Integrated terminal box in battery pack of electric vehicles

Abstract

Techniques for integrating a terminal box in a battery pack are described. In an example, a battery pack includes a Battery Management System (BMS) with a pair of terminals, a terminal box including a plurality of connection points, and a plurality of busbars to electrically couple the BMS to the terminal box. A first busbar from the plurality of busbars couples the first terminal to a first connection point from the plurality of connection points, while a second busbar from the plurality of busbars couples the second terminal to a second connection point from the plurality of connection points. The plurality of connection points further includes a first plurality of connection points and a second plurality of connection points electrically coupled to the first connection point and the second connection point, respectively, to facilitate the charging and discharging processes of the battery pack.

Description

TECHNICAL FIELD

[0001] The present subject matter pertains, in general, to battery packs for electric vehicles, and in particular, to the battery packs with integrated terminal boxes.BACKGROUND

[0002] Electric vehicles (EVs) are powered by battery packs that supply electrical power required to drive the vehicle. A battery pack in an EV is a combination of battery cells coupled in series or parallel to generate the desired voltage-current capacity in order to provide the necessary power required to drive the electric motor and other components of the EV.BRIEF DESCRIPTION OF DRAWINGS

[0003] Figure 1 illustrates schematic of a battery pack, in accordance with an example of the present subject matter.

[0004] Figures 2A and 2B illustrate top perspective views of the battery pack, in accordance with examples of the present subject matter.

[0005] Figures 3 and 4 illustrate side perspective views of the battery pack, in accordance with examples of the present subject matter.

[0006] Figure 5 illustrates schematic of a vehicle including the battery pack, in accordance with an example of the present subject matter.

[0007] The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. 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

[0008] Battery packs are integrated with a Battery Management System (BMS), which monitors and controls the operation of the battery cells. The BMS has a pair of electrical load terminals comprising a positive terminal and a negative terminal. The positive terminal and the negative terminal are electrically connected to the corresponding terminals of the battery pack. These load terminals serve as the primary interface points through which power flows in and out of the battery pack. For example, the load terminals may be used for charging the battery and delivering power to the vehicle’s motor and other auxiliary loads.

[0009] To facilitate discharging and charging of the battery pack via the same set of electrical terminals, a pair of harnesses is used to route power from the BMS load terminals to a connected load, such as motor and auxiliary components, and another pair of harnesses is used to route power from an external power source to the battery pack via the BMS terminals.

[0010] However, reliance on a harness to transfer power introduces multiple design, cost, and performance challenges within the battery pack. For instance, the use harnesses require careful routing within the confined space of battery housing. This not only limits flexibility in battery pack layout but also increases the design complexity of the entire battery system. The harness must be mechanically secured using additional components such as brackets, clamps, fasteners, and insulation shields, all of which consume space and introduce added constraints for thermal and electrical isolation.

[0011] Moreover, each additional component used to support the harness including connectors, mounting hardware, and protective elements contribute to higher material cost and labour during assembly. This directly impacts the manufacturing cost of the battery pack and, by extension, the overall cost of the EV. Further, harness-based battery systems include multiple mechanical interfaces and connection points, which are susceptible to long-term wear, vibration, and potential failure. These vulnerabilities reduce the overall reliability and service life of the battery pack.

[0012] According to examples of the present subject matter, techniques for reducing complexity involved in battery pack design and manufacturing are described.

[0013] In an example, a battery pack includes a Battery Management System (BMS) accommodated within the housing of the battery pack, where the BMS is configured to control the operations of the battery pack. The BMS includes a pair of terminals including a first terminal and a second terminal.

[0014] The battery pack further includes a terminal box accommodated within the housing of the battery pack. The terminal box includes a plurality of connection points. Further, the battery pack includes a plurality of busbars to electrically couple the BMS to the terminal box. The plurality of busbars includes a first busbar and a second busbar.

[0015] The first busbar electrically couples the first terminal with a first connection point from the plurality of connection points. The electrical coupling between the first terminal and the first connection point is such that a first end of the first busbar is electrically coupled to the first terminal and a second end of the first busbar is electrically coupled to the first connection point.

