overall, the design minimizes the complexity of managing manufacturing resources and helps keep production costs and capital expenditures manageable.

[0028] In the present subject matter, the uniform enclosure allows different cell sizes to be accommodated without requiring changes to othercomponents. Unlike conventional designs that necessitate significant modifications to the enclosure for different cell sizes. In the present subject matter only the cell holder needs to be adjusted to fit different cell dimensions, while the rest of the battery pack, including the enclosure, remains consistent. This simplifies production, reduces costs, and allows for greater flexibility in battery design.

[0029] In the present subject matter addresses the dependency on a single supplier by enabling the use of different cells from various suppliers within the uniform enclosure. This uniformity eliminates the need for a unique enclosure and associated components for each cell type, thus allowing manufacturers to easily switch between suppliers without redesigning the enclosure. The use of a standardized enclosure ensures that different cell sizes from different suppliers can be integrated smoothly, reducing supply chain risks and increasing production flexibility.

[0030] In the present subject matter, switching between different types of cells is greatly simplified by the use of a uniform enclosure. This design allows for various cell types to be used interchangeably within the same enclosure, without requiring a redesign of the enclosure or related components. Whether the manufacturer needs to switch cell types due to performance variations or to manage inventory more efficiently, the present invention facilitates this transition by maintaining a consistent enclosure design. This reduces the need for multiple inventories and streamlines production, offering a more adaptable and cost-effective solution for managing different cell types.

[0031] Figure 1A, 1 B, 1 C, 1 D, and 1 E illustrate an energy storage assembly 100, in accordance with various implementations of present subject matter. The energy storage assembly 100 corresponds to a battery assembly. In an example, the battery assembly may be used in vehicles such as electric or hybrid vehicles. The energy storage assembly 100 is designed to store and provide electrical energy efficiently, powering thevehicle's propulsion system and other electrical components. The energy storage assembly will be explained with reference to battery assembly.

[0032] The battery assembly includes a plurality of cells 110. A cell is a fundamental unit of energy storage. In an example, the cell may be lithium- ion, nickel-metal hydride, or other advanced battery technologies, each chosen for its specific energy density, power output, and longevity characteristics. For example, a high-performance electric sports car may use lithium-ion cells for their high energy density and power output, while a hybrid city car may opt for nickel-metal hydride cells for their reliability and cost-effectiveness.

[0033] The plurality of cells 110 are the individual battery cells that store and provide electrical energy. For example, in a 7.44 kWh configuration of the battery pack there may be 420 cells arranged in a 14 series and 30 parallel (14s30p) configuration. The plurality of cells 110 are accommodated in a holding assembly. The holding assembly may serve as both a structural support and an organizational component for the cells. The holding assembly includes a bottom cell holder (BCH) 106 and a top cell holder (TCH) 112. The holding assembly will securely hold the plurality of cells 110, creating a stable and organized battery pack. The dual-holder design ensures that the plurality of cells 110 are securely held in place from both above and below, minimizing the risk of movement or displacement during vehicle operation. In an example, the design of the holding assembly may incorporate features such as thermal management channels or electrical connection pathways, enhancing the overall performance and safety of the battery assembly.

[0034] The BCH and TCH forms a battery assembly with additional components such as a power receiving cord (not shown in figures) and a discharge cord (not shown in figures). The power receiving cord and the discharge cord is connected to the plurality of cells to enable charging and discharging of the plurality of cells respectively. The power receiving cord allows the battery to be charged from external power sources, such as homecharging stations or fast-charging networks. The discharge cord, on the other hand, facilitates the flow of stored energy from the battery to the vehicle's electric motor and other devices. In an example, the cords may incorporate advanced features like liquid cooling to manage heat during high-current charging or discharging scenarios.

[0035] The battery assembly is housed within an enclosure 102. The enclosure 102 protects the cells from external elements, provides structural integrity to the battery pack, and integrates the battery assembly into the vehicle. In an example implementation, the enclosure 102 may have a cavity. The cavity is designed to precisely fit the battery assembly, maximizing space utilization within the vehicle. The cavity may include an inner surface and an outer surface. The inner surface may define the boundaries of an interior volume of the enclosure 102 and the outer surface may form an external periphery of the enclosure 102.

