A printed connecting member for an energy storage unit and a method thereof

Abstract

The present disclosure relates to a printed connecting member (300) for an energy storage unit (200) and a method (400) of assembly thereof. The printed connecting member (300) comprises a plurality of first interconnectors (301), and a plurality of second interconnectors (302). One of the plurality of first interconnectors (301) connects with a positive terminal (201P) of energy storage cell (201) of energy storage unit (200). One of the plurality of second interconnectors (302) connects with a negative terminal (201N) of the energy storage cell (201) of energy storage unit (200). The plurality of first interconnectors (301) and the plurality of second interconnectors (302) are configured to connect at a first side (201F) of the energy storage unit (200).

Description

TITLE OF INVENTION:A PRINTED CONNECTING MEMBER FORAN ENERGY STORAGE UNIT AND A METHOD THEREOFTECHNICAL FIELD

[0001] The present disclosure relates to a printed connecting member, an energy storage unit, and a method of assembly thereof. More particularly, the present subject matter relates to a printed connecting member, an energy storage unit, and a method to assemble the energy storage unit.BACKGROUND

[0002] The development of the battery packs employed in automobile industry is influenced by various key factors like market demands, customer feedback, Value Analysis / Value Engineering (VAVE), Engineering Change Request (ECR), and Emerging Technology Trends. The development is driven by the growing demand for efficient, reliable battery assembly in the expanding electric vehicle (EV) market,. Customer feedback also highlighted the need for improved assembly and durability. Value Analysis / Value engineering focused on cost reduction, process optimization, and maintaining quality. Specific changes are also requested to improve alignment, simplify welding, and reduce assembly time. The development of the battery packs also considers emerging industry trends toward modular, easy-to-assemble solutions that minimize labour and enhanced consistency.

[0003] Even after considering the above mention factors, several significant challenges in the current battery module and vehicle configuration still persist, all of which negatively impact the efficiency, reliability, and quality of the battery pack and the assembly process. Presently, cells in the battery pack are interconnected using multiple metal strips, interconnectors, and welded joints. These complex interconnections lead to high resistance due to numerous contact points, which adversely affects pack efficiency and performance. Each additional joint and connection point introduces chances of operational errors during assembly, leading to inconsistencies and an increased likelihood of rejectedbattery packs. The intricate layout of connections makes quality control more difficult and time-consuming. The intricate nature of series and parallel connections of the cells with the metal strips or other connectors increases material costs and requires additional labour for assembly. This contributes to higher costs and increases the time spent on quality checks. The cumulative impact of multiple joints can cause Connection Integrity Management (CIM) issues. If any contact point is loose or improperly welded, the functionality of the entire battery pack is compromised, resulting in potential warranty claims or failure in the field. The currently employed methods for connection create a bulkier battery pack, which may limit the ability to optimize space in compact vehicle structure.

[0004] Also, the existing battery packs may lack rigidity due to the flexibility of interconnectors, making them susceptible to damage from vibration or impact, which can impact vehicle durability. The use of flexible interconnectors can allow slight movements during assembly, which can lead to positional shifts, operational errors, and Connection Integrity Management issues. Such configuration also have more failure points, which compromises with the durability and complicates manufacturing.

[0005] Existing solutions involve welding each metal strip or interconnector individually, which increases the complexity and probability of errors during assembly. Errors such as misplaced fasteners or screws falling into the space between the module and the casing can result in short circuits, posing a significant safety risk. Such mistakes are frequent in complex assembly processes and require additional quality checks to mitigate the risk. This process is labour-intensive and prone to misalignment, resulting in high manufacturing costs and variable quality, making it unsuitable for high-throughput production.

[0006] Multiple connection points can generate heat due to resistance, potentially leading to overheating and reduced battery longevity. Further, the resistance introduced by multiple connections can lead to cell imbalance, where certain cells underperform due to uneven load distribution. This reduces the overall efficiency and lifespan of the battery pack.

[0007] Traditionally, separate Printed Connected Boards and interconnectors are used, which increases the size and cost of the system. The use of separate interconnectors and Printed Connected Boards requires additional materials and labour, driving up costs. Managing a large number of parts further adds to the logistical and operational complexity of the assembly process. Also, presently available solutions do not fully utilize laser welding for all connections due to technical limitations, resulting in higher assembly times.

[0008] Given the above challenges, it is clear that the existing battery packs fall short to overcome problems like bulky structure, short circuits, overheating, and mechanical failures. There is an urgent need for a solution that addresses these issues by providing simplified assembly process, reduced operational errors and improved overall reliability, durability and efficiency of the battery pack.SUMMARY OF THE INVENTION

[0009] The present subject matter relates to a printed connecting member for an energy storage unit. The printed connecting member comprises a plurality of first interconnectors, and a plurality of second interconnectors. One of the plurality of first interconnectors is configured to connect with a positive terminal of at least one energy storage cell of the energy storage unit. One of the plurality of second interconnectors is configured to connect with a negative terminal of the at least one energy storage cell of the energy storage unit. The plurality of first interconnectors and the plurality of second interconnectors are configured to connect at a first side of the energy storage unit.