[0016] Further, the second busbar electrically couples the second terminal with a second connection point from the plurality of connection points. The electrical coupling between the second terminal and the second connection point is such that a first end of the second busbar is electrically coupled to the second terminal and a second end of the second busbar is electrically connected to the second connection point.

[0017] The plurality of connection points further includes a first plurality of connection points electrically coupled to the first connection point and a second plurality of connection points electrically coupled to the second connection point. The first plurality of connection points and the second plurality of connection points are usable for charging and discharging of the battery pack.

[0018] By using a combination of busbars and a plurality of connection points within the terminal box, the battery pack establishes direct and distributed electrical connections between the terminals of the BMS, the motor and the auxiliary loads. Specifically, the first and second terminals of the BMS are electrically coupled to corresponding first and second connection points within the terminal box via using the first busbar and the second busbar. The first connection point and the second connection point, in turn, are electrically connected to a first and second plurality of connection points respectively, which are used for charging and discharging operations.

[0019] The above-mentioned architecture effectively eliminates the need for conventional harnesses typically used to route power for charging or discharging. As a result, ancillary components such as external seals, fasteners, and additional mounting hardware required for securing harnesses are no longer necessary thereby significantly reducing the design complexity of the battery pack and simplifying the assembly process. Furthermore, the direct and distributed coupling facilitated by the first busbar, the second busbar and the first and second connection points supports a more compact battery pack architecture, enhancing layout flexibility and simplifying the electrical management within the constrained space of the battery housing.

[0020] The above aspects are further described in conjunction with the figures, and in associated description below. It should be noted that the description and figures merely illustrate principles of the present subject matter. Therefore, various arrangements that encompass the principles of the present subject matter, although not explicitly described or shown herein, may be devised from the description and are included within its scope.

[0021] Figure 1 illustrates the schematic of a battery pack 100, in accordance with an example of the present subject matter.

[0022] The battery pack 100, as illustrated in figure 1 , may be utilized in a vehicle, such as an Electric Vehicle (EV) or a Hybrid Electric Vehicle(HEV). The battery pack 100 may be realized using a variety of chemistries, including but are not limited to, Lithium-Ion (Li-Ion) batteries, Nickel-Metal Hydride (NiMH) batteries, Solid-State Batteries (SSBs), Lead-Acid batteries, and Aluminum-lon (Al-lon) batteries.

[0023] The battery pack 100 may further include a Battery Management System (BMS) 104. In an example, the BMS 104 may be accommodated within a housing 102 of the battery pack 100. The BMS 104 is configured to control the operations of the battery pack 100, such as power flow regulation, fault detection, and communication with external systems.

[0024] The BMS 104 includes a pair of terminals. In an example, the pair of terminals includes a first terminal 106-1 and a second terminal 106-2. The first terminal 106-1 may be of a first polarity and the second terminal 106-2 may be of a second polarity opposite to the first polarity. The first terminal 106-1 and the second terminal 106-2 are provisioned to provide electrical connectivity for bidirectional power flow transfer during charging and discharging operations of the battery pack 100.

[0025] In an example, the BMS 104 is configured to manage the transfer of power within the battery pack 100 by actively controlling the direction, magnitude, and duration of power flow through the first terminal 106-1 and the second terminal 106-2. During charging operations, the BMS 104 regulates the input current and voltage supplied via the first terminal 106-1 and the second terminal 106-2 to ensure that power is delivered to the battery cells in a controlled and efficient manner. This regulation helps to prevent overcharging, thermal stress, and degradation of battery health.

[0026] During discharging operations, the BMS 104 controls the output power drawn from the battery cells and delivered through the first terminal 106-1 and second terminal 106-2 to auxiliary loads associated with the battery pack 100.

[0027] The battery pack 100 further includes a terminal box 108 accommodated within the housing 102. The terminal box 108 includes aplurality of connection points 110, wherein the plurality of connection points 110 includes a first connection point 112 and a second connection point 114.

[0028] The battery pack 100 further includes a plurality of busbars, where the plurality of busbars is to electrically couple the terminal box 108 to the BMS 104. The plurality of busbars includes a first busbar 116-1 and a second busbar 116-2.