[0036] The BCH 106 is removably attached on the inner surface of the enclosure 102. The removable design of the BCH 106 allows for easier maintenance, upgrades, or replacements of individual components without necessitating a complete overhaul of the battery system. The BCH 106 is secured in place by a bottom cell holder docking means 108. In an example, the bottom cell holder is secured to the inner surface of the cavity by a bottom cell holder docking means. The docking means 108 may be selected from various options such as a snap fit lock, push fit lock, screw, or blind rivet, ensuring flexibility in assembly methods depending on specific requirements of the manufacturers For example, the snap fit lock may be preferred in a mass-production scenario where rapid assembly is crucial, while the screw mechanism may be chosen for a high-performance vehicle where frequent servicing and precise adjustments are expected. Further, the push fit lock may be ideal for applications requiring a balance between quick assembly and secure fastening, while blind rivets may be selected for their ability to create a strong, permanent bond in tight spaces.

[0037] The BCH 106 serves as a base for arranging the plurality of cells 110. The BCH 106 is designed with a plurality of slots (not shown in figures). Each slot is designed to securely hold a single cell. For instance, each slot is specifically adapted to receive each cell from the plurality of cells 110. In an example, the design of the slots may vary depending on the physical attributes, such as a size and a type of cell to be used. For instance, cylindrical cells may require circular slots with additional features to prevent rotation, while prismatic cells might need rectangular slots with provisions for expansion during charge cycles. The cells 110 are positioned within the slots in a predetermined order, ensuring that the configuration (which is explained in detail later in the description) is optimal for the specific power requirements of a vehicle segment. The vehicle segment may include but is not limited to 7.44 kWh, 6 kWh, 4.5 kWh, 3.5 kWh, or 2.5 kWh. Such customization may allow manufacturers to tailor the battery pack to different vehicle models and use cases. For example, a 7.44 kWh configuration may be suitable for a plug-in hybrid vehicle with extended electric-only range, while a 2.5 kWh setup may be ideal for a mild hybrid system in a compact car. The secure placement of each cell within the BCH 106 minimizes movement and ensures that the cells remain in their intended positions during operation.

[0038] Once the plurality of cells 110 are positioned in the BCH 106, the top cell holder (TCH) 112 is placed over them. The TCH 112 facilitates maintaining the stability of the cells 110 within the enclosure 102. The TCH 112 may provide downward pressure on the cells, ensuring they remain firmly seated in their slots even under the dynamic conditions experienced during vehicle operation. The TCH 112 is securely docked using a top cell holder docking means 114 with the enclosure 102, similar to the BCH 106. The docking means 114 may also be selected from snap fit lock, push fit lock, screw, or blind rivets, depending on the specific assembly needs.

[0039] The design of the energy storage assembly 100 allows for the accommodation of various battery configurations within the uniformenclosure 102. This adaptability is achieved through the BCH 106 and TCH 112, which can be adjusted to fit different cell configurations. For instance, the cells 110 may be arranged in configurations such as 7.44 kWh (14s30p), 6 kWh (14s24p), 4.5 kWh (14s18p), 3.5 kWh (14s14p), or 2.5 kWh (14s10p). For instance, 14s30p refers to 14 cells in series and 30 cells in parallel. The flexibility in cell arrangement within a consistent enclosure facilitates achieving required power capacity. For instance, the cells 110 in different configuration of the battery are depopulated in the respective cell configuration. The depopulating of cells in the aforementioned configuration may facilitate in maintaining shift of the center of gravity of a vehicle. The reduced need for multiple enclosure designs leads to a significant decrease in material waste during production. For example, instead of manufacturing separate enclosures for 7.44 kWh, 6 kWh, and 4.5 kWh batteries, a single enclosure design can accommodate all these configurations. Such an approach minimizes the production of excess or obsolete enclosures, reducing the overall material consumption and associated waste.

[0040] The enclosure 102 is designed to accommodate various sizes of the plurality of cells 110. The adaptability of the enclosure 102 is achieved by way of the removably attached bottom cell holder (BCH) 106 and the top cell holder (TCH) 112, which securely hold the plurality of cells 110 within the enclosure 102, regardless of the size or configuration of the cells 110.

[0041] A gap within the enclosure 102, which is the unoccupied space surrounding cells 110, may be filled with a filler material. The filler material is positioned within a gap between the plurality of cells and the enclosure. The filling ensures that all excess space within the enclosure 102 is occupied, providing additional stability to the cells 110 by cushioning them against vibrations and movement. The filler material enhances the overall performance and longevity of the battery pack.