[0010] The present subject matter also relates to an energy storage unit. The energy storage unit comprises at least one energy storage cell, and a printed connecting member. The at least one energy storage cell comprising a positive terminal and a negative terminal. The printed connecting member comprises a plurality of first interconnectors, and a plurality of second interconnectors. One of the plurality of first interconnectors is configured to connect with the positive terminal. One of the plurality of second interconnectors is configured to connect with the negative terminal. The plurality of first interconnectors and the pluralityof second interconnectors are configured to connect at a first side of the energy storage unit.

[0011] The present subject matter further relates to a method for assembling an energy storage unit. The method comprises a plurality of steps. A first step of the plurality of steps involves arranging at least one energy storage cell in a holder assembly. The at least one energy storage cell comprises a positive terminal and a negative terminal. The positive terminal and the negative terminal are disposed on a first side of the at least one energy storage cell. A second step of the plurality of steps involves attaching a printed connecting member on to the holder assembly. The printed connecting member comprises a plurality of first conductive pathways, a plurality of second conductive pathways, a plurality of first interconnectors, and a plurality of second interconnectors. The plurality of first conductive pathways is configured to transmit a plurality of data signals. The plurality of second conductive pathways is configured to transmit a current. A third step of the plurality of steps involves connecting one of the plurality of first interconnectors and one of the plurality of second interconnectors with the positive terminal and the negative terminal respectively. A fourth step of the plurality of steps involves coupling the plurality of first conductive pathways to a Battery Management System to transmit the plurality of data signals to the Battery Management System.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The details are described with reference to an embodiment of a printed connecting member, an energy storage unit, and a method to assemble the same. The same reference numbers are used throughout the drawings to refer to similar features and components.

[0013] Figure 1 illustrates a top view of a printed connecting member in an energy storage unit, in accordance with an embodiment of the present disclosure.

[0014] Figure 2A illustrates an enlarged view of printed connecting member in the energy storage unit, in accordance with an embodiment of the present disclosure.

[0015] Figure 2B illustrates an enlarged view of a printed connecting member, in accordance with an embodiment of the present disclosure.

[0016] Figure 2C illustrates a side perspective view of the printed connecting member, in accordance with an embodiment of the present disclosure.

[0017] Figure 3 illustrates a side perspective view of the energy storage unit with printed connecting member, in accordance with an embodiment of the present disclosure.

[0018] Figure 4 illustrates a flow chart of a method to assemble an energy storage unit, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION

[0019] In order to overcome one or more of the above-mentioned challenges, the present disclosure entails a printed connecting member, an energy storage unit, and a method to assemble the same. The present disclosure eliminates the inadequacies of the existing battery packs like bulky structure, short circuits, overheating, and mechanical failures while increasing throughput and reducing the assembly costs. The present disclosure decreases the complexity of the assembly process and reduces the probability of errors during assembly. Thus, improving the efficiency and reliability of the energy storage unit without compromising the integrity of the energy storage cells.

[0020] As per one embodiment of the disclosure, a printed connecting member for an energy storage unit is disclosed. The printed connecting member comprises a plurality of first interconnectors, and a plurality of second interconnectors. One of the plurality of first interconnectors is configured to connect with a positive terminal of at least one energy storage cell of the energy storage unit. One of the plurality of second interconnectors is configured to connect with a negative terminal of the at least one energy storage cell of the energy storage unit. The plurality of first interconnectors and the plurality of second interconnectors are configured to connect at a first side of the energy storage unit.

[0021] As per one embodiment of the disclosure, the printed connecting member comprises a plurality of first conductive pathways, and a plurality of second conductive pathways. The plurality of first conductive pathways is configured totransmit a plurality of data signals. The plurality of second conductive pathways is configured to transmit electric current.

[0022] As per one embodiment of the disclosure, the one of the plurality of second interconnectors is connected with the printed connecting member through at least one of a plurality of overcurrent protection units.

[0023] As per one embodiment of the disclosure, the printed connecting member comprises a plurality of layers. The plurality of layers comprises a first layer, a second layer, a third layer and a fourth layer. The plurality of first conductive pathways is embedded in the first layer and the second layer. The plurality of second conductive pathways is embedded in the third layer and the fourth layer.

[0024] As per one embodiment of the disclosure, at least one heat sink is embedded in at least one of the plurality of layers.

[0025] As per one embodiment of the disclosure, the plurality of first conductive pathways is coupled to a Battery Management System to transmit the plurality of data signals to the Battery Management System. The plurality of data signals comprises a real time value of a temperature of the at least one energy storage cell, and a real time value of a voltage across the at least one energy storage cell.

[0026] As per one embodiment of the disclosure, the Battery Management System is mounted through a plurality of pips. The plurality of pips is formed on a first surface of a holder assembly. The first surface of the holder assembly is configured to support the printed connecting member.

[0027] As per one embodiment of the disclosure, the plurality of first interconnectors has a curved profile. The curved profile is parallel and non-coplanar to the printed connecting member. The plurality of second interconnectors has a circular profile. The circular profile is coplanar to the printed connecting member.

[0028] As per one embodiment of the disclosure, the one of the plurality of first interconnectors and the one of the plurality of second interconnectors are configured to connect with the positive terminal and the negative terminal using connectors.

