Energy storage devices

Abstract

An energy storage device (102) is provided where the energy storage device (102) includes an energy storage device enclosure (104), a plurality of energy storage cells (108) sandwiched between a bottom cell holder (106) and a top cell holder (112) of the energy storage device (102) in a predetermined layout. At least the plurality of energy storage cells (108) and the bottom cell holder (106) are enclosed within the energy storage device enclosure (104). A solidified foam (110) occupies empty spaces within the energy storage device (102), wherein the solidified foam (110) adheres to the plurality of energy storage cells (108) and the bottom cell holder (106) to fix the plurality of energy storage cells (108) to their respective positions in the bottom cell holder (106) and to secure the plurality of energy storage cells (108) in the predetermined layout.

Description

ENERGY STORAGE DEVICESFIELD OF INVENTION

[0001] The present disclosure relates to energy storage devices, and more particularly but not exclusively, to an energy storage device with a plurality of energy storage cells.BACKGROUND

[0002] An energy storage device, such as a battery pack, may be used in various applications, such as powering electric vehicles, portable electronic devices, and energy storage systems. The energy storage device may typically consist of multiple individual energy storage cells stacked together. Examples of the energy storage cells may include but are not limited to battery cells, as used in battery packs. Typically, a plurality of energy storage cells are arranged in a Specific layout within the energy storage device for various purposes. To ensure proper operation, functioning and safety of the energy storage device and to protect the plurality of energy storage cells from at least external factors including but not limited to vibration, shock, and thermal events, each individual energy storage cell of the plurality of energy storage cells may be securely held in its place using various fixing, mounting, and attaching means.BRIEF DESCRIPTION OF DRAWINGS

[0003] The features, aspects, and advantages of the subject matter will be better understood with regard to the following description and accompanying figures. The use of the same reference number in different figures indicates similar or identical features and components.

[0004] Figure. 1A illustrates a perspective view of an energy storage device in accordance with an example implementation of the present subject matter;

[0005] Figure. IB illustrates a side view of the energy storage device in accordance with an example implementation of the present subject matter;

[0006] Figure 2 illustrates a plurality of inlets of the energy storage device in accordance with an example implementation of the present subject matter.

[0007] Figure 3 A illustrates an isometric view of a bottom cell holder of the energy storage device in accordance with an example implementation of the present subject matter;

[0008] Figure 3B illustrates another perspective view of the energy storage device in accordance with an example of the present subject matter; and

[0009] Figure 4 illustrates a method for assembly of an energy storage device in accordance with an example implementation of the present subject matter.

[0010] Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. 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

[0011] Energy storage devices, such as battery packs are employed across a wide range of applications, including electric vehicles, portable electronic gadgets, and large-scale energy storage systems. These energy storage devices consist of multiple energy storage cells, which are individual units capable of storing and releasing electrical energy. The energy storage cell(s) may hereinafter be interchangeably referred to as battery cell(s). The performance, reliability, and safety of the energy storage devices are influenced by various factors, such as the Specific layout or arrangement of plurality of battery cells within the energy storage device. The Specific layout is typically designed to achieve safety, heat management, and the desired energy output. Therefore, it is important that each individual battery cell stays at its designated position within the Specific layout. Therefore, to ensure that no battery cell gets displaced from its designated position, protective measures are employed to shield the cells from external factors, such as mechanical vibrations, physical shocks, and thermal events.

[0012] Conventional design of an energy storage device may employ means including a top cell holder and a bottom cell holder to securely hold each individualbattery cell of the plurality of battery cells in its place within the Specific layout. The top cell holder and the bottom cell holder typically comprise mechanical parts to hold each individual battery cell from top and bottom respectively. Another means, which may be used in a conventional energy storage device design, for securely fixing each individual battery cell of the plurality of battery cells at their respective designated positions within the Specific layout may include adhesives.

[0013] In the above example, the bottom cell holder provides structural support and maintains the individual battery cell in its proper alignment within the arrangement of the plurality of battery cells. The bottom cell holder is secured to the energy storage device using various mounting elements which may include but are not limited to fasteners and snap-fit mechanisms. The use of the bottom cell holders therefore necessitates use of mounting elements resulting in the requirement of additional components, including inserts or specialized features in energy storage device enclosure. This not only adds to the bulk and weight associated with the energy storage device but also increases the bill of materials and manufacturing complexity. Additionally, the reliance on mechanical fastening introduces potential failure points in energy storage device assembly over time, especially in applications subject to frequent vibration or thermal cycling.

[0014] Further, the application of adhesives to secure each individual battery cell to its designated position within the Specific layout comes with its own set of challenges. Application of adhesives to each battery cell of the plurality of battery cells is highly time-consuming and is prone to human error. Therefore, adhesive application can lead to potential inconsistencies in placement, thereby causing a potential risk of failure of the energy storage device. Furthermore, the use of adhesives requires additional materials and processes, which may increase production costs and complexity. Examples of materials which are used along with adhesive application include primers to enhance adhesion to metals or plastics. Examples of processes which are used along with adhesive application include cleaning and drying to enhance adhesion to metals or plastics.

[0015] The conventional techniques of using top and bottom cell holders or using adhesives, further lack effective heat dissipation, temperature regulation, insulationand uniform temperature distribution. As a result, the energy storage device is susceptible to risks including thermal runaway, reduced battery life, performance issues, safety hazards and damage to the plurality of battery cells. Henceforth, there is a requirement to employ, in a conventional energy storage device using top and bottom cell holders or adhesives for securely fixing the plurality of battery cells, various means including cooling mechanisms, heat sinks, and thermal fuses. This further adds to the manufacturing, operating and maintenance costs of the energy storage device.

[0016] Therefore, conventional techniques of securely holding each individual battery cell of the plurality of battery cells within the Specific layout in the energy storage device presents several technical problems that not only hinder the operational and performance efficiency associated with the energy storage device but also negatively impact the cost-effectiveness of the energy storage device.