[0042] The polyurethane foam or similar filler materials facilitate not only filling the gap but also conforms to the exact shape of the space within the enclosure 102. Such conformity ensures a snug fit around the cells andother components, eliminating any potential for movement or rattling during vehicle operation. The filler material facilitates reducing the risk of damage or displacement during vehicle operation such as in scenarios involving sudden acceleration, braking, or impact. The foam also serves as an insulator, protecting the cells 110 from external shocks and thermal variations. The insulation property of the foam may help in maintaining optimal operating temperatures across the battery assembly, which directly impacts the performance and lifespan of the cells. In extreme weather conditions, for instance, the foam insulation may prevent rapid temperature changes that may otherwise stress the cells.

[0043] The enclosure 102 may include a protective lid (not shown in figures) that is affixed to the enclosure 102. The protective lid serves as an additional layer of protection, sealing the battery assembly from external elements and providing a surface that can be integrated seamlessly into the vehicle's design. A sealing element (not shown in figures) may be positioned between the protective lid and the enclosure 102 to prevent ingress of an external element. The sealing element maintains the integrity of the battery assembly, protecting against moisture, dust, and other contaminants that can potentially damage the cells or electrical components. In an example, the sealing element may be made of materials like EPDM rubber or silicone, chosen for their durability, temperature resistance, and excellent sealing properties.

[0044] The enclosure 102 is also equipped with a plurality of mounting points 104. These mounting points 104 facilitate secure attachment of the enclosure 102 to the vehicle frame (not shown in figures). The placement of the plurality of mounting points 104 in the enclosure 104 ensures that the battery assembly is securely integrated into the vehicle structure, contributing to the overall rigidity of the vehicle while also allowing for some flexibility to absorb road vibrations and impacts.

[0045] The modular nature of the BCH 106 and TCH 112 allows for easy customization within the uniform enclosure 102. The modular natureof the holders enables the manufacturers to adjust the number of cells 110 and their configuration without changing the size or design of the enclosure 102. For instance, a manufacturer may create multiple battery assembly options for the same vehicle model, offering customers choices in range and performance without requiring significant changes to the vehicle's structure or assembly process. This adaptability simplifies the production process and allows for quicker assembly line adjustments based on varying customer demands or advancements in power cell technology. Such flexibility is advantageous in a rapidly evolving market like electric vehicles, allowing manufacturers to quickly incorporate new cell technologies or respond to shifts in consumer preferences without requiring extensive retooling or redesign of their production lines.

[0046] The uniform enclosure 102 across different vehicle segments eliminates the need for multiple enclosure designs, reducing manufacturing complexity. The present subject matter addresses the inefficiencies associated with conventional vehicle designs where different enclosure sizes are required for different cell capacities. By using a uniform enclosure design, the manufacturing process is streamlined, reducing both production costs and the need for extensive inventory.

[0047] The present subject matter also reduces the logistical burden associated with maintaining multiple assembly lines. With a uniform enclosure design that fits all cell configurations, the need for specialized assembly lines for different enclosures is eliminated. This reduction in assembly line diversity decreases the demand for skilled labor and reduces the risk of mismatches and errors during installation.

[0048] The uniform enclosure also minimizes the need for plant expansion. Manufacturers do not need to invest in additional infrastructure to accommodate different enclosure designs. The uniform enclosure size leads to a significant reduction in capital expenditure, as the existing plant setup can handle the production of the energy storage assembly 100 without the need for extensive modifications or new equipment.

[0049] In an example implementation, Figures 1A-1 E and Figures 1 F- 1 H, illustrate an energy storage assembly depicting different cell packs of different energies, in accordance with various implementations of present subject matter. The figures depict various types of cells that can be accommodated within the uniform enclosure 102 by replacing holders, specifically the bottom cell holder (BCH) 106 and the top cell holder (TCH) 112. The shape and dimensions of the cells vary based on their capacity, which necessitates different holder sizes to secure the cells within the enclosure 102.

[0050] For instance, a first type of cell, as illustrated in Figures 1 A-1 E, is shown with a cell configuration that may be characterized by a specific individual cell capacity or different form factor requirements. When implementing these cells, the corresponding bottom cell holder and top cell holder must be specifically designed to accommodate the cells without any change in the enclosure while maintaining secure positioning and electrical connectivity, if the cell size is changing. If the cell remains same, the same bottom cell holder and top cell holder can also be used. In an example, the spacing between individual cell positions within the holders may be optimized to ensure adequate thermal management and prevent thermal runaway propagation between adjacent cells.