[0029] As per one embodiment of the disclosure, an amount of the current, transmitted through the plurality of second conductive pathways, is controlled by at least one controller. The at least one controller is integrated within the printed connecting member.

[0030] As per another embodiment of the disclosure, an energy storage unit is disclosed. The energy storage unit comprises at least one energy storage cell, and a printed connecting member. The at least one energy storage cell comprises a positive terminal and a negative terminal. The printed connecting member comprises a plurality of first interconnectors, and a plurality of second interconnectors. One of the plurality of first interconnectors is configured to connect with the positive terminal. One of the plurality of second interconnectors is configured to connect with the negative terminal. The plurality of first interconnectors and the plurality of second interconnectors are configured to connect at a first side of the energy storage unit.

[0031] As per another embodiment of the disclosure, the printed connecting member comprises a plurality of first conductive pathways, and a plurality of second conductive pathways. The plurality of first conductive pathways is configured to transmit a plurality of data signals. The plurality of second conductive pathways is configured to transmit electric current.

[0032] As per another embodiment of the disclosure, the energy storage unit comprises a Battery Management System. The Battery Management System is configured to receive the plurality of data signals from the plurality of first conductive pathways. The plurality of data signals comprises a real time value of a temperature of the at least one energy storage cell, and a real time value of a voltage across the at least one energy storage cell.

[0033] As per another embodiment of the disclosure, the Battery Management System is configured to isolate the at least one energy storage cell through at least one protection circuit upon a determination of the failure of the at least one energy storage cell. The at least one protection circuit is embedded within the printed connecting member.

[0034] As per another embodiment of the disclosure, the printed connecting member is connected to the Battery Management System through a coupler connection.

[0035] As per another embodiment of the disclosure, the printed connecting member is connected to the Battery Management System through a wireless communication module.

[0036] As per another embodiment of the disclosure, at least one energy storage cell is disposed in a holder assembly. The printed connecting member comprises a plurality of locators. The plurality of locators is configured to align a placement of the printed connecting member on the holder assembly.

[0037] As per yet another embodiment of the disclosure, a method for assembling an energy storage unit is disclosed. A first step of the plurality of steps involves arranging at least one energy storage cell in a holder assembly. The at least one energy storage cell comprises a positive terminal and a negative terminal. The positive terminal and the negative terminal are disposed on a first side of the at least one energy storage cell. A second step of the plurality of steps involves attaching a printed connecting member on to the holder assembly. The printed connecting member comprises a plurality of first conductive pathways, a plurality of second conductive pathways, a plurality of first interconnectors, and a plurality of second interconnectors. The plurality of first conductive pathways is configured to transmit a plurality of data signals. The plurality of second conductive pathways is configured to transmit a current. A third step of the plurality of steps involves connecting one of the plurality of first interconnectors and one of the plurality of second interconnectors with the positive terminal and the negative terminal respectively. A fourth step of the plurality of steps involves coupling the plurality of first conductive pathways to a Battery Management System to transmit the plurality of data signals to the Battery Management System.

[0038] The embodiments of the present disclosure will now be described in detail with reference to an embodiment of a printed connecting member (300), an energy storage unit (200), and a method (400) to assemble the same, along withthe accompanying drawings. However, the disclosed disclosure is not limited to the present embodiments. The embodiments shown in Figure 1 are taken for discussion. Figure 1 illustrates top view of a printed connecting member (300) in an energy storage unit (200).

[0039] The energy storage unit (200) comprises at least one energy storage cell (201), holder assembly (not shown), a housing assembly (not shown), a printed connecting member (300) and a Battery Management System (not shown). In a preferred embodiment, the energy storage unit (200) is a rechargeable battery which stores and supplies an electrical energy to one or more electrical components such as in a vehicle (not shown). The vehicle can be an electrical vehicle, a hybrid vehicle or a combustion engine vehicle. In a preferred embodiment, the energy storage unit (200) is connected to an electric motor which propels the vehicle by providing necessary torque and traction.

[0040] The energy storage cell (201) is an electrochemical secondary cell. Naturally, the energy storage unit (200) comprises a plurality of said energy storage cell (201). The energy storage cell (201) includes but not limited to lead-acid cells, Nickel-cadmium cells, Nickel-iron cells, Nickel-metal hydride cells, Lithium-ion cells, Lithium-ion polymer cells and fuel cells. The energy storage cell (201) may also include other experimental types of battery cells like Lithium-sulphur cells, Sodium-ion cells, Thin-film lithium cells, Zinc-bromine cells, Zinc-cerium cells, Vanadium redox cells, Sodium-sulphur cells, Molten-salt cells, Silver-zinc cells, Nickel-zinc cells and Quantum battery cells. In the shown embodiments, the energy storage cell (201) has a cylindrical shape. However, the shape of the energy storage cell (201) can also be prismatic. The energy storage cell (201) comprises a positive terminal (20 IP) and a negative terminal (20 IN) which are disposed on a first side (20 IF) of the energy storage cell (201).