[0029] To electrically couple the terminal box 108 to the BMS 104, the first busbar 116-1 is to electrically couple the first terminal 106-1 to the first connection point 112. Further, the second busbar 116-2 is to electrically couple the second terminal 106-2 to a second connection point 114 from the plurality of connection points 110.

[0030] In an example, the first busbar 116-1 and the second busbar 116- 2 are spatially separated by a predetermined distance. The predetermined distance may be equal to or greater than the distance between the first connection point 112 and the second connection point 114. This spatial separation improves electrical isolation between the first busbar 116-1 and the second busbar 116-2 and mitigates the risk of arcing or short circuits, especially in high-voltage implementations of the battery pack 100.

[0031] In an example, the first busbar 116-1 and the second busbar 116- 2 may be over moulded within the housing 102. The over moulding may be performed using an injection moulding process, whereby the first busbar 116-1 and the second busbar 116-2 are encapsulated in an electrically insulative material to provide mechanical support and electrical isolation. The over moulding of the first busbar 116-1 and the second busbar 116-2 may be carried out using the same material as that used to form the housing 102 to ensure material compatibility and effective bonding between the housing 102 and the over moulded first busbar 116-1 and the second busbar 116-2. In an example, the material used to form the housing 102 may be, but not limited to, thermoplastics or thermosetting polymers with high dielectric strength. It would be noted that over moulding the first busbar 116- 1 and the second busbar 116-2 within the housing 102 allows the first busbar116-1 and the second busbar 116-2 to be securely fixed in place while maintaining precise alignment with the corresponding electrical terminals, facilitates efficient routing of electrical pathways within a compact structure, and minimizes the need for additional fasteners or insulation layers. This also enhances the structural integrity and manufacturability of the battery pack by enabling modular assembly and reducing assembly time and potential failure points.

[0032] Further, the first busbar 116-1 and the second busbar 116-2 may be coated with a corrosion-resistant coating to enhance the durability and operational lifespan of the battery pack 100, especially in harsh automotive environments. The coating material may include various materials, such as nickel plating, tin plating, or epoxy-based protective layers. The materials are selected for their high resistance to moisture, electrolytic corrosion, chemical exposure, and thermal cycling.

[0033] This protective coating prevents oxidation of the busbar surfaces, which could otherwise lead to increased electrical resistance, localized heating, and degradation in current-carrying performance over time. The corrosion-resistant layer also ensures stable and low-resistance electrical contact at the terminal interfaces, thereby preserving the integrity of power transmission between the BMS 104 and the terminal box 108. Additionally, the coating contributes to long-term reliability and reduced maintenance in automotive or high-humidity deployment scenarios.

[0034] In an example, in addition to the first connection point 112 and the second connection point 114, the plurality of connection points 110 may further include a first plurality of connection points 112-1 , 112-2, ... 112-N electrically coupled to the first connection point 112 and a second plurality of connection points 114-1 , 114-2, ... 114-N electrically coupled to the second connection point 114. The first plurality of connection points 112-1 , 112-2, ...112-N and the second plurality of connection points 114-1 , 114-2, ...114- N are provisioned to distribute power during charging and discharging operations of the battery pack 100.

[0035] By electrically coupling the BMS 104 to a terminal box using the first busbar 116-1 and the second busbar 116-2 where each busbar has one end directly connected to the first terminal 106-1 and the second terminal 106-2 and another end connected to the first connection point 112 and the second connection point 114 within the terminal box and further branching these primary connection points into the first plurality of connection points 112-1 , 112-2, ... 112-N and second plurality of connection points 114-1 , 114- 2, ... 114-N, a structured and enclosed power distribution path is established entirely within the housing 102 of the battery pack 100.

[0036] The internal busbar-based coupling allows the terminal box 108 to be structurally and functionally integrated within the battery pack 100, rather than existing as an externally connected unit. As a result of the integration of the terminal box 108 within the battery pack 100, the conventional requirement of using wire harnesses to route power from the BMS 104 terminals to charging ports, auxiliary loads, or distribution nodes is eliminated. In conventional designs, such harnesses required routing paths, mechanical fasteners, protective sheathing, and insulation measures to prevent abrasion or arcing. These components increased the complexity of the battery pack layout, introduced additional material and labour costs, and created potential points of mechanical failure due to vibration, thermal cycling, or connector fatigue.