[0017] As already described in the aforementioned paragraphs of the present disclosure, the application of adhesives to secure individual battery cells is timeconsuming, prone to human error, and can lead to inconsistencies in placement thereby causing potential risk of hazardous failure. This not only reduces production efficiency but also increases costs due to the use of additional materials. Furthermore, the traditional mounting of bottom cell holders using fasteners or snap-fit mechanisms may introduce complexity in the form of supporting parts, features, and inserts. These additional components increase the bill of materials and manufacturing complexity, potentially leading to higher production costs. Also, the use of mechanical fasteners may introduce potential failure points in the energy storage device assembly, particularly in applications subject to vibration or thermal cycling.

[0018] Additionally, the conventional techniques cannot account for risks including thermal runaway, reduced battery life, performance issues, safety hazards and damage to the plurality of battery cells unless employed with means including cooling mechanisms, heat sinks, and thermal fuses. This further adds to the manufacturing, operating and maintenance costs of the energy storage device.

[0019] Another disadvantage associated with such conventional techniques is the lack of flexibility in adapting to various energy storage device designs and sizes, thereby limiting optimization opportunities for different applications. Therefore, these unresolved technical issues underscore the need for an innovative solution that can simplify the manufacturing process, reduce component count, and enhance the overall operation, reliability and cost-effectiveness of the energy storage device.

[0020] According to an example implementation of the present subject matter, an energy storage device is provided. An example of the energy storage device may include, but is not limited to, a battery pack. In an example, the energy storage device includes an energy storage device enclosure. In an example, the energy storage device enclosure may be a physical construct for enclosing one or more components of the energy storage device. The energy storage device further includes a plurality of energy storage cells, for instance, battery cells, as used in battery packs. Examples of an energy storage cell may include, but are not limited to, lithium-ion cells, nickel-metal hydride cells, and lead-acid cells. The energy storage cell(s) may hereinafter be interchangeably referred to as battery cell(s).

[0021] Further, the energy storage device includes a bottom cell holder having a plurality of slots to receive and hold the plurality of energy storage cells. In an example, the bottom cell holder is a physical platform having the plurality of slots. The plurality of energy storage cells are positioned within the plurality of slots of the bottom cell holder in a predetermined layout. The predetermined layout may be designed to provide a desired energy output and ensure safe and optimal operation of the energy storage device. The energy storage device further includes a top cell holder to receive and hold the plurality of energy storage cells positioned in the bottom cell holder. In an example, the bottom cell holder and the top cell holder may sandwich the plurality of energy storage cells. In one example, the top cell holder may be a physical platform having a plurality of slots similar to the bottom cell holder. The plurality of slots of the top cell holder may receive top ends of the energy storage cells to hold the plurality of energy storage cells in the predetermined layout.

[0022] In an example, the energy storage device includes a foam material that adheres at least to the plurality of energy storage cells, the bottom cell holder, and the energy storage device enclosure. Examples of the foam material may include, but are not limited to, Polyurethane (Pu) foam, Epoxy based foam, and Silicone foam. In an example, the foam material is dispensed in the energy storage device, in its liquid state, by utilizing a plurality of dispensers. The plurality of dispensers may be connected or coupled to a plurality of inlets of the energy storage device to dispense the foam material in the energy storage device. In an example, the plurality of dispensers may include nozzles. In an example, the plurality of inlets may include a plurality of small openings positioned across the energy storage device to receive the foam material and to disperse the foam material within the energy storage device. In one example, the plurality of inlets may be spread throughout or at designated positions on the top cell holder to receive the plurality of dispensers. The foam material in its liquid state may hereinafter be interchangeably referred to as liquified foam.

[0023] Once dispensed, the liquified foam starts to uniformly spread and occupy empty spaces within the energy storage device. For instance, the liquified foam may seep into empty spaces between adjacent energy storage cells, empty spaces between the plurality of energy storage cells and the bottom cell holder, and empty spaces between the bottom cell holder and the energy storage device enclosure. In an example, the liquified foam is preferably dispensed via the plurality of inlets which directly allow passage of the liquified foam into at least the empty spaces of the energy storage device.

[0024] The liquified foam is then allowed to rest for a predetermined time period. The liquified foam may then rise and expand horizontally and vertically to completely fill empty spaces within the energy storage device and at least partially cover the plurality of energy storage cells vertically. The liquified foam may finally solidify within set-time period to form a solid structure. In an example, the set-time period for the liquefied foam to solidify may be 600 seconds for Pu foam. The solid state foam material obtained subsequent to the solidification of the liquified foam may hereinafter be interchangeably referred to as solidified foam. The solidifiedfoam thus occupies empty spaces within the energy storage device and acts as an adhesive, structural support, and thermal propagation retardant. In one example, the solidified foam may be entirely rigid. In another example, the solidified foam may have flexing properties. The solidified foam adheres to the plurality of energy storage cells and the bottom cell holder to fix each of the plurality of energy storage cells to their respective positions in the bottom cell holder. This may securely fix the plurality of energy storage cells in the predetermined layout. The solidified foam may also adhere to the bottom cell holder and the energy storage device enclosure to fix the bottom cell holder relative to the energy storage device enclosure. The solidified foam thus clamps and fixes the plurality of energy storage cells, the bottom cell holder, and the energy storage device enclosure in their respective positions within the energy storage device without the involvement of any attaching or mounting or clamping or fixing means.

[0025] In operation, initially the bottom cell holder having the plurality of slots, is securely placed within the energy storage device enclosure. Each individual energy storage cell of the plurality of energy storage cells is then positioned within a corresponding slot of the plurality of slots in the bottom cell holder according to the predetermined layout. This may include positioning each individual energy storage cell of the plurality of energy storage cells in at least one of a grid pattern, staggered pattern, or random pattern. The predetermined layout may be optimized for energy output, thermal management, and structural stability. Once the plurality of energy storage cells are placed within the bottom cell holder and the enclosure, the top cell holder is positioned over the plurality of energy storage cells. Upon positioning of the top cell holder over the plurality of energy storage cells, liquified foam is dispensed. In one example, chemical compounds, for example, a first chemical compound and a second chemical compound are mixed in predetermined ratios within a dispenser chamber to obtain the liquified foam. In one example, where the liquified foam is a Pu foam, the first chemical compound may be selected from a group of polyols, while the second chemical compound may be selected from a group of isocyanates. In another example, where the liquified foam is an Epoxy based foam, the first chemical compound may be an Epoxy resin, for example, athermosetting polymer, while the second chemical compound may be a hardener, for example, an amine, an anhydride, and a polyamide. In another example, where the liquified foam is Silicone foam, the first chemical compound may be a silicone resin, for example, a silicone base polymer, while the second chemical compound may be a curing agent, for example, a crosslinker or catalyst like platinum catalyst. The first chemical compound and the second chemical compound may be selected such that the obtained liquified foam has desired thermal, adhesive, and structural properties.