[0041] The holder assembly comprises structural components which can hold and secure individual energy storage cell (201) within the energy storage unit (200). The housing assembly is the physical enclosure or casing that contains and protects the energy storage cell (201). The housing assembly serves both aprotective and structural function, ensuring the safety, stability, and performance of the energy storage unit (200). The housing assembly is the physical enclosure or casing that contains and protects the energy storage cell (201). The housing assembly serves both a protective and structural function, ensuring the safety, stability, and performance of the energy storage unit (200). Common materials like polypropylene (PP), Acrylonitrile Butadiene Styrene (ABS), or polycarbonate (PC) can be used for making the housing assembly due to their lightweight, cost-effective, and insulating properties. However, in high-performance or heavy-duty applications, metal (typically aluminium or steel) or composite materials (like carbon fibre) can also be used for better strength, heat dissipation, and durability.

[0042] The printed connecting member (300) physically and electrically connects the energy storage cell (201) with the other electrical components of the energy storage unit (200) like the Battery Management System, connectors, capacitors, switches, transistors, control units and microcontrollers by using conductive pathways (traces) in the form of a plurality of first conductive pathways and a plurality of second conductive pathways. The plurality of first conductive pathways transmits a plurality of data signals. The printed connecting member (300) comprises a plurality of locators. The plurality of locators align a placement of the printed connecting member (300) on the holder assembly.

[0043] The printed connecting member (300) can be a single layer medium or can be a laminated sandwich structure of multiple conductive and insulating layers. The printed connecting member (300) can have a rigid, a rigid-flex or a flexible structure. The printed connecting member (300) can be made up of a solid, inflexible base material like fiberglass-reinforced epoxy to provide rigidity. Further, the printed connecting member (300) can be made up of a flexible substrates like polyimide, Polyester, Polyimide, which can bend without breaking to render desired flexibility to the printed connecting member (300). The rigid-flex configuration of the printed connecting member (300) allows for both rigid sections for mounting components and flexible sections for specific parts of the circuit that need to bend.

[0044] In an embodiment of the present disclosure, Module Level Printed Circuit Board (MLPCB) is used. The MLPCB is a specialized printed connecting member (300) configured for managing the electrical and thermal requirements of the energy storage unit (200) in an Electric Vehicle. The Module Level Printed Circuit Board (MLPCB) integrates features like electrical interconnections, thermal management, and mechanical stability to ensure efficient power distribution, safety, and reliability within the energy storage unit (200). The MLPCBs typically consist of layers such as of a conductive copper circuit layer for current flow, a dielectric layer for insulation, and a metal base layer, such as aluminium or copper layer, to dissipate heat effectively. They often incorporate components of the Battery Management System, including monitoring and balancing circuits for the energy storage cell (201), to enhance the performance and safety of the energy storage unit (200). Further, MLPCBs offer a compact, lightweight, and durable solution that withstands the mechanical stresses and thermal demands of automotive environments, making them essential for modem Electric Vehicles.

[0045] The printed connecting member (300) comprises a plurality of first interconnectors (301) and a plurality of second interconnectors (302). One of the plurality of first interconnectors (301) connects with the positive terminal (20 IP). One of the plurality of second interconnectors (302) connects with the negative terminal (20 IN). The plurality of first interconnectors (301) and the plurality of second interconnectors (302) are configured to connect at a first side (20 IF) of the energy storage unit (200) respectively with the positive terminal (20 IP) and the negative terminal (20 IN) on the same side of the at least one energy storage cell (201), the requirement of dual-side welding is completely eliminated as both the terminals of the energy storage cell (201) are disposed towards single side of the energy storage cell (201). Further, the need for separate printed connecting member (300) for each side of the energy storage cell (201) is eliminated as both the terminals of the energy storage cell (201) are disposed on same side and are connected to the same printed connecting member (300). This configuration notonly facilitates single side welding but also simplifies assembly but also improves alignment, reduces vibrations, and provides robust connections.

[0046] The Battery Management System (BMS) is responsible for monitoring and managing the health, safety, and performance of the energy storage unit (200) by ensuring that the energy storage cell (201) operate within safe limits. The Battery Management System receives the plurality of data signals from the plurality of first conductive pathways. The plurality of data signals comprises a real time value of parameters such as a temperature of the at least one energy storage cell (201), and a real time value of a voltage across the at least one energy storage cell (201). The Battery Management System determines a failure of the at least one energy storage cell (201) on the basis of the plurality of data signals. The Battery Management System isolates the at least one energy storage cell (201) through at least one protection circuit upon a determination of the failure of the at least one energy storage cell (201). The at least one protection circuit is embedded within the printed connecting member (300).

[0047] The Battery Management System can have a single centralized controller for monitoring and controlling functions of the plurality of energy storage cell (201). In alternate embodiment, the Battery Management System comprises multiple controllers that are used across the energy storage unit (200). Each controller monitors a specific section of the energy storage unit (200) and communicates with a central unit. The Battery Management System can also has a modular configuration with a more flexible structure that allows for easy expansion and modification based on the size and configuration of the energy storage unit (200). The Battery Management System is connected to a plurality of sensing units for monitoring the voltage, State of Charge, State of Health and temperature of the plurality of energy storage cell (201).