[0037] In contrast, the integrated terminal box 108 within the battery pack 100 simplifies assembly of the battery pack 100, reduces component count, improves long-term durability, and enhances safety through improved electrical isolation and reduced risk of loose or degraded connections. Furthermore, the use of busbars ensures consistent electrical performance under high-load conditions, while the distributed connection points support multiple interfaces for both charging and discharging, including parallel routing to auxiliary loads and external systems.

[0038] In this manner, the above-described configuration of the battery pack overcomes the physical and functional drawbacks of harness-basedbattery packs and also supports a modular, manufacturable, and spaceefficient battery architecture for EVs.

[0039] Figures 2A and 2B illustrate a perspective inside-view of the battery pack illustrated in figure 1 , in accordance with an example of the present subject matter.

[0040] Figure 2A illustrates a top perspective view of the battery pack 100, in accordance with an example of the present subject matter. While Figure 1 presents a conceptual block-level overview, Figure 2A provides a more tangible representation of the physical arrangement of components within the housing 102.

[0041] As shown in Figure 2A, the BMS 104 is accommodated within the housing 102. As explained earlier, the BMS 104 manages the operations of the battery pack 100 by managing and controlling power flow to and from the battery cells.

[0042] The BMS 104 includes a pair of terminals, including a first terminal 106-1 and a second terminal 106-2, which serve as primary points for electrical conduction during charging and discharging. In an example, the first terminal 106-1 corresponds to a first polarity, while the second terminal 106-2 corresponds to a second polarity opposite to the first polarity.

[0043] The battery pack 100 further includes a terminal box 108, accommodated within the housing 102. In an example, the terminal box 108 includes a plurality of connection points 110. In the example, the plurality of connection points 110 includes a first connection point 112 and a second connection point 114.

[0044] The battery pack 100 further includes a plurality of busbars. In an example, the plurality of busbars may include a first busbar 116-1 and a second busbar 116-2. In an example, the first busbar 116-1 and the second busbar 116-2 form electric conductive paths that connect the first terminal 106-1 and the second terminal 106-2 to the terminal box 108.

[0045] In an example, the first busbar 116-1 and the second busbar 116- 2 are spaced apart by a predetermined distance. In an example, thepredetermined distance may be more than or equal to a distance between the first connection point 112 and the second connection point 114.

[0046] As already described, the terminal box 108 includes a plurality of connection points 110, including the first connection point 112 and the second connection point 114. In an example, the first connection point 112 is positioned at a vertical offset 118 relative to the second connection point 114. This vertical offset provides improved insulation and electrical isolation between the connection points, thereby reducing the risk of short circuits or arcing during operation. Additionally, the vertical offset 118 arrangement facilitates easier identification and access during assembly or maintenance procedures, enhancing the overall reliability and safety of the battery pack 100.

[0047] It would be noted that the vertical offset 118 along with spatial separation between the first busbar 116-1 and the second busbar 116-2 by the predetermined distance collectively enhances the electrical insulation and mechanical robustness of the battery pack 100. The above-mentioned configuration minimizes the risk of electrical arcing or short circuits, particularly under high-voltage operating conditions, by ensuring sufficient physical clearance and directional separation between the first busbar 116- 1 and the second busbar 116-2 which are the electrical paths coupling the BMS 104 to the terminal box 108.

[0048] Figure 2B illustrates the top perspective view of the terminal box 108, in accordance with another example of the present subject matter. As illustrated, the terminal box 108 is accommodated within the housing 102. In an example, the terminal box 108 may serve as a centralized electrical interface for distributing power between the BMS 104, the charging unit and various loads of the battery pack 100.

[0049] In an example, the first busbar 116-1 electrically connects the first terminal 106-1 to the first connection point 112. In the example, a first end 116-1 a of the first busbar 116-1 is electrically coupled to the first terminal 106-1 and a second end 116-1 b is electrically coupled to the firstconnection point 112. Further, the second busbar 116-2 connects the second terminal 106-2 to the second connection point 114. In this case, a first end 116-2a of the second busbar 116-2 is electrically connected to the second terminal 106-2 and a second end 116-2b of the second busbar 116- 2 is electrically connected to the second connection point 114.

