A battery pack

Abstract

The present invention relates to a battery pack (10). The battery pack (10) includes a plurality of battery modules (20) disposed adjacent to each other. Each of the plurality of battery modules (20) has a plurality of cells housed within an enclosure (30). The plurality of cells is electrically interconnected by one or more connectors (40). Further, the battery pack (10) includes an isolation sheet (50) sandwiched between two adjacent battery modules (20) of the plurality of battery modules (20). The isolation sheet (50) has a plurality of isolating sections (52) formed next to each other. Each of the isolating sections (52) are configured to insulate at least two oppositely facing connectors (40) of the adjacent battery modules (20) to reduce the risk of electrical short circuit and improve thermal management within the battery pack (10).

Description

[0001] TITLE OF INVENTION

[0002] A Battery Pack

[0003] FIELD OF THE INVENTION

[0004]

[0001] The present invention relates to a battery pack. More particularly, the present invention relates to a battery pack for a vehicle.

[0005] BACKGROUND OF THE INVENTION

[0006]

[0002] Battery packs are widely utilized in various applications such as vehicles, renewable energy storage, and portable electronics due to their high energy density, long cycle life, and reusability. These battery packs consist of multiple battery modules, with each module containing several cells that are interconnected to provide the required voltage and capacity. However, the configuration and interconnection of these cells and modules present several challenges including their modularity, compactness and thermal efficiency which impacts the performance, safety, and reliability of the battery pack.

[0007]

[0003] One of the primary challenges in designing the battery packs is ensuring proper isolation between the adjacent battery modules. The interconnection of cells within each module is typically achieved using connectors, which are conductive connectors that link the terminals of the cells. When multiple battery modules are placed in close proximity within a battery pack, there is a risk that the connectors of adjacent modules could come into electrical contact, leading to potential short circuits. Such short circuits can result in safety hazards, including thermal runaway, overheating, or even fire, which could damage the battery pack or the device the battery pack powers.

[0008]

[0004] Another problem arises from mechanical stability of the battery modules. As the modules are positioned side by side within the battery pack, there is a risk of mechanical interference between adjacent modules. This could result in physical damage to the battery cells or their connections, reducing the overall lifespan and performance of the battery pack. Inadequate separation between modules may also leadto misalignment or shifting during operation, further increasing the risk of mechanical failure.

[0009]

[0005] Additionally, the current solutions for isolating battery modules, such as the use of insulating materials or spacers, often fail to effectively isolate the connectors. These existing isolation materials may not provide sufficient electrical insulation, mechanical support, or thermal management. In many cases, the insulating materials used are either too thin or too rigid, which limits their ability to prevent short circuits between the connectors of adjacent battery modules while maintaining the required level of stability and durability.

[0010]

[0006] Moreover, existing isolation systems do not always offer an efficient method for securing the insulating materials in place, which can complicate the assembly of the battery pack and affect its long-term reliability. The lack of secure attachment methods can lead to misalignment or movement of the insulating components during the operation of the battery pack, further compromising safety and performance.

[0011]

[0007] Thus, there is a need in the art for a battery pack which addresses at least the aforementioned problems.

[0012] SUMMARY OF THE INVENTION

[0013]

[0008] In an aspect, the present invention relates to a battery pack. The battery pack includes a plurality of battery modules disposed adjacent to each other. Each of the plurality of battery modules has a plurality of cells housed within an enclosure. The plurality of cells is electrically interconnected by one or more connectors. Further, the battery pack includes an isolation sheet sandwiched between two adjacent battery modules of the plurality of battery modules. The isolation sheet has a plurality of isolating sections formed next to each other. Each of the isolating sections are configured to insulate at least two oppositely facing connectors of the adjacent battery modules to reduce the risk of electrical short circuit and improve thermal management within the battery pack.

[0009] In a further embodiment, the isolation sheet extends longitudinally between a first end and a second end. Each of the first end and the second end includes one or more mounting holes.

[0014]

[0010] In a further embodiment, the one or more mounting holes are configured to receive one or more fasteners for securing the isolation sheet to the enclosures of the plurality of battery modules.

[0015] [Oil] In a further embodiment, the isolation sheet is made of at least a plastic material.

[0016]

[0012] In a further embodiment, each of the plurality of isolating sections corresponds to shape of each of the oppositely facing connectors of the plurality of battery modules.

[0017]

[0013] In a further embodiment, each of the plurality of battery cells of each of the plurality of battery modules includes terminals.

[0018]

[0014] In a further embodiment, the terminals of the plurality of cells are interconnected with each other by the one or more of connectors.

[0019]

[0015] In a further embodiment, at least one of the isolating sections includes one or more perforations for ventilation and cooling of the battery modules.

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021]

[0016] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.