[0048] The printed connecting member (300) is connected to the Battery Management System through a coupler connection. In an alternate embodiment, the printed connecting member (300) is connected to the Battery Management System through a wireless communication module like Wi-Fi, Bluetooth, and Zigbee. The Battery Management System communicates with other systems inthe vehicle by using communication protocols like Controller Area Network (CAN bus), Modbus or wireless communication modules like Wi-Fi, Bluetooth, and Zigbee. The wireless communication modules streamline the assembly process by reducing the need for additional signal wiring. This also enhances reliability of the energy storage unit (200) by eliminating physical connections that are prone to wear or damage.

[0049] The embodiments shown in Figure 2A, Figure 2B and Figure 2C are taken together for discussion. Figure 2A illustrates an enlarged view of the energy storage unit (200). Figure 2B illustrates an enlarged view of a printed connecting member (300). Figure 2C illustrates a side perspective view of the printed connecting member (300).

[0050] In the present disclosure, the functions of the Printed Circuit Board (PCB) and interconnectors like busbars combined into a single component as printed connecting member (300), thereby eliminating the need for separate parts. This integration addresses the various challenges pertaining to space optimization in the energy storage unit (200) as wells as streamlining the assembly process.

[0051] The plurality of first conductive pathways and the plurality of second conductive pathways are critical conductive tracks etched or printed onto the surface of the printed connecting member (300). These tracks are primarily made of material such as but not limited to copper, which offers excellent conductivity and durability. Their primary function is to establish electrical connections between different components on the printed connecting member (300), enabling the seamless flow of electric current and data signals. The width and thickness of the tracks determined by the amount of current they are required to carry. Tracks intended for high-current applications are made wider and thicker to ensure that the load can be handles without overheating or causing excessive resistance. Conversely, tracks carrying low-power data signals can be narrower, optimizing space on the board for compact construction. Spacing between these tracks is another critical consideration in the configuration of the printed connecting member (300). Adequate spacing is essential to prevent short circuits caused by accidental electrical contact between adjacent tracks. This spacing also helps toensure that the printed connecting member (300) operates reliably, even in environments prone to electrical noise or high temperatures. The layout of the tracks is carefully planned to minimize interference and signal loss. This involves strategic routing to prevent overlapping paths and to optimize the flow of electric current and data signals. Special care is taken to align components and route tracks in a manner that reduces cross-talk (interference between adjacent signal paths) and maintains signal integrity, especially in high-frequency applications. By using these tracks as integrated conductive pathways, the need for traditional wires is eliminated. This not only reduces the complexity of the manufacturing process but also improves the reliability of the energy storage unit (200). Additionally, the compact and organized nature of the tracks supports the creation of highly efficient, space-saving configurations for printed connecting member (300), which are particularly beneficial for applications like energy storage unit (200) in electric vehicles, where compactness and reliability are paramount.

[0052] The printed connecting member (300) comprises a plurality of locators. The plurality of locators facilitates secure and precise mounting of the printed connecting member (300) onto the holder assembly. The plurality of locators act as alignment guides, ensuring that the printed connecting member (300) is correctly positioned during the assembly process. The inclusion of the plurality of locators eliminates the need for manual adjustments, reduces assembly errors, and ensures consistency across all the energy storage unit (200). This streamlines the manufacturing process, enhances positional accuracy, and minimizes the risk of misalignment during operation.

[0053] The one of the plurality of second interconnectors (302) is connected with the printed connecting member (300) through at least one of a plurality of overcurrent protection units (303). The neck portion of the plurality of second interconnectors (302) is calibrated based on the capacity of the at least one energy storage cell (201) to form the overcurrent protection units (303). The overcurrent protection units (303) functions as a fuse at the level of the at least one energy storage cell (201). When the current exceeds the calibrated threshold, theovercurrent protection units (303) melts or disconnects, effectively isolating the affected energy storage cell (201) from the circuit. This fusing mechanism provides an additional layer of protection by preventing overcurrent from damaging the entire energy storage unit (200) or causing a short circuit. This ensures the safety at the level of the energy storage cell (201), reducing the need for external fuses and enhancing the reliability of the energy storage unit (200).

[0054] In an additional embodiment, the printed connecting member (300) incorporates one or more protection circuits to guard against overvoltage and undervoltage conditions. These protection circuits are dedicated tracks on the printed connecting member (300) for monitoring voltage thresholds, linked to the Battery Management System for real-time voltage management. The protection circuits work as circuit breakers or resettable fuses for isolating energy storage cell (201) in extreme conditions, thereby protecting the energy storage cell (201) and circuitry from damage due to voltage fluctuations.

[0055] The printed connecting member (300) comprises a plurality of layers. The plurality of layers comprises a first layer, a second layer, a third layer and a fourth layer. The plurality of first conductive pathways is embedded in the first layer and the second layer. The plurality of second conductive pathways is embedded in the third layer and the fourth layer. The plurality of layers is made up of a rigid material. The rigid construction of the printed connecting member (300) not only make it less susceptible to damage from vibrations or impacts but also reduces the chances of any slight movements, positional shifts or operational errors.