[0050] Further, in addition to the first connection point 112 and the second connection point 114, the plurality of connection points 110 further includes a first plurality of connection points 112-1 , 112-2, ...112-N, where the first plurality of connection points 112-1 , 112-2, ...112-N are electrically coupled to the first connection point 112.

[0051] Furthermore, the plurality of connection points 110 also includes a second plurality of connection points 114-1 , 114-2, ...114-N, where the second plurality of connection points 114-1 , 114-2, ...114-N are electrically coupled to the second connection point 114. The first plurality of connection points 112-1 , 112-2, ...112-N and the second plurality of connection points 114-1 , 114-2, ...114-N are provisioned to distribute power during charging and discharging operations of the battery pack 100.

[0052] The above-mentioned configuration enables a direct and enclosed electrical pathway from the first terminal 106-1 and the second terminal 106-2 to the terminal box 108 through the first busbar 116-1 and the second busbar 116-2, respectively. The first busbar 116-1 includes a first end 116-1 a connected to the first term inal 106-1 and a second end 116- 1 b connected to the first connection point 112 within the terminal box 108. Similarly, the second busbar 116-2 includes a first end 116-2a connected to the second terminal 106-2 and a second end 116-2b connected to the second connection point 114 within the terminal box 108. This arrangement establishes a direct electrical coupling between the BMS 104 and the terminal box 108, enabling efficient and enclosed power transfer.

[0053] The pluralities of connection points serve as distributed electrical nodes, allowing the power regulated by the BMS 104 to be transferred in parallel to various endpoints such as charging unit and auxiliary loads of thebattery pack. The presence of multiple connection points facilitates simultaneous and modular interfacing with multiple subcomponents of the battery pack 100 thereby enhancing power handling capacity and design flexibility of the battery pack 100.

[0054] Consequently, this integrated electrical pathway eliminates the need for conventional wiring harnesses that are typically used to route power from the BMS 104 to external systems. Further, the fixation and electrical bonding of the first end 116-1 a and second end 116-1 b of the first busbar 116-1 and first end 116-2a and second end 116-2b of the second busbar 116-2 ensure stable, low-resistance paths for power flow.

[0055] Figure 3 illustrates a top perspective view of the battery pack 100, in accordance with an example of the present subject matter.

[0056] As illustrated in figure 3, the battery pack 100 further includes a first pair of electrical ports. In an example, the first pair of electrical ports includes a first electrical port 300-1 and a second electrical port 300-2. The first electrical port 300-1 and the second electrical port 300-2 may be provisioned to serve as input interfaces for receiving power from the BMS 104 for charging the battery pack 100.

[0057] In an example, the battery pack 100 may include a first wire frame 302-1 arranged on a first side plane of the housing 102. In the example, the first wire frame 302-1 may allow a wire to be housed therein to establish a connection between the first electrical port 300-1 and a third connection point, e.g., the connection point 112-3, from the first plurality of connection points 112-1 , 112-2, ..., 112-N.

[0058] The battery pack 100 may further include a second wire frame 302-2 arranged on the first side plane of the housing 102. In the example, the second wire frame 302-2 may allow a wire to be housed therein to establish a connection between the second electrical port 300-2 and a fourth connection point, for example 114-4, from the second plurality of connection points 114-1 , 114-2, ... , 114-N wire frame.

[0059] In an example, the first wire frame 302-1 and second wire frame 302-2 may facilitate modular arrangement of cables within the housing 102 to enable efficient charging of the battery pack 100. When an external charger is connected to the first electrical port 300-1 and second electrical port 300-2, the input current may be directed through the third connection point 112-3 and fourth connection point 114-4, which are already electrically coupled to the first connection point 112 and the second connection point 114, respectively. Accordingly, power may be conducted from the first connection point 112 and the second connection point 114 to the first terminal 106-1 and second terminal 106-2 through the first busbar 116-1 and second busbar 116-2, ultimately leading to charging of the battery pack 100.