[0026] The intermixing of the chemical compounds may be carried out in a controlled environment to ensure proper chemical reaction consistency and optimal foam characteristics. The prepared liquified foam is then introduced into the energy storage device through the strategically positioned plurality of inlets, which may include multiple small openings that facilitate controlled distribution throughout the empty spaces within the energy storage device. During the dispersion, the liquified foam flows systematically to occupy empty spaces between adjacent energy storage cells, between the plurality of energy storage cells and the bottom cell holder, and between the bottom cell holder and the energy storage device enclosure, ensuring comprehensive filling and interconnection of all components through the foam medium. Further, dispensation of the liquified foam is carefully controlled to ensure proper filling without overfilling or underfilling of the available empty spaces, maintaining optimal distribution patterns throughout the energy storage device.

[0027] The liquified foam soon starts to expand and solidify into solidified foam, with adhesive, structural support, and thermal propagation retardant properties. The solidified foam expands sideways and upwards within the empty spaces while maintaining its position around the plurality of energy storage cells and structural components of the energy storage device including the bottom cell holder and the energy storage device enclosure. This creates a comprehensive matrix that at least partially encapsulates the plurality of battery cells while simultaneously adhering to each battery cell, the bottom cell holder and the energy storage device enclosure. In an example, once the solidified foam is formed in the energy storage device, the plurality of the energy storage cells, the bottom cell holder, the energy storagedevice enclosure, and the top cell holder are sealed and completely encased using a housing seal.

[0028] The foam-based approach to use solidified foam for securely holding each component within the energy storage device provides comprehensive securing means that adheres to all components within the energy storage device, while simultaneously functioning as an adhesive to maintain component positioning, a structural support to provide mechanical stability, and a thermal propagation retardant to manage heat distribution and prevent thermal runaway events. The solidified foam may fix each of the plurality of energy storage cells to their respective positions in the bottom cell holder while securing the bottom cell holder relative to the energy storage device enclosure, completely eliminating the need for traditional mechanical fasteners or separate adhesive application components and processes.

[0029] The use of the solidified foam also provides superior vibration resistance and structural stability while simultaneously reducing component count, potential failure points, manufacturing complexity, and assembly time. The foam material may further provide a lightweight solution for shock-absorption and insulation. Therefore, all components of the energy storage device are secured through the multifunctional solidified foam, providing enhanced safety, improved performance characteristics, and manufacturing efficiency compared to conventional energy storage device designs. Further, customization of foam, for example, by changing the chemical compounds or their ratios, may help in altering properties, such as adhesive strength, thermal characteristics, and solidification timing for specific applications and operating conditions, while maintaining consistent and reliable positioning of all components throughout the energy storage device. This also ensures that the energy storage device can be used in a wide array of applications. For instance, the foam material may be formulated with different densities and flame-retardant properties, making it suitable for safety-critical energy storage applications (like Electric Vehicle battery packs).

[0030] The present disclosure therefore effectively addresses the technical problem of securely positioning plurality of energy storage cells within battery packs whileeliminating the need for complex mechanical fasteners and time-consuming adhesive applications. The dispensing of the liquified foam into empty spaces within the energy storage device, where it solidifies to simultaneously provide structural support, thermal management, and adhesive properties enables the present disclosure to securely fix the plurality of energy storage cells, bottom cell holder, and the energy storage device enclosure at their respective positions without the use of any attachment or mounting or clamping or fixing means. The foambased fixing and clamping significantly reduces manufacturing complexity by eliminating traditional mounting hardware and adhesive application processes, while providing enhanced thermal propagation resistance between energy storage cells. Improved manufacturing efficiency, reduced component count, enhanced safety through better thermal management, and elimination of potential mechanical failure points associated with the energy storage device of the present disclosure thereby provides a new and improved energy storage device when compared to conventional energy storage device designs.

[0031] The description hereinafter describes the energy storage device as per the present subject matter. The manner in which the energy storage device as per the present subject matter shall be implemented has been explained in detail with respect to Figures 1A to 4. Further, it should be noted that the description and figures merely illustrate the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope. Furthermore, all examples recited herein are intended only to aid the reader in understanding the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects and implementations of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0032] Figure 1A and Figure IB of the present subject matter illustrate a perspective view and a side view, respectively of an energy storage device 102 in accordance with an example implementation of the present subject matter. Figures 1 A and IB have been described in combination. In an example, the energy storagedevice 102 may be a battery pack. In an example, the energy storage device 102 includes an energy storage device enclosure 104, a bottom cell holder 106, a plurality of energy storage cells 108, a foam material 110, and a top cell holder 112. Examples of the plurality of energy storage cells 108 include, but are not limited to, battery cells, such as lithium-ion cells, nickel-metal hydride cells, and lead-acid cells. The energy storage cell(s) may hereinafter be interchangeably referred to as battery cell(s).

[0033] In an example, the energy storage device enclosure 104 may be a physical construct for enclosing one or more components of the energy storage device 102. The energy storage device enclosure 104 may securely enclose the one or more components, including the bottom cell holder 106 and the plurality of energy storage cells 108, thereby providing protection against external factors like moisture, dust, temperature variations, and mechanical impacts. In an example, the bottom cell holder 106 may act as a physical platform to receive and hold the plurality of energy storage cells 108. In an example, the top cell holder 112 may act as a physical platform to cover and hold the plurality of energy storage cells 108 positioned within the bottom cell holder 106. The top cell holder 112 and the bottom cell holder 106 may sandwich the plurality of energy storage cells 108. Material for the top cell holder 112 may be selected based on its properties including temperature resistance, chemical stability, structural strength, electrical isolation, and shock absorption.