[0056] The plurality of second conductive pathways transmits electric current. The plurality of second conductive pathways can carry electric current of up to 120 Amps. The separation of plurality of second conductive pathways from the plurality of first conductive pathways by the plurality of layers reduces interference, noise and ensures efficient energy transfer. This robust configuration allows the printed connecting member (300) to handle high currents while maintaining reliability and operational stability, making it suitable for demanding applications.

[0057] The printed connecting member (300) can include integrated thermal management solutions to address heat dissipation and maintain optimal operating temperatures. At least one heat sink is embedded in at least one of the plurality of layers of the printed connecting member (300). The at least one heat sink is made up of material such as but limited to copper, aluminium or the like. The at least one heat sink can be embedded within the plurality of layers of the printed connecting member (300), directly connected to heat-generating components such as interconnectors and terminals. A dedicated thermal layer could be added to the plurality of layers to distribute heat evenly across the printed connecting member (300). This configuration prevents overheating, which improves the longevity and safety of the energy storage unit (200).

[0058] The plurality of first interconnectors (301) has a curved profile. The curved profile can be such as but not limited to a crescent shape. The curved profile is parallel and non-coplanar to the printed connecting member (300). The plurality of second interconnectors (302) has a circular profile. The circular profile is coplanar to the printed connecting member (300). The plurality of first interconnectors (301) and the plurality of second interconnectors (302) serve as contact points, allowing secure connections between the energy storage cell (201) and the printed connecting member (300). The plurality of first interconnectors (301) and the plurality of second interconnectors (302) are disposed on the back side of the printed connecting member (300). Further, the plurality of first interconnectors (301) and the plurality of second interconnectors (302) are positioned to align with the respective terminals of the energy storage cell (201).

[0059] The curved profile of the plurality of first interconnectors (301) and the circular profile of plurality of second interconnectors (302) maximizes the contact area between the terminals and the printed connecting member (300). By utilizing the entire surface of the terminals, the disclosed configuration ensures better electrical conductivity, reduced resistance and prevents thermal runway of the energy storage cell (201).

[0060] Since the plurality of first interconnectors (301) and the plurality of second interconnectors (302) are positioned on different planes, clearancebetween the plurality of first interconnectors (301) and the plurality of second interconnectors (302) is enhanced. This enhanced clearance reduces any interference between the two interconnectors, thereby facilitating easier assembly, precise attachment with the terminals during manufacturing process.

[0061] An amount of the current, transmitted through the plurality of second conductive pathways, is controlled by at least one controller. The at least one controller is integrated within the printed connecting member (300). The at least one controller is a part of current shunting circuits that dynamically adjust current flow based on the health of the energy storage cell (201) or load demands. These circuits redirect current automatically in the event of failure of the energy storage cell (201) to balance loads dynamically across the energy storage cell (201). This extends the lifespan of the energy storage unit (200) by preventing overloading of individual energy storage cell (201).

[0062] The embodiments shown in Figure 3 are taken for discussion. Figure 3 illustrates a side perspective view of the energy storage unit (200).

[0063] The construction of the printed connecting member (300) accommodates flexibility in the series and parallel configuration of the energy storage cell (201), depending on the specific requirements of the energy storage unit (200). Two or more energy storage cells (201) are connected in series to increase the voltage output. Two or more energy storage cells (201) are connected in parallel to increase the current capacity. This flexibility allows the printed connecting member (300) to be adapted to various energy storage unit (200) specifications, ensuring compatibility with different vehicle models and applications. By enabling customizable configurations, this construction can cater to a wide range of uses, thereby enhancing versatility and scalability of energy storage unit (200).

[0064] The Battery Management System is mounted through a plurality of pips. The plurality of pips is formed on a first surface of a holder assembly. The first surface of the holder assembly supports the printed connecting member (300).

[0065] The one of the plurality of first interconnectors (301) and the one of the plurality of second interconnectors (302) are configured to connect with the positive terminal (20 IP) and the negative terminal (20 IN) using connectors. In apreferred embodiment, the connector is a plug and play connector. The plug-and-play connectors for individual energy storage cell (201) or group of energy storage cells (201), enables quick replacements without disturbing the entire energy storage unit (200). This enhances modularity, allows easy disassembly for repair or replacement of faulty energy storage cell (201), eliminates the need for additional fasteners and reduces downtime during maintenance or repairs.

[0066] In an alternate embodiment, the one of the plurality of first interconnectors (301) and the one of the plurality of second interconnectors (302) are configured to connect with the positive terminal (20 IP) and the negative terminal (20 IN) respectively through laser welding, spot welding, soldering or other suitable techniques. In the energy storage cell (201) with single-sided terminals, the positive terminal (anode, 20 IP) and negative terminal (cathode, 20 IN) are positioned on the same face of the energy storage cell (201), referring as top of the energy storage cell (201). More specifically, the side where the positive terminal (20 IP) and the negative terminal (20 IN) are located is referred to as the top of the energy storage cell (201), as it serves as the interface for electrical connections. Conversely, the opposite side, referred to as the bottom of the energy storage cell (201), which typically does not feature any of the positive terminal (20 IP) and negative terminal (20 IN) may include structural or thermal management features.

[0067] The embodiments shown in Figure 4 are taken for discussion. Figure 4 illustrates a flow chart of a method (400) to assemble the energy storage unit (200). A first step of the plurality of steps involves arranging (401) at least one energy storage cell (201) in a holder assembly (202).