[0060] The above-mentioned routing through the first wire frame 302-1 and the second wire frame 302-2 supports modularity and design flexibility. The selection of connection points from among the respective pluralities (e.g., 112-3 and 114-4 in the above example) allows different system architectures to tailor wire frame paths according to packaging constraints, thermal zones, or serviceability requirements. Furthermore, this configuration provides redundancy options; alternative connection points within the first and second pluralities can be employed for additional charger inputs or future expansions.

[0061] In an example, the first wire frame 302-1 and second wire frame 302-2 may also incorporate protective features such as shielding, over moulded connectors, or quick-disconnect fittings to enhance durability and safety in automotive environments. The inclusion of such wire frames eliminates the need to route charging wires through multiple intermediary boards or relay systems, streamlining both the manufacturing process and overall reliability of the battery pack 100.

[0062] In another example of the present subject matter, the battery pack 100 further includes a second pair of electrical ports provisioned to facilitate electrical power delivery from the battery pack 100 to the motorand various other auxiliary loads. The auxiliary loads may include, but are not limited to, vehicle drive inverters, power control units (PCUs), auxiliary systems, or high-voltage distribution modules within the Electric or Hybrid Vehicle.

[0063] In an example, the second pair of electrical ports include a first electrical port and a second electrical port (not illustrated in figures) disposed on the other side (opposite to the side where the first pair of electrical ports are mounted) of the housing 102 of the battery pack 100. The first electrical port and the second electrical port may be provisioned to serve as output interfaces for transferring power from the BMS 104 to the auxiliary loads associated with the battery pack 100.

[0064] Figure 4 illustrates the side perspective view of the battery pack, in accordance with another example of the present subject matter.

[0065] In an example, the battery pack 100 may include a third wire frame 402-1 arranged along a second side plane opposite to the first side plane of the housing 102. In the example, the third wire frame 402-1 may allow a wire to be housed therein to establish a connection between the first electrical port 400-1 from the second pair of electrical ports to a fifth connection point from the first plurality of connection points 112-1 , 112-2, ...112-N.

[0066] The battery pack 100 may further include a fourth wire frame 402- 2 arranged on the second side plane. In the example, the fourth wire frame 402-2 may allow a wire to be housed therein to establish a connection between the second electrical port 400-2 from the second pair of electrical ports to a sixth connection point, from the second plurality of connection points 114-1 , 114-2, ... ,114-N.

[0067] In an example, the third wire frame 402-1 and the fourth wire frame 402-2 may facilitate modular arrangement of cables with the housing 102 to enable efficient transfer of power from the BMS 104 to the auxiliary loads associated with the battery pack 100.

[0068] In an example, when the auxiliary load is connected via the second pair of electrical ports, power is drawn from the battery cells and routed through the connection points, respectively, and subsequently through the first busbar 116-1 and second busbar 116-2 to the first terminal 106-1 and the second terminal 106-2. The BMS 104 continuously monitors and regulates this power flow to ensure safe discharge operation.

[0069] This configuration allows a direct, point-to-point electrical discharge pathway to be implemented from the terminal box 108 to the auxiliary loads, without relying on traditional multi-branch harnesses. The modularity introduced by selecting different connection points (112-3 and 114-4 in the example) supports load balancing, redundancy, and customizable distribution topologies based on system-level requirements.

[0070] Thus, the configuration as illustrated in figure 3, the pair of electrical ports and the associated wire frames simplifies external load integration. This results in reduced assembly complexity, improved electrical performance under dynamic load conditions, and enhanced serviceability.

[0071] Figure 5 illustrates schematic of a vehicle 500, in accordance with an example of the present subject matter.

[0072] Examples of the vehicle 500 may include, but is not limited to, an Electric Vehicle (EV) or a Hybrid Electric Vehicle (HEV). In an example, the vehicle 500 may include the battery pack 100. As already described, the battery pack 100 may include a Battery Management System BMS 104. In an example, the BMS 104 may be accommodated within a housing 102 of the battery pack 100. The BMS 104 is configured to control the operations of the battery pack 100, such as power flow regulation, fault detection, and communication with external systems.

[0073] The BMS 104 includes a pair of terminals. In an example, the pair of terminals includes a first terminal 106-1 and a second terminal 106-2. The first terminal 106-1 may be of a first polarity and the second terminal 106-2 may be of a second polarity, opposite to the first polarity. The first terminal106-1 and the second terminal 106-2 are provisioned to provide electrical connectivity for bidirectional power flow transfer during charging and discharging operations of the battery pack 100.