[0034] In an example, the foam material 110 may be one of a Polyurethane (Pu) foam, Epoxy based foam, and a Silicone foam. The foam material 110, referred to as solidified foam 110 in its solid state, occupies empty spaces within the energy storage device 102 to adhere to and fix various components within the energy storage device 102. The solidified foam 110 thus fixes each of the plurality of energy storage cells 108 to their respective positions in the bottom cell holder 106 while securing the bottom cell holder 106 relative to the energy storage device enclosure 104, completely eliminating the need for traditional mechanical fasteners or separate adhesive application components and processes. In one example, the foam material 110, in a liquified form, is inserted into the energy storage device102 during assembling of the energy storage device 102 to ensure proper clamping of the various components within the energy storage device enclosure 104. The foam material 110 in its liquid state may hereinafter be referred to as liquified foam 110.

[0035] To assemble the various components within the energy storage device 102, the bottom cell holder 106 is initially securely placed within the energy storage device enclosure 104. In an example, to securely place the bottom cell holder 106 within the energy storage device enclosure 104, one or more openings (not shown in figures) may be provided in the energy storage device enclosure 104. The one or more openings provide a pathway for secure placing of the bottom cell holder 106. The shape of the energy storage device enclosure 104 may be such that it can securely house and enclose the bottom cell holder 106.

[0036] In one example, to securely place the bottom cell holder 106 within the energy storage device enclosure 104 a locking feature (not shown in figures), for instance, a locator pin may be provided. In another example, secure placing of the bottom cell holder 106 within the energy storage device enclosure 104 may be achieved using only the foam material 110. In another example, secure placing of the bottom cell holder 106 within the energy storage device enclosure 104 may be achieved using the foam material 110 along with the locking feature.

[0037] Once the bottom cell holder 106 is securely placed within the energy storage device enclosure 104, the plurality of energy storage cells 108 are positioned within the enclosed bottom cell holder 106 in a predetermined layout. The Specific layout is typically designed to achieve safety, heat management, and the desired energy output. Examples of the predetermined layout may include but are not limited to arrangements including one of a grid pattern, a staggered pattern and a random pattern. To ensure proper arrangement of the plurality of energy storage cells 108 in the bottom cell holder 106, the bottom cell holder 106 may have a design suitable to accommodate each individual energy storage cell as per the required predetermined layout.

[0038] In an example, the bottom cell holder 106 may include a plurality of slots (not shown in Figures 1A and IB) to receive and securely accommodate theplurality of energy storage cells 108, as described in detail in Figure 3A. Each slot of the plurality of slots may have a shape suitable for receiving and holding an individual energy storage cell of the plurality of energy storage cells 108. Each individual energy storage cell is positioned in its respective slot of the plurality of slots. The plurality of slots therefore receive the plurality of energy storage cells 108 in the bottom cell holder 106 to allow arrangement of the plurality of energy storage cells 108 as per the predetermined layout. Once the plurality of energy storage cells 108 are set up on the bottom cell holder 106 within the energy storage device enclosure 104, the top cell holder 112 is positioned over the plurality of energy storage cells 108 to cover the plurality of energy storage cells 108. In an example, the top cell holder 112 may include a plurality of slots (not shown in figures) similar to the plurality of slots of the bottom cell holder 106 to receive and securely accommodate the plurality of energy storage cells 108, positioned within the bottom cell holder 106. Each slot of the plurality of slots of the top cell holder 112 may have a shape suitable for receiving and holding an individual energy storage cell of the plurality of energy storage cells 108 by its top end, i.e., end opposite to bottom end, where the bottom end is placed within the bottom cell holder 106. Each individual energy storage cell is positioned to be covered by its respective slot of the plurality of slots of the top cell holder 112. The plurality of slots therefore receive and cover the plurality of energy storage cells 108 in the top cell holder 112 to facilitate arrangement of the plurality of energy storage cells 108 as per the predetermined layout. In an example, a locking feature (not shown in figures), for instance, a locator pin may be provided to secure the top cell holder 112 over the plurality of energy storage cells 108. Other means may also be used for securing the top cell holder 112 over the plurality of energy storage cells 108. Once the plurality of energy storage cells 108 are set up within the bottom cell holder 106 and the top cell holder 112 within the energy storage device enclosure 104, the foam material 110 is introduced to adhere to the plurality of energy storage cells 108, the bottom cell holder 106, and the energy storage device enclosure 104.

[0039] In an example, the foam material 110 is initially obtained in a liquid form by intermixing a first chemical compound with a second chemical compound in adispenser chamber (not shown in figures) external to the energy storage device 102. The foam material 110 in its liquid form may hereinafter be interchangeably referred to as liquified foam 110. In one example, where the liquified foam 110 is a Pu foam, the first chemical compound may be selected from a group of polyols, while the second chemical compound may be selected from a group of isocyanates. In another example, where the liquified foam 110 is an Epoxy based foam, the first chemical compound may be an Epoxy resin, for example, a thermosetting polymer, while the second chemical compound may be a hardener, for example, an amine, an anhydride, and a polyamide. In another example, where the liquified foam 110 is a Silicone foam, the first chemical compound may be a silicone resin, for example, a silicone base polymer, while the second chemical compound may be a curing agent, for example, a crosslinker or catalyst like platinum catalyst. The first and the second chemical compounds may be intermixed in a predetermined ratio. For instance, in one example, where the liquified foam 110 is a Pu foam, the ratio of the first chemical compound to the second chemical compound may be in a range of 1 : 1 to 1 : 1.2 (by volume or weight). The range of ratio 1 : 1 to 1 : 1.2 may be selected depending on the desired rigidity and curing speed. In another example, where the liquified foam 110 is an Epoxy based foam, the ratio of the first chemical compound to the second chemical compound may be in a range of 2: 1 to 4: 1 (by weight). The range of ratio 2: 1 to 4: 1 may be selected based on curing conditions and mechanical properties. In another example, where the liquified foam 110 is Silicone foam, the ratio of the first chemical compound to the second chemical compound may be in a range of 10: 1 to 15: l(by weight). The predetermined ratios of the first and the second chemical compounds may be customizable and may be determined based on various properties desired for the resulting foam material 110.