[0068] A second step of the plurality of steps involves attaching (402) a printed connecting member (300) on to the holder assembly. A third step of the plurality of steps involves connecting (403) one of the plurality of first interconnectors (301) and one of the plurality of second interconnectors (302) with the positive terminal (201P) and the negative terminal (201N) respectively.

[0069] A fourth step of plurality of steps involves coupling (404) the plurality of first conductive pathways to a Battery Management System to transmit the plurality of data signals to the Battery Management System.

[0070] The disclosure and its embodiments have several advantages. All the terminals of the energy storage cell (201) face in the same direction. This configuration can effectively work with the printed connecting member (300) allowing for single-side welding. This simplifies the welding process, decreases assembly time, and reduces the risk of misaligned welds. The same orientation of the energy storage cells (201) with respect to the printed connecting member (300) facilitates automated or semi -automated single-side welding, increasing throughput and reducing labor costs.

[0071] By integrating the plurality of first interconnectors (301) and the plurality of second interconnectors (302) into the printed connecting member (300), the assembly process is simplified, eliminating additional steps. Accordingly, the printed connecting member (300) acts as the connecting member and the interconnectors thereby eliminating the need for additional metal strips or separate interconnectors. This reduces assembly complexity and ensures higher positional accuracy. This results in higher positional accuracy, ensuring consistent and reliable connections between various components of the energy storage unit (200). The integrated configuration of the printed connecting member (300) enables it to perform dual roles i.e. carrying data signals as well as electric current within a single component. This eliminates the need for separate interconnectors, reducing material requirements and improving the overall efficiency of the energy storage unit (200). Further, the risk of short circuits and current imbalance is significantly reduced due to the improved configuration and streamlined assembly process. The modular nature of the energy storage unit (200) also allows for robust and secure connections, ensuring safety during operation.

[0072] Reduction in part count mean lower material costs and reduced labour requirements. The simplified assembly process also cuts down on manufacturing time, making the method (400) more economical for high-volume production ofthe energy storage unit (200). Rigid structure of the printed connecting member (300) provides strong mechanical interface that ensures structural stability and durability, making it resistant to vibrations and impacts.

[0073] The separation of planes for the plurality of first interconnectors (301) and the plurality of second interconnectors (302) simplifies the alignment process during assembly, reducing errors and improving efficiency. Reduction in errors such as misplaced fasteners or screws falling into the space between the module and the casing reduces the chances of short circuits. The placement of the plurality of first interconnectors (301) on a separate plane and the the plurality of second interconnectors (302) on the same plane with the printed connecting member (300) optimizes the layout, making the configuration more compact and easier to scale for various applications.

[0074] The larger contact area of the plurality of first interconnectors (301) and the plurality of second interconnectors (302) with the positive terminal (20 IP) and the negative terminal (20 IN) enhances the reliability of the electrical connection. This reduces the chances of connection failure and improves overall performance of the energy storage unit (200). The increased surface area minimizes resistance, leading to more efficient energy transfer. This enhances the performance and longevity of the energy storage unit (200). Further, the ability to use various methods such as soldering or laser welding ensures compatibility with a wide range of materials, making the printed connecting member (300) adaptable to different manufacturing requirements.

[0075] The present disclosed disclosure relates to a printed connecting member (300) for an energy storage unit (200) and a method (400) to assemble the same. Embodiments illustrated in the present disclosure can be worked with any type of energy storage unit (200) comprising energy storage cell (201). Further, the disclosure is not limited to the aforementioned embodiments. For example, as used in this specification and the appended claims, the singular forms “a,” “an” and “they” can include plural referents unless the context clearly indicates otherwise. Further, when introducing elements / components / etc. of the assembly / system / method described and / or illustrated herein, the articles “a”,“an”, “the”, and “said” are intended to mean that there is one or more of the element (s) / component(s) / etc. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional element(s) / component(s) / etc. other than the listed element(s) / component(s) / etc.

[0076] This written description uses examples to provide details on the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems. The scope of the disclosure is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein. Many modifications and variations of the present subject matter are possible in light of the above disclosure.LIST OF REFERENCE NUMERALS0 Energy storage unit1 Energy storage cellF First side of the energy storage cell N Negative terminalP Positive terminal0 Printed connecting member 1 First interconnectors Second interconnectors3 Overcurrent protection units 0 Method1 ArrangingAttaching3 ConnectingCoupling

Claims

We Claim:

1. A printed connecting member (300) for an energy storage unit (200), the printed connecting member (300) comprising:a plurality of first interconnectors (301), one of the plurality of first interconnectors (301) being configured to connect with a positive terminal (201P) of at least one energy storage cell (201) of the energy storage unit (200); and a plurality of second interconnectors (302), one of the plurality of second interconnectors (302) being configured to connect with a negative terminal (20 IN) of the at least one energy storage cell (201) of the energy storage unit (200),the plurality of first interconnectors (301) and the plurality of second interconnectors (302) being configured to connect at a first side (201F) of the energy storage unit (200).