[0051] In an example, 21700 cells may be arranged in the common enclosure to achieve different energy capacities of the battery pack. For example, 21700 cells may be configured in the common enclosure for a 2.5 kWh battery capacity (as illustrated in Figure 1A). In another example, 21700 cells may be configured in the common enclosure for a 3.5 kWh battery capacity (as illustrated in Figure 1 B). In yet another example, 21700 cells may be configured in the common enclosure for a 4.5 kWh battery capacity (as illustrated in Figure 1 C). Further, 21700 cells may also be configured in the common enclosure for a 6 kWh battery capacity (as illustrated in Figure 1 D). Additionally, 21700 cells may be configured in thecommon enclosure for a 7.44 kWh battery capacity (as illustrated in Figure 1 E).

[0052] On the other hand, Figures 1 F-1 H depicts a second type of cell, which is larger than the cells depicted in Figures 1A-1 E. To achieve the same capacity, a lesser number of second type of cells may be required compared to the first type cells, leading to a different configuration of the BCH 106 and TCH 112 to accommodate the increased quantity.

[0053] In an example, 4680 cells may be arranged in the common enclosure to achieve different energy capacities of the battery pack. For example, 4680 cells may be configured in the common enclosure for a 6.5 kWh battery capacity (as illustrated in Figure 1 F). In another example, 4680 cells may be configured in the common enclosure for a 7.75 kWh battery capacity (as illustrated in Figure 1 G). In yet another example, 4680 cells may be configured in the common enclosure for a 9.05 kWh battery capacity (as illustrated in Figure 1 H).

[0054] The figures 1A-1 E and 1 F-1 H depict different cell arrangements that may be accommodated within the uniform enclosure 102 by simply replacing the corresponding removable holders, BCH 106 and TCH 112, ensuring a secure and stable assembly regardless of the specific cell size or shape and the present subject matter is not only limited to these two types of the cell. In the present subject matter, for example, by changing the removably attached BCH 106 and TCH 112 corresponding to the cell 110 type the same enclosure 102 can be used without any change in the enclosure for the varying dimension of cells 110.

[0055] The simplified manufacturing process resulting from the present subject matter also has positive implications for inventory management. With a single enclosure design, the need for extensive inventory space to store different types of enclosures is reduced. This leads to lower inventory costs and more efficient use of storage facilities.

[0056] The present subject matter enhances the vehicle’s design flexibility by allowing future upgrades in cell technology without the need fora new enclosure. As new cell configurations are developed, they can be accommodated within the existing enclosure 102, ensuring that the vehicle can be easily updated without requiring significant redesign or retooling.

[0057] The energy storage assembly 100 also contributes to the vehicle’s overall safety and performance. The secure placement of cells 110 within the enclosure 102, combined with the cushioning effect of the filler material, reduces the risk of cell damage during operation. This enhances the reliability of the vehicle’s power system and contributes to a longer operational lifespan.

[0058] The adaptability of the enclosure 102 to different cell configurations also supports the vehicle’s structural integrity. By maintaining a uniform enclosure, the vehicle’s frame and other components do not need to be extensively modified to accommodate different cells. This consistency reduces the risk of structural imbalances and ensures that the vehicle remains stable and performs well under different operating conditions.

[0059] The present subject matter also has significant implications for supply chain management. The use of a single enclosure design simplifies the sourcing and procurement processes for manufacturers. Suppliers can focus on producing a standardized set of components, reducing lead times and simplifying quality control measures.

[0060] The design of the energy storage assembly 100 also supports environmental sustainability. The reduced need for multiple enclosure designs leads to a decrease in material waste during production. The use of expandable filler materials such as polyurethane foam ensures that all available space within the enclosure 102 is utilized, minimizing excess material use.

[0061] The present subject matter’s approach to energy storage assembly design also enhances the vehicle’s adaptability to different market needs. Manufacturers can quickly adjust the cell configuration within the same enclosure to meet specific regional or customer requirements without altering the overall vehicle design.

[0062] The energy storage assembly 100, as described, represents a significant advancement in vehicle design and manufacturing. The ability to use a uniform enclosure for various cell configurations streamline production, reduces costs, and enhances the vehicle’s adaptability to future technological advancements. The present subject matter thus offers a robust solution to the challenges associated with conventional energy storage designs.

[0063] Although the present subject matter has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the subject matter, will become apparent to person skilled in the art upon reference to the description of the subject matter.