[0040] In an example, different types of foam material 110, constituent first and second chemical compounds along with their ratios, are listed in the Table 1 provided below. While the Table 1 mentions one or more exemplary advantages of each foam material 110, it will be understood by a person skilled in the art that each foam material 110 may exhibit various other advantages as mentioned throughout the specification.TABLE 1

[0041] As previously described, the above described first and second chemical compounds when mixed in the specific ratios may provide one or more advantages, such as ability to influences rigidity and curing speed, high mechanical strength and chemical resistance, flexibility and high-temperature stability, excellent fire resistance and thermal insulation, provide open-cell and high thermal stability, high fire resistance and dimensional stability, lower weight and impact resistance, good thermal insulation with reduced weight, high stiffness and chemical resistance, good thermal insulation and brittle nature, elastic and cushioning properties, chemical resistance and low water absorption, and flexibility, cushioning, and resilience. For instance, the PU foam, among various advantages, may provide better rigidity and curing characteristics. Similarly, other foam materials may provide one or more advantages, including the exemplary advantages mentioned in the Table 1.

[0042] The liquefied foam 110 obtained after the intermixing of the first and second chemical compounds is then dispensed within the energy storage device enclosure 104 enclosing at least the bottom cell holder 106 and the plurality of energy storage cells 108, where the plurality of energy storage cells 108 are stacked between the bottom cell holder 106 and the top cell holder 112. In an example, a plurality of dispensers (not shown in figures) may be utilized for dispensing, for example by spray foaming or injection foaming, the liquified foam 110 within the energy storage device enclosure 104. The plurality of dispensers may be external to the energy storage device 102 and may receive the liquified foam 110 from the dispenser chamber(s). In one example, the plurality of dispensers may include nozzles for dispensing the liquified foam 110. The plurality of dispensers may be engaged to interact with a plurality of inlets (not shown in Figures 1A and IB) provided across the energy storage device 102 to receive the foam material 110 and to disperse the foam material 110 within the energy storage device 102. In an example, the plurality of inlets may be small openings provided across or at strategically distributed locations on the top cell holder 112, as described in detail in Figure 2 to receive the plurality of dispensers and ensure desired uniform and complete spread of the liquified foam 110 within the energy storage deviceenclosure 104. In one example, the plurality of inlets on the top cell holder 112 may be small circular openings having 12mm diameters and spread strategically throughout the top cell holder 112. Upon engagement with the plurality of inlets, the plurality of dispensers may be activated to pour out the liquified foam 110. The liquified foam 110 is then dispersed through the plurality of inlets into empty spaces within the energy storage device 102.

[0043] As the liquified foam 110 continues to be dispensed within the energy storage device 102, the liquified foam 110 may start dispersing uniformly throughout the empty spaces between adjacent energy storage cells of the plurality of energy storage cells 108, empty spaces within the plurality of energy storage cells 108 and the bottom cell holder 106 and empty spaces within the bottom cell holder 106 and the energy storage device enclosure 104. In an example, quantity of the liquified foam 110 poured into the energy storage device 102 may be controlled based on the adhesive, structural, and thermal properties required from the solidified foam 110. The quantity of the liquified foam 110 poured into the energy storage device 102 may also be controlled based on how much portion of the plurality of energy storage cells 108 are to be covered by the solidified foam 110. In one example, the liquid foam 110 is dispensed until a predetermined amount of the liquid foam 110 is received to ensure that the solidified foam 110 covers around 60-70% of the empty space within the energy storage device 102.

[0044] The liquified foam 110 may then be allowed to rest for a predetermined settime period. In an example, the predetermined set-time period may be associated with time taken by the liquified foam 110 to solidify. The liquified foam 110 dispersed in the energy storage device during resting rises and expands to fill empty spaces within the energy storage device 102 and at least partially covers the plurality of energy storage cells 108. The liquified foam 110 may finally solidify to form a solid structure. In an example, the predetermined set-time period for the liquefied foam 110 to solidify may be 600 seconds for Pu foam. The solid state foam material obtained subsequent to the solidification of the liquified foam 110 may hereinafter be interchangeably referred to as the solidified foam 110.

[0045] The solidified foam 110 may thus occupy empty spaces within the energy storage device 102 to adhere to the energy storage device enclosure 104, the bottom cell holder 106, and the plurality of energy storage cells 108. The solidified foam 110 occupying the empty spaces in the energy storage device 102 therefore acts as an adhesive, structural support, and thermal propagation retardant. In one example, the solidified foam 110 may occupy around 60-70% of the empty space within the energy storage device 102. The solidified foam 110 may expand horizontally and vertically to cover the empty space up to a predetermined height of the energy storage cells 108. In one example, the height of the energy storage cells 108 immersed within the solidified foam 110 may be up to about 60 -70% of its total height.

[0046] As described above, the solidified foam 110 adheres to the plurality of energy storage cells 108 and the bottom cell holder 106 to fix each of the plurality of energy storage cells 108 to their respective positions in the bottom cell holder 106 to secure the plurality of energy storage cells 108 in the predetermined layout while being covered by the top cell holder 112. The solidified foam 110 may also adhere to the bottom cell holder 106 and the energy storage device enclosure 104 to fix each of the plurality of energy storage cells 108 to securely fix the bottom cell holder 106 relative to the energy storage device enclosure 104. The solidified foam 110 may thus clamp and securely fix the energy storage device enclosure 104, the bottom cell holder 106, and the plurality of energy storage cells 108 to their respective positions within the energy storage device 102 without the involvement of any attaching or mounting or clamping or fixing means.