[0074] The battery pack 100 further includes a terminal box 108 accommodated within the housing 102. The terminal box 108 includes a plurality of connection points 110, wherein the plurality of connection points 110 includes a first connection point 112 and a second connection point 114.

[0075] The battery pack 100 further includes a plurality of busbars, where the plurality of busbars is to electrically couple the terminal box 108 to the BMS 104. The plurality of busbars includes a first busbar 116-1 and a second busbar 116-2.

[0076] To electrically couple the terminal box 108 to the BMS 104, the first busbar 116-1 is to electrically couple the first terminal 106-1 to the first connection point 112. To electrically couple the first terminal 106-1 to the first connection point 112, a first end 116-1 a of the first busbar 116-1 may be electrically coupled to the first terminal 106-1 , and a second end 116-1 b of the first busbar 116-1 may be electrically coupled to the first connection point 112.

[0077] Further, the second busbar 116-2 is to electrically couple the second terminal 106-2 to a second connection point 114 from the plurality of connection points 110. To electrically couple the second terminal 106-2 to the second connection point 114, a first end 116-2a of the second busbar 116-2 is electrically coupled to the second terminal 106-2 and a second end 116-2b of the second busbar 116-2 is electrically coupled to the second connection point 114.

[0078] In an example, in addition to the first connection point 112 and the second connection point 114, the plurality of connection points 110 may further include a first plurality of connection points 112-1 , 112-2, ... 112-N, and a second plurality of connection points 114-1 , 114-2, ... 114-N electrically coupled to the second connection point 114. The first plurality of connection points 112-1 , 112-2, ... 112-N and the second plurality of connection points114-1 , 114-2, ... 114-N are provisioned to distribute power during charging and discharging operations of the battery pack 100.

[0079] In an example, the first busbar 116-1 and the second busbar 116- 2 may be over moulded within the housing 102. The over moulding may be performed using an injection moulding process, whereby the first busbar 116-1 and the second busbar 116-2 is encapsulated in an electrically insulative material to provide mechanical support and electric isolation. The over moulding of the first busbar 116-1 and the second busbar 116-2 may be carried out using the same material as that used to form the housing 102 to ensure material compatibility and effective bonding between the housing 102 and the over moulded first busbar 116-1 and the second busbar 116-2. In an example, the material used to form the housing 102 may be, but not limited to, thermoplastics or thermosetting polymers with high dielectric strength.

[0080] By electrically coupling the BMS to a terminal box using the first busbar 116-1 and the second busbar 116-2 where each busbar has one end directly connected to the first terminal 106-1 and the second terminal 106-2 and another end connected to the first connection point 112 and the second connection point 114 within the terminal box and further branching these primary connection points into the first plurality of connection points 112-1 , 112-2, ... 112-N, and second plurality of connection points 114-1 , 114- 2, ... 114-N, inside the terminal box, a structured and enclosed power distribution path is established entirely within the housing of the battery pack.

[0081] The internal busbar-based coupling allows the terminal box to be structurally and functionally integrated within the battery pack, rather than existing as an externally connected unit. As a result of the integration of the terminal box within the battery pack, the conventional requirement of using wire harnesses to route power from the BMS terminals to charging ports, auxiliary loads, or distribution nodes is eliminated. In conventional designs, such harnesses required routing paths, mechanical fasteners, protectivesheathing, and insulation measures to prevent abrasion or arcing. These components increased the complexity of the battery pack layout, introduced additional material and labour costs, and created potential points of mechanical failure due to vibration, thermal cycling, or connector fatigue.

[0082] In contrast, the integrated terminal box within the battery pack simplifies assembly of the battery pack, reduces component count, improves long-term durability, and enhances safety through improved electrical isolation and reduced risk of loose or degraded connections. Furthermore, the use of busbars ensures consistent electrical performance under high-load conditions, while the distributed connection points support multiple interfaces for both charging and discharging, including parallel routing to auxiliary loads and external systems. In this manner, the abovedescribed configuration of the battery pack overcomes the physical and functional drawbacks of harness-based battery packs and also supports a modular, manufacturable, and space-efficient battery architecture for EVs.