2. The printed connecting member (300) as claimed in claim 1, wherein the printed connecting member (300) comprising:a plurality of first conductive pathways, the plurality of first conductive pathways being configured to transmit a plurality of data signals; anda plurality of second conductive pathways, the plurality of second conductive pathways being configured to transmit electric current.

3. The printed connecting member (300) as claimed in claim 1, wherein the one of the plurality of second interconnectors (302) being connected with the printed connecting member (300) through at least one of a plurality of overcurrent protection units (303).

4. The printed connecting member (300) as claimed in claim 2, whereinthe printed connecting member (300) comprises a plurality of layers, the plurality of layers comprising a first layer, a second layer, a third layer and a fourth layer;the plurality of first conductive pathways being embedded in the first layer and the second layer; andthe plurality of second conductive pathways being embedded in the third layer and the fourth layer.

5. The printed connecting member (300) as claimed in claim 4, wherein at least one heat sink being embedded in at least one of the plurality of layers.

6. The printed connecting member (300) as claimed in claim 2, wherein the plurality of first conductive pathways being coupled to a Battery Management System to transmit the plurality of data signals to the Battery Management System, the plurality of data signals comprising at least one of:a real time value of a temperature of the at least one energy storage cell (201), anda real time value of a voltage across the at least one energy storage cell (201).

7. The printed connecting member (300) as claimed in claim 6, wherein the Battery Management System being mounted through a plurality of pips, the plurality of pips being formed on a first surface of a holder assembly; the first surface of the holder assembly being configured to support the printed connecting member (300).

8. The printed connecting member (300) as claimed in claim 1, wherein the plurality of first interconnectors (301) comprises a curved profile, the curved profile being parallel and non-coplanar to the printed connecting member (300); and the plurality of second interconnectors (302) comprises a circular profile, the circular profile being coplanar to the printed connecting member (300).

9. The printed connecting member (300) as claimed in claim 1, wherein the one of the plurality of first interconnectors (301) and the one of the plurality of second interconnectors (302) being configured to connect with the positive terminal (201P) and the negative terminal (20 IN) using connectors.

10. The printed connecting member (300) as claimed in claim 2, wherein an amount of the current, transmitted through the plurality of second conductive pathways, being controlled by at least one controller, the at least one controller being integrated within the printed connecting member (300).

11. An energy storage unit (200), the energy storage unit (200) comprising:at least one energy storage cell (201), the at least one energy storage cell (201) comprising a positive terminal (201P) and a negative terminal (201N); anda printed connecting member (300), the printed connecting member (300) comprising:a plurality of first interconnectors (301), one of the plurality of first interconnectors (301) being configured to connect with the positive terminal (20 IP); anda plurality of second interconnectors (302), one of the plurality of second interconnectors (302) being configured to connect with the negative terminal (20 IN), the plurality of first interconnectors (301) and the plurality of second interconnectors (302) being configured to connect at a first side (20 IF) of the energy storage unit (200).

12. The energy storage unit (200) as claimed in claim 11, wherein the printed connecting member (300) comprising:a plurality of first conductive pathways, the plurality of first conductive pathways being configured to transmit a plurality of data signals; anda plurality of second conductive pathways, the plurality of second conductive pathways being configured to transmit electric current.

13. The energy storage unit (200) as claimed in claim 12, wherein the energy storage unit (200) comprises a Battery Management System, the Battery Management System being configured to receive the plurality of data signals from the plurality of first conductive pathways, the plurality of data signals comprising:a real time value of a temperature of the at least one energy storage cell (201), anda real time value of a voltage across the at least one energy storage cell (201).

14. The energy storage unit (200) as claimed in claim 13, wherein the Battery Management System being configured to isolate the at least one energy storage cell (201) through at least one protection circuit upon a determination of the failure of the at least one energy storage cell (201), the at least one protection circuit being embedded within the printed connecting member (300); the printed connecting member (300) being connected to the Battery Management System through a coupler connection.

15. The energy storage unit (200) as claimed in claim 11 , wherein the at least one energy storage cell (201) being disposed in a holder assembly, the printed connecting member (300) comprises a plurality of locators, the plurality of locators being configured to align a placement of the printed connecting member (300) on the holder assembly.

16. A method (400) to assemble an energy storage unit (200), the method (400) comprising a plurality of steps of:arranging (401) at least one energy storage cell (201) in a holder assembly, the at least one energy storage cell (201) comprising a positive terminal (20 IP) and a negative terminal (20 IN), the positive terminal (20 IP) and the negative terminal (20 IN) being disposed on a first side (201F) of the at least one energy storage cell (201);attaching (402) a printed connecting member (300) on to the holder assembly, the printed connecting member (300) comprises:a plurality of first conductive pathways, the plurality of first conductive pathways being configured to transmit a plurality of data signals, a plurality of second conductive pathways, the plurality of second conductive pathways being configured to transmit a current, a plurality of first interconnectors (301), anda plurality of second interconnectors (302);connecting (403) one of the plurality of first interconnectors (301) and one of the plurality of second interconnectors (302) with the positive terminal (20 IP) and the negative terminal (20 IN) respectively; andcoupling (404) the plurality of first conductive pathways to a Battery Management System to transmit the plurality of data signals to the Battery Management System.

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