[0047] Figure 2 illustrates a plurality of inlets 202-1, 202-2. . . ,202-N, similar to the plurality of inlets as described in Figures 1A and IB, of the energy storage device 102, in accordance with an example implementation of the present subject matter. The plurality of inlets 202-1, 202-2. .. ,202-N may hereinafter be interchangeably collectively referred to as the plurality of inlets 202. In an example, the plurality of inlets 202 may be a set of openings provided throughout the energy storage device 102, for instance, on the top cell holder 112, as shown in Figure 2.

[0048] In one example, upon placing the plurality of energy storage cells 108 within the bottom cell holder 106 as per the predetermined layout, the top cell holder 112 may be used to securely cover the plurality of energy storage cells 108. Multiple openings may be provided throughout the top cell holder 112 which may function as the plurality of inlets 202 throughout the energy storage device 102. After placing the top cell holder 112, the plurality of inlets 202 may be utilized to receive the plurality of dispensers for filling the energy storage device 102 with liquified foam 110 (not shown in Figure 2).

[0049] In an example, each inlet of the plurality of inlets 202 may have a varying diameter. The varying diameter may be predetermined to ensure that the plurality of inlets 202 effectively receive differently sized nozzles of the plurality of dispensers for dispensing the liquified foam 110. The plurality of dispensers may be inserted within or over the plurality of inlets 202 of the energy storage device 102 to dispense the foam material 110 in the energy storage device 102.

[0050] The plurality of inlets 202 are strategically positioned and distributed to control volume and flow rate of the liquified foam 110 being poured into different regions of the energy storage device 102. For instance, inlets may be positioned closer to each other where fast initial filling of liquified foam 110 is required. Similarly, inlets may be separated and farther to each other for gradual topping of empty spaces within the energy storage device 102. The size of diameter for circular inlets may also be varied for pressure control during foam infilling. Further, the plurality of inlets 202 may be positioned to ensure that once the plurality of dispensers start pouring the liquified foam 110 via the plurality of inlets 202, the liquified foam 110 does not fall over top end of any energy storage cell of the plurality of energy storage cells 108. This may help avoid formation of any solidified foam 110 over the top ends of the plurality of energy storage cells 108.

[0051] In an example, the plurality of inlets 202 may be angled to help guide the liquified foam 110 directly to the empty spaces in the energy storage device 102. The plurality of inlets 202 may thus provide passage for the liquified foam 110 to fill the empty spaces in the energy storage device 102 ensuring the liquified foam 110 is in contact with the energy storage device enclosure 104, the bottom cellholder 106 and the plurality of energy storage cells 108. Optimized distribution of the liquified foam 110 using the plurality of inlets 202 ensures that the solidified foam 110 sufficiently surrounds at least the plurality of energy storage cells 108 and the bottom cell holder 106. In an example, the plurality of dispensers may be engaged in a sequential order to optimize uniformity in foam distribution and curing dynamics of the liquified foam 110.

[0052] After filling by the liquified foam 110, the energy storage device enclosure 104 may be sealed with a housing seal (not shown in figures). Examples of the housing seal may include but are not limited to a removable cover, and a permanent seal strip. The sealing may be performed using means including but not limited to welding, adhesive bonding, or mechanical fastening. The housing seal may encase completely the plurality of energy storage cells 108, the bottom cell holder 106, the top cell holder 112 and the energy storage device enclosure 104.

[0053] Figure 3 A illustrates an isometric view of the bottom cell holder 106 in accordance with an example implementation of the present subject matter. Further, Figure 3B illustrates another perspective view of the energy storage device 102 in accordance with an example of the present subject matter. The Figures 3 A and 3B are explained hereinafter collectively.

[0054] In an example, the bottom cell holder 106 may be the physical platform having the plurality of slots 302-1, 302-2 302-N as shown in Figure 3A. The plurality of slots 302-1, 302-2 302-N may hereinafter interchangeably be collectively referred to as the plurality of slots 302. In one example, the physical platform of the bottom cell holder 106 may include a rigid or semi-rigid substrate that serves as the platform for the plurality of slots 302 for placing and positioning the plurality of energy storage cells 108 (not shown in Figures 3A and 3B) within the energy storage device 102. In an example, the plurality of slots 302 may be such that adjacent energy storage cells of the plurality of energy storage cells 108, when positioned within the bottom cell holder 106, are spaced 5mm apart for better foam flow within the energy storage device 102. The bottom cell holder 106 may receive and hold the plurality of energy storage cells 108 within the plurality of slots 302 as per the predetermined layout. Material for the bottom cell holder 106 may beselected based on its properties including temperature resistance, chemical stability, structural strength, electrical isolation, and shock absorption.

[0055] In an example, the plurality of slots 302 may be such that each slot of the plurality of slots 302 may have a shape appropriately dimensioned to receive an individual energy storage cell of the plurality of energy storage cells 108 in predetermined layout. For instance, in one example, as shown in Figure 3A, the plurality of the slots 302 may be cup shaped to receive circular cross section of a cylindrically shaped energy storage cell. In an example, the plurality of slots 302 may be arranged in various patterns depending on the desired energy density and thermal management requirements. For instance, the plurality of slots 302 may be organized in a regular grid pattern to maximize packing efficiency, while in other instances, the plurality of slots 302 may be positioned with strategic spacing to optimize thermal dissipation pathways. In an example, the plurality of slots 302 may include retention features such as partial walls or guides that help maintain cell positioning during the foam dispensing process.

[0056] The energy storage device enclosure 104 may enclose the one or more components of the energy storage device 102 including the bottom cell holder 106 and the plurality of energy storage cells 108. This may provide protection against external factors like moisture, dust, temperature variations, and mechanical impacts. Further, the energy storage device enclosure 104 may be constructed from materials offering durability and resistance to corrosion, ensuring long-term reliability of the energy storage device 102.

[0057] In an example, the energy storage device enclosure 104 encloses the bottom cell holder 106 and the plurality of the energy storage cells 108 that may be in contact with foam material 110 during the curing of the liquified foam 110. In an example, the energy storage device enclosure 104 may include integrated cooling channels or thermal management features.