[0022] Figure 1 illustrates a perspective view of a battery pack, in accordance with an embodiment of the present invention.

[0023] Figure 2 illustrates an exploded perspective view of the battery pack, in accordance with an embodiment of the present invention.

[0024] DETAILED DESCRIPTION OF THE INVENTION

[0017] The present invention relates to a battery pack. More particularly, the present invention relates to a battery pack in a vehicle. In an embodiment, the vehicle can be an Internal Combustion Engine (ICE) vehicle, an electric vehicle or a hybrid vehicle. The battery pack is typically used in a vehicle such as, but not limited, a two-wheeled vehicle. However, it should be understood that the battery pack as illustrated may also find its application in other kinds of vehicle like, a three wheeled vehicle, or a four wheeled vehicle, or other multi-wheeled vehicles, or any non-automotive application which may use the battery pack.

[0025]

[0018] The terms “battery pack” and “battery” may be interchangeably used in the present disclosure. However, the term “battery” may be used less often for brevity. In some embodiments, the battery pack may be a battery pack made of lithium-ion cells. It may be contemplated that the battery pack is not limited to only battery pack made of Lithium-ions, and the battery pack may be made of any other material known in the art. Thus, the scope of application of the present invention may not be limited to only a battery pack having the Lithium-ions.

[0026]

[0019] The battery pack includes two or more battery modules. Each battery module has a 13s5p battery cell configuration. The two battery modules are connected together so as to form a 13sl0p cell configuration. The battery modules are positioned side by side and are separated by an isolation sheet (e.g., a plastic separator unit). The battery modules are held together using a clamp (e.g., a plastic clamp) holding side ends of the battery modules. The isolation sheet is placed between the two battery modules, and the isolation sheet ensures that the terminals and interconnectors of the battery modules are not contacting each other. The battery pack can be mounted with at least one Battery Management System (BMS).

[0027]

[0020] Figure 1 illustrates a perspective view of a battery pack 10, in accordance with an embodiment of the present invention. As illustrated, the battery pack 10 comprises a plurality of battery modules 20 disposed adjacent to each other. In an embodiment, the plurality of battery modules 20 comprises at least a first battery module and a second battery module.

[0021] Further, each of the plurality of battery modules 20 has a plurality of cells housed within an enclosure 30. In an embodiment, the enclosure 30 is made of at least a plastic material. In an embodiment, each of the plurality of battery cells of each of the plurality of battery modules 20 comprises terminals 22.

[0028]

[0022] In a non-limiting example, each of the first battery module and the second battery module comprises the plurality of cells arranged in a 13s5p configuration wherein, 13 groups of 5 parallelly connected cells are connected in series within the enclosure 30. In another embodiment, each of the first battery module and the second battery module comprises the plurality of cells arranged in any other configuration known in the art.

[0029]

[0023] Furthermore, the plurality of cells is electrically interconnected by one or more connectors 40. In an embodiment, the terminals 22 of the plurality of cells are interconnected with each other by the one or more of connectors 40. In another nonlimiting embodiment, the connectors 40 comprise a metal strip made of at least one of nickel, aluminium, and copper. In an embodiment, the connectors 40 are mounted to the enclosure 30 of the battery module 20.

[0030]

[0024] Figure 2 illustrates an exploded perspective view of the battery pack 10, in accordance with an embodiment of the present invention. Referring to Figure 2 along with Figure 1, the battery pack 10 comprises an isolation sheet 50 sandwiched between two adjacent battery modules 20 of the plurality of battery modules 20. In an embodiment, the isolation sheet 50 is made of a plastic material. In an embodiment, the isolation sheet 50 has a predefined thickness. In an exemplary embodiment, the thickness of the isolation sheet 50 may be dependent on battery capacity of the battery modules 20 of the battery pack 10.

[0031]

[0025] In an embodiment, the isolation sheet 50 extends longitudinally between a first end 50a and a second end 50b. Each of the first end 50a and the second end 50b comprises one or more mounting holes 60. In a non-limiting embodiment, each of the first end 50a and the second end 50b comprises two threaded mounting holes 60. The one or more mounting holes 60 are configured to receive one or more fasteners forsecuring the isolation sheet 50 to the enclosures 30 of the plurality of battery modules 20.

[0032]

[0026] Moreover, the isolation sheet 50 has a plurality of isolating sections 52 formed next to each other. Each of the isolating sections 52 are configured to insulate at least two oppositely facing connectors 40 of the adjacent battery modules 20 to reduce the risk of electrical short circuit and improve thermal management within the battery pack 10.

[0033]

[0027] In an embodiment, each of the plurality of isolating sections 52 corresponds to shape of each of the oppositely facing connectors 40 of the plurality of battery modules 20. In an embodiment, the isolating section 52 comprises a first portion 54 and a second portion 56. The first portion 54 corresponds to a shape of an upper peripheral portion of each of the oppositely facing the connector 40. The second portion 56 corresponds to a shape of a lower peripheral portion of each of the oppositely facing the connector 40.