[0083] The present subject matter has been disclosed in connection with certain examples but is not limited to the particular constructions herein disclosed and shown in the drawings but also comprises any modifications or equivalents within the scope of the present subject matter.

Claims

l / We Claim:1 . A battery pack, comprising: a Battery Management System (BMS) accommodated within a housing of the battery pack, wherein the BMS is configured to control the operation of the battery pack, and wherein the BMS comprises a pair of terminals comprising a first terminal and a second terminal; a terminal box accommodated within the housing, wherein the terminal box comprises a plurality of connection points; and a plurality of busbars to electrically couple the BMS to the terminal box, wherein the plurality of busbars comprises a first busbar and a second busbar, wherein the first busbar is to electrically couple the first terminal with a first connection point from the plurality of connection points, and wherein a first end of the first busbar is electrically coupled to the first terminal and a second end of the first busbar is electrically coupled to the first connection point, and wherein the second busbar is to electrically couple the second terminal with a second connection point from the plurality of connection points, and wherein a first end of the second busbar is electrically coupled to the second terminal and a second end of the second busbar is electrically connected to the second connection point, and wherein the plurality of connection points further comprises a first plurality of connection points electrically coupled to the first connection point and a second plurality of connection points electrically coupled to the second connection point, wherein the first plurality of connection points and the second plurality of connection points are usable for charging and discharging of the battery pack.

2. The battery pack as claimed in claim 1 , wherein the first busbar and the second busbar are spaced apart by a predetermined distance, wherein the predetermined distance is more than or equal to a distance between the first connection point and the second connection point.

3. The battery pack as claimed in claim 1 , wherein the first busbar and the second busbar are over moulded in the housing.

4. The battery pack as claimed in claim 3, wherein the first busbar and the second busbar are over moulded by an injection moulding process.

5. The battery pack as claimed in claim 4, wherein the injection moulding is carried out by injecting an electrically insulative material.

6. The battery pack as claimed in claim 1 , wherein the first connection point is positioned at a vertical offset with respect to the second connection point.

7. The battery pack as claimed in claim 1 , further comprising: a first pair of electrical ports to connect a charger to the battery pack; and a first wire frame extending from a first electrical port from the first pair of electrical ports to a third connection point from the first plurality of connection points; and a second wire frame extending from a second electrical port from the first pair of electrical ports to a fourth connection point from the second plurality of connection points.

8. The battery pack as claimed in claim 1 , further comprising: a second pair of electrical ports to connect a load to the battery pack; and a third wire frame extending from a first electrical port from the second pair of electrical ports to a fifth connection point from the first plurality of connection points; and a fourth wire frame extending from a second electrical port from the second pair of electrical ports to a sixth connection point from the second plurality of connection points.

9. The battery pack as claimed in claim 1 , wherein the first and second busbars are coated with a corrosion-resistant coating.

10. An electric vehicle, comprising: a battery pack, wherein the battery pack comprises:a Battery Management System (BMS) accommodated within a housing of the battery pack, wherein the BMS is configured to control the operation of the battery pack, and wherein the BMS comprises a pair of terminals comprising a first terminal and a second terminal; a terminal box accommodated within the housing, wherein the terminal box comprises a plurality of connection points; and a plurality of busbars to electrically couple the BMS to the terminal box, wherein the plurality of busbars comprises a first busbar and a second busbar, wherein the first busbar is to electrically couple the first terminal with a first connection point from the plurality of connection points, and wherein a first end of the first busbar is electrically coupled to the first terminal and a second end of the first busbar is electrically coupled to the first connection point, and wherein the second busbar is to electrically couple the second terminal with a second connection point from the plurality of connection points, and wherein a first end of the second busbar is electrically coupled to the second terminal and a second end of the second busbar is electrically connected to the second connection point, and wherein the plurality of connection points further comprises a first plurality of connection points electrically coupled to the first connection point and a second plurality of connection points electrically coupled to the second connection point, wherein the first plurality of connection points and the second plurality of connection points are usable for charging and discharging of the battery pack.

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