[0058] When liquified foam 110 is dispensed through the plurality of inlets 202 (not shown in Figures 3A and 3B), it flows into the empty spaces between the plurality of energy storage cells 108 and the plurality of slots 302, as well as the empty spaces between the bottom cell holder 106 and the energy storage deviceenclosure 104. As the liquified foam 110 solidifies, the solidified foam 110 forms secure contact with surfaces of the plurality of energy storage cells 108, interior surfaces of the plurality of slots 302 in connection with the plurality of energy storage cell 108, and the energy storage device enclosure 104. The solidified foam 110 thus locks all components of the energy storage device 102 together in a secure manner.

[0059] Figure 4 illustrates a method 400 for assembly of an energy storage device, similar to the energy storage device 102, in accordance with an example implementation of the present subject matter. The order in which the method 400 is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the method 400, or an alternative method.

[0060] At block 402, to assemble the various components within the energy storage device, a bottom cell holder similar to the bottom cell holder 106 is initially securely placed within an energy storage device enclosure, similar to the energy storage device enclosure 104. In an example, to securely place the bottom cell holder within the energy storage device enclosure, one or more openings, similar to the one or more openings as described in Figures 1 A and IB, may be provided in the energy storage device enclosure. The one or more openings provide a pathway for secure placing of the bottom cell holder. The shape of the energy storage device enclosure may be such that it can securely house and enclose the bottom cell holder.

[0061] At block 404, once the bottom cell holder is securely placed within the energy storage device enclosure, a plurality of energy storage cells, similar to the plurality of energy storage cells 108 are positioned within the enclosed bottom cell. In one example, the energy storage cells 108 may be positioned in a predetermined layout. The predetermined layout may be designed to achieve desired safety, heat management, and energy output. Examples of the predetermined layout may include, but are not limited to, a grid pattern, staggered pattern, and a random pattern. To ensure proper arrangement of the plurality of energy storage cells in the bottom cell holder, the bottom cell holder may have a design suitable toaccommodate each individual energy storage cell as per the required predetermined layout.

[0062] In an example, the bottom cell holder may include a plurality of slots, similar to the plurality of slots 302, to receive and securely accommodate the plurality of energy storage cells. Each slot of the plurality of slots may have a shape suitable for receiving and holding an individual energy storage cell of the plurality of energy storage cells. Each individual energy storage cell is positioned in its respective slot of the plurality of slots. The plurality of slots therefore receive the plurality of energy storage cells in the bottom cell holder to allow arrangement of the plurality of energy storage cells as per the predetermined layout. Once the plurality of energy storage cells are set up on the bottom cell holder within the energy storage device enclosure, a top cell holder, similar to the top cell holder 112, is positioned over the plurality of energy storage cells to cover the plurality of energy storage cells. The top cell holder and the bottom cell holder sandwich the plurality of energy storage cells.

[0063] At block 406, once the plurality of energy storage cells are set up between the bottom cell holder and the top cell holder within the energy storage device enclosure, the foam material is introduced to adhere to the plurality of energy storage cells, the bottom cell holder, and the energy storage device enclosure. In an example, the foam material, similar to the foam material as described in Figures 1 A and IB may be initially obtained in a liquid form by intermixing a first chemical compound with a second chemical compound, in a dispenser chamber (not shown in figures) external to the energy storage device. The first chemical compound and the second chemical compound may respectively be similar to the first and second chemical compounds as described in Figures 1A and IB. The foam material in its liquid form may hereinafter be interchangeably referred to as liquified foam, similar to the liquified foam 110. The first and the second chemical compounds may be intermixed in a predetermined ratio, similar to the ratios as described in Figures 1 A and IB. The predetermined ratios of the first and the second chemical compounds may be customizable and may be determined based on various properties desired for the resulting foam material.

[0064] In an example, the liquified foam obtained after the intermixing of the first and second chemical compounds may then be dispensed within the energy storage device where the energy storage device enclosure encloses at least the bottom cell holder and the plurality of energy storage cells stacked between the bottom cell holder and the top cell holder, similar to the top cell holder as described in Figures 1A and IB. In an example, a plurality of dispensers, similar to the plurality of dispensers as described in Figures 1A and IB may be utilized for dispensing the liquified foam within the energy storage device. The plurality of dispensers may be external to the energy storage device and may receive the liquified foam from the dispenser chamber(s).

[0065] In one example, the plurality of dispensers may include nozzles for dispensing the liquified foam. The plurality of dispensers may be engaged to interact with a plurality of inlets, similar to the plurality of inlets as described in Figures 1A to 2, provided on the top cell holder. In an example, the plurality of inlets may be small openings provided across or at distributed locations throughout the energy storage device, as described in detail in Figure 2 to ensure desired uniform and complete spread of the liquified foam within the energy storage device. Upon engagement with the plurality of inlets, the plurality of dispensers may be activated to pour out the liquified foam. The liquified foam is then dispersed through the plurality of inlets into empty spaces within the energy storage device.

[0066] As the liquified foam continues to be dispensed within the energy storage device enclosure, the liquified foam may start dispersing uniformly throughout the empty spaces between adjacent energy storage cells of the plurality of energy storage cells, empty spaces within the plurality of energy storage cells and the bottom cell holder and empty spaces within the bottom cell holder and the energy storage device enclosure. In an example, quantity of the liquified foam poured into the energy storage device may be controlled based on the adhesive, structural, and thermal properties required. The quantity of the liquified foam poured into the energy storage device may also be controlled based on how much portion of the plurality of energy storage cells are to be covered by the foam. In one example, the liquid foam is dispensed until a predetermined amount of the liquid foam is receivedto ensure that the solidified foam covers around 60-70% of the empty space within the energy storage device.