Claims

I / We Claim:1 . An energy storage assembly (100), comprising: an enclosure (102) having a cavity, the cavity comprising an inner surface defining the boundaries of an interior volume of the enclosure (102), and an outer surface forming the external periphery of the enclosure (102); a plurality of cells (110) positioned within the interior volume of the enclosure (102); a modular holding assembly to retain the plurality of cells (110), the holding assembly comprising: a bottom cell holder (106) removably attached to a first end of the inner surface of the cavity, wherein the bottom cell holder (106) includes a plurality of slots, each slot amongst the plurality of slots is to receive and position one of the plurality of cells (110); and a top cell holder (112), removably attached to a second end of the inner surface of the cavity and positioned above the plurality of cells (110), to secure the plurality of cells (110) within the enclosure (102); wherein the bottom cell holder (106) and the top cell holder (112) corresponds to the plurality of cells (110) and are reconfigurable based on at least one of a physical parameter and configuration of the plurality of cells (110).

2. The energy storage assembly (100) as claimed in claim 1 , wherein the plurality of cells (110) is positioned in a predetermined order within the plurality of slots, the predetermined order being indicative of the arrangement of each cell amongst the plurality of cells in a configuration, wherein the configuration is selected based on a predefined energy storage capacity.

3. The energy storage assembly (100) as claimed in claim 1 , wherein the plurality of cells (110) are positioned in a stacked arrangement within the interior volume of the enclosure (102), and wherein cells are depopulated from a higher energy storage capacity configuration to a lower energy storage capacity configuration by selectively removing the number of cells from an uppermost layer of a stack in the stacked arrangement of the plurality of cells (110).

4. The energy storage assembly (100) as claimed in claim 1 , wherein the bottom cell holder (106) is secured to the first end of the inner surface of the cavity by a bottom cell holder docking means (108), and wherein the bottom cell holder docking means (108) includes at least one of a snap fit lock, push fit lock, screw, and blind rivet.

5. The energy storage assembly (100) as claimed in claim 1 , wherein the top cell holder (112) is secured to the second end of the inner surface of the cavity by a top cell holder docking means (114), and wherein the top cell holder docking means (114) includes at least one of a snap fit lock, push fit lock, screw, and blind rivet.

6. The energy storage assembly (100) as claimed in claim 1 , wherein the top cell holder (112) mechanically engages with the bottom cell holder (106) to form a support structure around the plurality of cells (110).

7. The energy storage assembly (100) as claimed in claim 1 , wherein a filler material is positioned within a gap between the plurality of cells (110) and the enclosure (102), wherein the filler material provides stability to the plurality of cells (110) by cushioning them against vibrations and movement.

8. The energy storage assembly (100) as claimed in claim 7, wherein the filler material comprises polyurethane foam to conform to an exact shape of the gap within the enclosure (102).

9. The energy storage assembly (100) as claimed in claim 1 , wherein a protective lid is affixed to the enclosure (102).

10. The energy storage assembly (100) as claimed in claim 9, wherein a sealing element is positioned between the protective lid and the enclosure (102) to prevent ingress of an external element.

11. The energy storage assembly (100) as claimed in claim 2, wherein the predefined energy storage capacity comprises at least one of 7.44 kWh, 6 kWh, 4.5 kWh, 3.5 kWh, and 2.5 kWh.

12. The energy storage assembly (100) as claimed in claim 1 , wherein the configuration corresponding to the predefined energy storage capacity comprises 14s30p for 7.44 kWh, 14s24p for 6 kWh, 14s18p for 4.5 kWh, 14s14p for 3.5 kWh, and 14s10p for 2.5 kWh, where s denotes arrangement of cells in series and p denotes arrangement of cells in parallel.

13. The energy storage assembly (100) as claimed in claim 1 , wherein the physical parameter includes a size, design, and type of the plurality of cells (110).

14. The energy storage assembly (100) as claimed in claim 1 , wherein a power receiving cord and a discharge cord are connected to the plurality of cells (110) to enable charging and discharging of the plurality of cells (110).

15. The energy storage assembly (100) as claimed in claim 1 , wherein the enclosure (102) comprises a plurality of mounting points (104) to secure attachment of the enclosure (102) to a frame of a vehicle.

16. The energy storage assembly (100) as claimed in claim 1 , wherein the enclosure (102) is of a uniform structure across different vehicle segments and accommodates the plurality of cells (110) by replacing the bottom cell holder (106) and the top cell holder (112).

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