[0034]

[0028] In an embodiment, at least one of the isolating sections 52 comprises one or more perforations 58 for ventilation and cooling of the battery modules 20. In a nonlimiting example, the one or more perforations 58 are circular openings for ventilation and cooling of the battery modules 20. In a non-limiting embodiment, each of the isolating sections 52 comprises one or more perforations 58 for ventilation and cooling of the battery modules 20.

[0035]

[0029] In an embodiment, the perforations 58 may be of a predetermined size. In an exemplary embodiment, the size of the perforations 58 may be dependent on a size of the cells of the battery module 20 or capacity of the battery modules 20 of the battery pack 10, but should not be construed as limiting to the scope of the present invention.

[0036]

[0030] Advantageously, in the present invention, the incorporation of the isolation sheet between adjacent battery modules effectively prevents direct contact between the modules. The isolation sheet ensures that the connectors of adjacent modules are isolated, preventing short circuits, reducing the risk of thermal runaway, and ensuringthe safety and longevity of the battery pack. This contributes to a more reliable and durable energy storage solution.

[0037]

[0031] Further, a symmetric design of the battery modules and the isolation sheet ensures uniformity in module arrangement and simplifies the overall assembly process. This symmetry enhances the mechanical stability and reliability of the battery pack, reducing the likelihood of misalignment or shifting during operation. Additionally, the invention leverages more common parts, which contributes to ease of manufacturing, reduces supply chain complexity, and lowers production costs. Furthermore, the design also improves scalability and maintainability of the battery pack.

[0038]

[0032] The modular nature of the design allows for flexibility in the configuration and assembly of the battery modules with more compactness. This modularity not only facilitates easier customization for different applications but also improves repairability and upgradeability, providing a sustainable long-term solution for energy storage. The design is also cost-effective, due to the use of standardized, readily available parts and streamlined manufacturing processes. This helps reduce the overall cost of production while maintaining high performance and safety standards.

[0039]

[0033] Furthermore, the invention provides a significant increase in power density. The isolation sheet enables optimizing the design of the battery modules and ensuring efficient utilization of available space, the battery pack can store more energy in a given volume, thus achieving a high power output per unit volume. This is particularly beneficial for space- constrained applications such as electric vehicles and portable electronics.

[0040]

[0034] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

[0041] List of Reference Numerals

[0042] 10: Battery pack20: Battery module

[0043] 22: Terminals

[0044] 30: Enclosure

[0045] 40: Connector

[0046] 50: Isolation sheet

[0047] 50a: First end of isolation sheet

[0048] 50b: Second end of isolation sheet

[0049] 52: Isolating sections

[0050] 54: First portion of the isolating section 56: Second portion of the isolating section 58: Perforations

[0051] 60: Mounting holes

Claims

WE CLAIM:

1. A batery pack (10), the batery pack (10) comprising:a plurality of batery modules (20) disposed adjacent to each other, each of the plurality of battery modules (20) having a plurality of cells housed within an enclosure (30), the plurality of cells being electrically interconnected by one or more connectors (40); andan isolation sheet (50) sandwiched between two adjacent battery modules (20) of the plurality of battery modules (20), the isolation sheet (50) having a plurality of isolating sections (52) formed next to each other, each of the isolating sections (52) being configured to insulate at least two oppositely facing connectors (40) of the adjacent batery modules (20) to reduce the risk of electrical short circuit and improve thermal management within the battery pack (10).

2. The battery pack (10) as claimed in claim 1, wherein the isolation sheet (50) extends longitudinally between a first end (50a) and a second end (50b), each of the first end (50a) and the second end (50b) comprises one or more mounting holes (60).

3. The battery pack (10) as claimed in claim 2, wherein the one or more mounting holes (60) being configured to receive one or more fasteners for securing the isolation sheet (50) to the enclosures (30) of the plurality of batery modules (20).

4. The battery pack (10) as claimed in claim 1, wherein the isolation sheet (50) being made of at least a plastic material.

5. The batery pack (10) as claimed in claim 1, wherein each of the plurality of isolating sections (52) corresponds to shape of each of the oppositely facing connectors (40) of the plurality of batery modules (20).

6. The battery pack (10) as claimed in claim 1 , wherein each of the plurality of battery cells of each of the plurality of battery modules (20) comprises terminals (22).

7. The battery pack (10) as claimed in claim 6, wherein the terminals (22) of the plurality of cells being interconnected with each other by the one or more of connectors (40).

8. The battery pack (10) as claimed in claim 1, wherein at least one of the isolating sections (52) comprises one or more perforations (58) for ventilation and cooling of the battery modules (20).

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