[0067] At block 408, the liquified foam may then be allowed to rest for a predetermined set-time period, similar to the predetermined set-time period as described in Figures 1A and IB. In an example, the predetermined set-time period may be associated with time taken by the liquified foam to solidify. The liquified foam dispersed in the energy storage device during resting rises and expands to fill empty spaces within the energy storage device and at least partially covers the plurality of energy storage cells. The liquified foam may finally solidify to form a solid structure. In an example, the predetermined set-time period for the liquefied foam to solidify may be 600 seconds for Pu foam. The solid state foam material obtained subsequent to the solidification of the liquified foam may hereinafter be interchangeably referred to as the solidified foam.

[0068] The solidified foam may thus occupy empty spaces within the energy storage device to adhere to the energy storage device enclosure, the bottom cell holder, and the plurality of energy storage cells. The solidified foam occupying the empty spaces in the energy storage device therefore acts as an adhesive, structural support, and thermal propagation retardant. In one example, the solidified foam may occupy around 60-70% of the empty space within the energy storage device. The solidified foam may expand horizontally and vertically to cover the empty space up to a predetermined height of the energy storage cells. In one example, the height of the energy storage cells immersed within the solidified foam may be up to about 60 -70% of its total height.

[0069] As described above, the solidified foam adheres to the plurality of energy storage cells and the bottom cell holder to fix each of the plurality of energy storage cells to their respective positions in the bottom cell holder to secure the plurality of energy storage cells in the predetermined layout. The solidified foam may also adhere to the bottom cell holder and the energy storage device enclosure to securely fix the bottom cell holder relative to the energy storage device enclosure. The solidified foam may thus clamp and securely fix the energy storage device enclosure, the bottom cell holder, and the plurality of energy storage cells to theirrespective positions within the energy storage device without the involvement of any attaching or mounting or clamping or fixing means.

[0070] While this detailed description has disclosed certain specific embodiments for illustrative purposes, various modifications will be apparent to those skilled in the art, and it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

Claims

I / We Claim:

1. An energy storage device (102) comprising: an energy storage device enclosure (104); a plurality of energy storage cells (108) positioned within a bottom cell holder (106), of the energy storage device (102), in a predetermined layout, wherein the plurality of energy storage cells (108) and the bottom cell holder (106) are enclosed within the energy storage device enclosure (104); and a solidified foam (110) occupying empty spaces within the energy storage device (102), wherein the solidified foam (110) adheres to the plurality of energy storage cells (108) and the bottom cell holder (106) to fix the plurality of energy storage cells (108) to their respective positions in the bottom cell holder (106) and to secure the plurality of energy storage cells (108) in the predetermined layout.

2. The energy storage device (102) as claimed in claim 1, wherein the solidified foam (110) is a solid structure obtained upon solidification of a liquified foam (110) dispersed in the energy storage device (102), and wherein the liquified foam (110) solidifies after a set time-period subsequent to dispensation in the energy storage device (102) to form the solidified foam (110).

3. The energy storage device (102) as claimed in claim 2, comprising a top cell holder (112) having a plurality of slots to receive the plurality of energy storage cells (108), wherein each of the plurality of slots have a shape suitable for receiving a top end of an individual energy storage cell of the plurality of energy storage cells (108).

4. The energy storage device (102) as claimed in claim 3, wherein the top cell holder (112) includes a plurality of inlets (202) to receive the liquified foam (110) and to disperse the liquified foam (110) within the energy storage device (102).

5. The energy storage device (102) as claimed in claim 1, wherein the solidified foam (110) occupies empty spaces between adjacent energy storage cells and empty spaces between the plurality of energy storage cells (108) and the bottom cell holder (106).

6. The energy storage device (102) as claimed in claim 1, wherein the solidified foam (110) occupies empty spaces between the bottom cell holder (106) and theenergy storage device enclosure (104) to secure the bottom cell holder (106) and the plurality of energy storage cells (108) within the energy storage device enclosure (104), and wherein the solidified foam (110) adheres to the bottom cell holder (106) and the energy storage device enclosure (104) to fix the bottom cell holder (106) relative to the energy storage device enclosure (104).

7. The energy storage device (102) as claimed in claim 1, wherein the bottom cell holder (106) comprises a plurality of slots (302) to receive the plurality of energy storage cells (108), wherein each of the plurality of slots have a shape suitable for receiving and holding an individual energy storage cell of the plurality of energy storage cells (108).

8. A method (400) for assembling of an energy storage device (102), the method comprising: securely placing a bottom cell holder (106) of the energy storage device (102) within an energy storage device enclosure (104) of the energy storage device (102); placing a plurality of energy storage cells (108) in a predetermined layout within a plurality of slots (302) of the bottom cell holder (106); placing atop cell holder (112) over the plurality of energy storage cells (108); dispensing liquified foam (110) in the energy storage device (102) to occupy empty spaces between the plurality of energy storage cells (108), the bottom cell holder (106), and the energy storage device enclosure (104) within the energy storage device (102); and resting the liquified foam (110) within the empty spaces to allow the liquified foam (110) to solidify and form solidified foam (110) within the empty spaces, wherein the solidified foam (110) adheres to the plurality of energy storage cells (108), the bottom cell holder (106), and the energy storage device enclosure (104) for fixing each of the plurality of energy storage cells (108) to their respective positions in the bottom cell holder (106) and for fixing the bottom cell holder (106) relative to the energy storage device enclosure (104).

9. The method (400) as claimed in claim 8, wherein dispensing the liquefied foam (110) comprises:intermixing at least a first chemical compound with a second chemical compound to obtain the liquefied foam (110); and pouring the liquified foam (110) into a plurality of inlets (202) positioned across a top cell holder (112) of the energy storage device (102).

10. The method (400) as claimed in claim 9, wherein placing each individual energy storage cell in the bottom cell holder (106) to have the predetermined layout of the plurality of energy storage cells (108) comprises one of positioning each individual energy storage cell as per a grid pattern; positioning each individual energy storage cell as per a staggered pattern; and positioning each individual energy storage cell as per a random pattern.

11. A vehicle comprising an energy storage device (102) as claimed in one of claims 1 to 7, wherein the energy storage device (102) is assembled using a method (400) as claimed in one of claims 8 to 10.

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